Patent Publication Number: US-2022220736-A1

Title: Wall panel apparatus

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from the U.S. provisional patent application Ser. No. 63/106,887, filed on Oct. 29, 2020, which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF INVENTION 
     The present invention relates to a prefabricated wall panel apparatus, and more particularly, the present invention relates to a prefabricated wall panel apparatus and assembling the prefabricated wall panels to erect a building. 
     BACKGROUND 
     Prefabricated wall panels are known in the art for erecting a building in a short time and at a low construction cost. The prefabricated wall panels can be constructed offsite in an industrial setting and finished wall panels can be transported to the construction site. The prefabricated wall panels can be assembled at the construction site to erect a building. The prefabricated wall panels have certain advantages over constructing a wall onsite. The primary advantage is that the insulation in the prefabricated wall panels can be efficiently made under an industrial setting. Secondly, the labor hours and human errors can be significantly reduced. 
     Typical prefabricated wall panels can include concrete blocks, an insulation panel sandwiched between the concrete blocks and further reinforced by steel rebars and mesh wire. The steel rebars can also provide for interlocking the two adjacent prefabricated wall panels. 
     An industrial need is always there for improving the existing technologies to be more economical or efficient or less laborious. 
     SUMMARY OF THE INVENTION 
     The following presents a simplified summary of one or more embodiments of the present invention to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify critical elements of all embodiments nor delineate the scope of any or all embodiments. Its sole purpose is to present some concepts of one or more embodiments in a simplified form as a prelude to the more detailed description that is presented later. 
     The principal object of the present invention is therefore directed to a prefabricated wall panel apparatus that allows erecting a building in less time, more efficiently, and with less labor. 
     It is another object of the present invention to increase the factory-based assembly and reduce the onsite work. 
     It is still another object of the present invention to reduce construction costs. 
     It is yet another object of the present invention to improve construction quality. 
     In one aspect, disclosed is a building apparatus for a residential or commercial building, the building apparatus comprises a prefabricated wall panel having a top side, a bottom side, a left side, and a right side. The prefabricated wall panel comprises a plurality of spaced-apart hollow tubes that extend between the top side and the bottom side of the prefabricated wall panel, each tube of the plurality of spaced-apart hollow tubes has a flange that extends perpendicularly from a periphery of the each tube, wherein the flange rests upon the top side of the prefabricated wall panel. The flange is welded to the periphery of the each tube, the plurality of spaced-apart hollow tubes configured to receive a plurality of rebars. The prefabricated wall panel further comprises a U-shape beam that extends from the top side to the bottom side and is positioned at or near the left side or the right side of the prefabricated wall panel, the U-shape beam has a base plate and two continuous and upstanding plates forming a U-shape, an inner surface of the U-shape beam is exposed. The prefabricated wall panel further comprises a plurality of slings fastened to the base plate of the U-shape beam, the plurality of slings are spaced apart at regular intervals along a length of the U-shape beam. The building apparatus further comprises: a horizontal beam mounted on the top side of the prefabricated wall panel, the horizontal beam has a top plate and a bottom plate, the bottom plate configured to be welded to the flange of each of the plurality of spaced-apart hollow tubes. The horizontal beam further comprises a plurality of bores that extend between the top plate and the bottom plate, wherein the plurality of bores are coaxially aligned to the plurality of spaced-apart hollow tubes. The prefabricated wall panel further comprises a first concrete block; a second concrete block; an insulation panel, wherein the insulation panel is sandwiched between the first concrete block and the second concrete block; and a plurality of U-shape connectors that extends perpendicularly between the first concrete block and the second concrete block, the plurality of U-shape connectors are configured to immobilize the insulation panel mounted over the second concrete block. 
     In one implementation, the prefabricated wall panel further comprises a rebar mesh that extends throughout the first concrete block and the second concrete block. The prefabricated wall panel further comprise a plurality of rebar truss to reinforce the first concrete block. The prefabricated wall panel further comprises one or more electrical receptacles configured in the first concrete block; and one or more conduits that extend from the one or more electrical receptacles within the first concrete block and open at the top side, wherein the one or more conduits are configured to allow electrical wires to pass through. The one or more electrical receptacles comprise light switches. 
