Abstract:
A prefabricated building panel to be used in constructing a building structure includes a generally planar concrete panel one surface and opposite surface also generally planar with a plurality of arrayed hooks couple through an insulation pad opposing hooks of a similar panel mostly mirrored to the first panel providing a cavity space being back filled with a foam insulation providing an lightweight foam core building panel with improved thermal isolation.

Description:
FIELD OF THE INVENTION  
       [0001]     The invention relates to concrete shapes used in construction or various structures. More particularly, it relates to panels providing walls and finished structures having increased strength over prior art to resist storms and earthquakes. Constructs derived from this building panel have improved thermal and insulation.  
       BACKGROUND INFORMATION  
       [0002]     Concrete blocks of the prior art are conventionally rectangular shapes having cavities extending from top to bottom through the blocks. These cavities are often filled with an insulation material to reduce the heat transfer. Often aligning features have been proposed to assist the workers in laying the block, however these are at an increased cost which makes these aids cost prohibitive and in the end skilled masonry workers prevail. Various mortarless interlocking blocks have been derived to facilitate construction of block walls and structures and the cost to benefit ratio works out so that it also is prohibitive.  
         [0003]     Block construction remains very much unchanged; applying mortar and laying block end to end then course on top of course with the set mortar providing the aligning feature to resist the blocks being displaced. When a catastrophe of sufficient forces to overcomes the mass loading and displaces these blocks more than a crack then the effected blocks must be reset or worse fall with crushing force. Much less dramatic shifting of the foundation is the most common reason that a building suffers occasionally a complete loss. The state of the art has shown this block construction to be non-compliant when the acting forces overcome the stiffness, then full recovery is not likely.  
         [0004]     While the proposed designs have shown blocks that require less skill to build with them and some even have improved thermal properties none are created by an outer panel and an inner panel joined by hooks insulated between the coupling surfaces. An approximate half pitch vertically staggered course joint is achieved by starting at the base with a half panel and likewise a staggered vertical joint line is achieved. None of the art seen has demonstrated these features.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention provides a panel having a specialized texture or natural finish planar surface and for special applications the surface might be curved. This generally rectangular surface has a substantially parallel opposite side with hook shaped protrusions with the body extending angularly with a tip segment at right angle to the body and a tip. The panel size determines the quantity, shape and arrangement to consider the load requirement of these hooks. In example, to cast the hooks of small panel because it is difficult to fill small features in a mold it would be preferable to produce them as continuous across the panel.  
         [0006]     The panel according to the present invention one method of manufactured will be by casting of concrete in a foam mold. At a manufacturing site a foam mold the rectangular size of the panel to be cast and having the intended hook and rib features created in the upper side is placed on a platen. Removable walls are closely fitted to all sides and extend above the top surface of the foam mold equal to the panel thickness to. This dammed area is filled with concrete level to the top of the walls and vibrated to fill all of the features of the mold. Prior to allow the concrete to set a finish surface or texture is applied. A finished panel is created when wall are removed and the mold material is cleared exposing the hooks. Another method of manufacturing construction panels is using a permanent mold in the mold process. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0007]     In the annexed drawings:  
         [0008]      FIG. 1  shows the inside view of the construction panel  
         [0009]      FIG. 2  shows the top view of the construction panel  
         [0010]      FIG. 3  shows the side view of the construction panel  
         [0011]      FIG. 4  shows a prospective view of the construction panel  
         [0012]      FIG. 5  shows an enlarged view  
         [0013]      FIG. 6  shows a inside prospective view of a construction panel with door frame and opening  
         [0014]      FIG. 7  shows an inside prospective view of a construction panel with window frame and opening  
         