     In one aspect, disclosed is a method for constructing a residential or a commercial building, the method comprising the steps of providing a prefabricated wall panel having a top side, a bottom side, a left side, and a right side. The prefabricated wall panel comprises a first concrete block, a second concrete block, an insulation panel, wherein the insulation panel is sandwiched between the first concrete block and the second concrete block, a plurality of U-shape connectors that extends perpendicularly between the first concrete block and the second concrete block, the plurality of U-shape connectors are configured to immobilize the insulation panel, and a plurality of spaced-apart hollow tubes that extend between the top side and the bottom side of the prefabricated wall panel, each tube of the plurality of spaced-apart hollow tubes has a flange that extends perpendicularly from a periphery of the each tube, wherein the flange rests upon the top side of the prefabricated wall panel, the plurality of spaced-apart hollow tubes configured to receive a plurality of rebars. The prefabricated wall panel further comprises a U-shape beam that extends from the top side to the bottom side and is positioned at or near the left side or the right side of the prefabricated wall panel, the U-shape beam has a base plate and two continuous and upstanding plates forming a U-shape, an inner surface of the U-shape beam is exposed, and a plurality of slings fastened to the base plate of the U-shape beam, the plurality of slings are spaced apart at regular intervals along a length of the U-shape beam. 
     In one implementation, the method further comprises the steps of brining the prefabricated wall panel close to an another prefabricated wall panel, such that the U-shape beam of the prefabricated wall panel and a U-shape beam of the another prefabricated wall panel forms an enclosed volume and the plurality of slings of the prefabricated wall panel and a plurality of slings of the another prefabricated wall panel overlap one above another; inserting a rebar into the plurality of slings of the prefabricated wall panel and the plurality of slings of the another prefabricated wall panel; and upon inserting the rebar, filling concrete into the enclosed volume. The method further comprises the steps of providing a horizontal beam, the horizontal beam comprises: a top plate and a bottom plate, the bottom plate configured to be welded to the flange of the each tube of the plurality of spaced-apart hollow tubes, and a plurality of bores that extends through the horizontal beam between the top plate and the bottom plate, wherein the plurality of bores are coaxially aligned to the plurality of spaced-apart hollow tubes, wherein the method further comprises the steps of mounting the horizontal beam on the top side of the prefabricated wall panel; upon mounting, mounting a ceiling panel upon the horizontal beam; and inserting a plurality of rebars through a plurality of bores in the ceiling panel into the plurality of bores of the horizontal beam and the plurality of spaced-apart hollow tubes of the prefabricated wall panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present invention. Together with the description, the figures further explain the principles of the present invention and enable a person skilled in the relevant arts to make and use the invention. 
         FIG. 1  shows a prefabricated wall panel, according to an exemplary embodiment of the present invention. 
         FIG. 2  shows a prefabricated wall panel apparatus, according to an exemplary embodiment of the present invention. 
         FIG. 3  shows the prefabricated wall panel apparatus shown in  FIG. 2  without the horizontal beam and without concrete in a front concrete block to illustrate the components, according to an exemplary embodiment of the present invention. 
         FIG. 4  shows a customized floor foundation that locks the walls, according to an exemplary embodiment of the present invention. 
         FIG. 5  is a side view of the customized floor foundation shown in  FIG. 4 , according to an exemplary embodiment of the present invention. 
         FIG. 6  shows a horizontal beam and an exploded view of the horizontal beam, the horizontal beam raises the customized floor foundation for HVAC and secures the corners, T&#39;s, and straightway securely, according to an exemplary embodiment of the present invention. 
         FIG. 7  shows the assembling of two walls and two horizontal beams, the horizontal beams allow to better lock the two walls together, according to an exemplary embodiment of the present invention. 
         FIG. 8  shows the steel brackets that can be bolt to the top of a wall to secure it, according to an exemplary embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Subject matter will now be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments. Subject matter may, however, be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any exemplary embodiments set forth herein; exemplary embodiments are provided merely to be illustrative. Likewise, the reasonably broad scope for claimed or covered subject matter is intended. Among other things, for example, the subject matter may be embodied as methods, devices, components, or systems. The following detailed description is, therefore, not intended to be taken in a limiting sense. 
     The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiments of the present invention” does not require that all embodiments of the invention include the discussed feature, advantage, or mode of operation. 
     The terminology used herein is to describe particular embodiments only and is not intended to be limiting of embodiments of the invention. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises”, “comprising,”, “includes” and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     The following detailed description includes the best currently contemplated mode or modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely to illustrate the general principles of the invention since the scope of the invention will be best defined by the allowed claims of any resulting patent. 
     Referring to  FIG. 1  which shows a perspective view of a prefabricated wall panel  100  according to an exemplary embodiment of the present invention. The disclosed prefabricated wall panel  100  can be made from concrete and reinforced using metal mesh and thick steel rebars.  FIG. 1  shows the prefabricated wall panel  100  has two concrete blocks, a front concrete block  110  and a rear concrete block  120 , and an insulation layer  130  sandwiched between the two concrete blocks. A section of the prefabricated wall panel is shown without concrete to illustrate the different components within the front concrete block. The thickness of the two concrete blocks can be varied and usually, one concrete block can be thicker than the second concrete block. The thinner concrete side can face outside the building and one or more suitable coatings can be applied to the thinner concrete block, for example, a stone veneer can be applied on the outer surface of the thinner concrete block. The rear concrete block  120  in  FIG. 1  is the thinner concrete block. 
     A rebar mesh  140  can be seen embedded throughout an area of the front concrete block  110 , wherein the rebar mesh  140  can provide for reinforcing the structure. The rebar mesh  140  can include metal wires arranged in a grid-like fashion such that a square void is formed between the interlocking metal wires. In one implementation, a 4 mm steel wire can be used for the rebar mesh  140  with square voids throughout. 
     The strength of the structure can be further enhanced by rebar truss  150 . The rebar truss  150  can be used to reinforce the wall panel and can be disposed around doors and windows and sides for added strength. The reinforcement of the concrete wall panels using the rebar mesh and rebar truss are known in the art and hence not further described herein. Also, the thickness of the two concrete blocks and the sandwiched insulation layer can be varied without departing from the scope of the present invention. In one implementation C30 concrete can be used for the two concrete blocks, the C30 concrete is known in the art. Also, disclosed is a method for reinforcing the insulation panel by using metal U-type connectors  160  for fastening the two concrete blocks and the insulation panel. The insulation panel can be extruded polystyrene insulation (XPS) panels commercially available, such as from OWENS CORNING®. It is understood, however, that any wall insulation panel known to a skilled person for use in precast wall panels can be used without departing from the scope of the present invention. The insulation panel, also known as an insulation board, can act as a sound barrier, heat barrier, and can also prevent moisture seeping into the walls from outside. Additionally, the exposed surface of the thinner concrete block that faces outside of the building can be treated with waterproof coatings. 
       FIG. 1  also shows a switch box  165  and an electrical functional box  170  built into the wall panel  100 . The switch box and the electrical functional box can be supported by the rebar mesh or rebar truss, and then the concrete can be filled into the front concrete block. The switch box and the electrical functional box can be any standard electrical components known and approved for use in a residential and commercial building. The location of the switch box and the electrical functional box can be predetermined and accordingly positioned in the wall panel. The provision of the built-in switch box and the electrical functional box offers a great advantage preventing later cutting off the wall to make room for the switch and electrical boxes that is messy, laborious, time-consuming, and increase the overall construction cost. Suitable conduits and extruded holes  175  can also be provided in the front concrete block  110  for electrical wires and plumbing that has to travel through the wall. The switch and electrical boxes can have connected conduits that open at the top of the wall panel and can be used for passing the electrical wires.  FIG. 1  shows a single switch and electrical box; however, it is understood that more than one switch and one electrical box can be provided without departing from the scope of the present invention. The unused extruded holes can be filled with concrete at the job site. 
     On the left side and the right side of the wall panel  100  can be seen a U-shape beam  180  that extends from top to bottom of the first concrete block  110 . The U-shape beam  180  can be made from a planar sheet that can be folded twice at a spaced-apart distance to form a three-sided or substantially U-shape beam. The U-shape beam  180  can be provided at the ends or near the ends of the wall panel for interlocking one wall panel to another wall panel while assembling the wall panels at the job site. The position of the U-shape beam  180  in a wall panel can depend upon the position and angle at which the two wall panels must be coupled. Steel slings  185  can also be provided along a length of the U-shape beam  180  at regular intervals to reinforce a joint between the two adjacent wall panels. The slings  185  can be fastened to a base of the U-shape beam  180  and extends outwards and away from the wall panel and in between the two plates of the U-shaped beam  180 . In use, the two wall panels that have to be assembled can be bought close to each other such that the slings  185  of the two wall panels are one above the other and the two U-shaped beam  180  of the two wall panels can form an enclosed volume. Thick rebar can be inserted which passes through the overlapping slings of the two wall panels. Once the rebar is through, concrete can then be poured into the enclosed volume to join the two wall panels. It is understood that the slings can be provided on other portions of the front concrete block, as shown in  FIG. 1 . The slings can be loop-shaped and fastened to the U-shape beam, the rebar, and/or rebar mesh. The loop-shaped slings can be replaced by U-shape brackets, and such U-shape brackets are within the scope of the present invention. Also, shown in  FIG. 1  are the connectors for steel girders. 
     Also, it can be seen in  FIG. 1  are the tubes  190  run top to bottom at regularly spaced intervals. The tubes  190  can be hollow and made from a durable material that can provide additional reinforcement to the prefabricated wall panel  100 . In one implementation, the tubes can be made of steel with an outer diameter of about 40 mm and the two tubes in the prefabricated wall panel can be spaced about 900 mm from each other. On top of the tube can be seen a flange  195  extending perpendicular from a periphery of the tube. The flange can be welded to the periphery of the tube and can rest upon the top side of the wall panel. Additionally, the flange can be fastened into the concrete of the wall panel using suitable fasteners. The flange can also be made from a durable material, such as steel. These flanges can provide support for the horizontal beams that are mounted on the top of the wall panels. 
     The horizontal beams can be mounted on the top of the wall panels and run along the length of the wall panels. The horizontal beams can allow mounting a ceiling on the top of the assembled wall panels. 
     Referring to  FIG. 2  which shows a prefabricate wall panel apparatus  205  having the prefabricated wall panel  200  and a horizontal beam  210  mounted on the top of the prefabricated wall panel  200 . The horizontal beam  210  can include a top plate  220  and a bottom plate  230  those could be parallel to each other. The bottom plate of the horizontal beam can rest upon the top of the wall panel  200  and can be welded to the several flanges of the tubes disposed in the wall panel  200 . Additionally, the steel plates can be used to join the horizontal beam to the wall panel or the two wall panels, wherein the steel plates can be of a rectangular shape, T-shape, or an L-shape. 
     The horizontal beam  210  can have several spaced apart bores  240  of a square shape therethrough between the top plate and the bottom plate. The space between the two adjacent bores of the horizontal beam can be equal to the space between the two adjacent tubes in the wall panel. In use, when the horizontal beam is mounted on the top of the wall panel such that the bottom plate of the horizontal beam rests upon the top of the wall panel, the horizontal beam can be positioned so that the bores of the horizontal beam can be coaxially aligned with the bores in the tubes of the wall panel. A ceiling panel can be mounted on the horizontal beams of the assembled wall panels, and the ceiling panel can also have bores through which rebars can be inserted, wherein the rebars can passthrough the bores of the horizontal beams into the tubes or extruded holes of the assembled wall panels. The bores in the horizontal beam can be square shape or cylindrical,  FIG. 2  shows square shape bores. 
     Referring to  FIG. 3  which shows the prefabricated wall panel  300  of the disclosed prefabricated wall panel apparatus as shown in  FIG. 2  but without the horizontal beam. The disclosed prefabricated wall panel  300  may differ from the prefabricated wall panel  100  shown in  FIG. 1  by omitting a few features such as the extruded holes, girders, and U-shape beam. In a preferred embodiment, the prefabricated wall panel  300  can include a rear concrete block  305 , an insulation panel  310 , and a front concrete panel  315 , the structure and functioning of the three has been described for the prefabricated wall panel  100  and hence not repeated here. The disclosed prefabricated wall panel  300  can also include wire mesh bar  320  that has been previously described for the prefabricated wall panel  100 . Wire mesh  325  can also be seen in  FIG. 3  that is typically dense wire mesh and can be used around doors and windows for added strength. The prefabricated wall panel  300  can further include steel rebars  330  for reinforcement and structural support. Steel rebars of a diameter of about 12-16 mm can be used, and more preferably, of about 16 mm can be used such that a building can easily withstand hurricanes, earthquakes, and the like natural disasters. The prefabricated wall panel  300  can further include a U-shape or rectangular or square grooves  335  in the front concrete block for the water pipes to run up the wall. The prefabricated wall panel  300  can further include electrical switches  340  and electrical functional boxes  345  both have been described for the prefabricated wall panel  100  and hence not repeated here. Tubes  350  can also be seen in  FIG. 3  that has been previously described for the prefabricated wall panel  100  in  FIG. 1 . The tubes  350  can be hollow and shown to be of square in shape. The steel tubes  350  can provide for additional reinforcement. Also, these tubes  350  can act as a support for mounting other elements, such as the horizontal beam. The flange  355  at a periphery of a square shape aperture can be welded to a periphery of the tube  350  and the flange can also include fasteners for anchoring to the concrete block, also described for the prefabricated wall panel  100  and not repeated here. 
     The prefabricated wall panel  300  can also include another U-shaped concrete molded U-beam  360  that can be stronger and better than using a metal U-shaped beam  180  in  FIG. 1 . The concrete molded U-beam can be molded at the time of manufacturing. A rigid double steel sling  365  can also be seen in  FIG. 3  that extends from the U-shaped concrete molded U-beam  360 . As described for the prefabricated wall panel  100 , the U-shaped concrete molded U-beam  360  and the rigid double steel sling  365  can be used for joining two prefabricated wall panels, and the process is not repeated here. The rigid double steel sling  365  in comparison to the slings  185  shown in  FIG. 1  can provide better strength and functionality. As shown in  FIG. 3 , a loop of the slings  360  can be wrapped around the tube  350  adjacent to the U-shaped concrete molded U-beam  360  and the end of the sling  365  can be further embedded into the concrete. A lifting point stiffer  370  can also be seen in  FIG. 3  that can be used to lift the prefabricated wall panels  300  and floor foundations into place. Also shown in  FIG. 3  is a C-type angle bracket  375  for horizontal section. 
     While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above-described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.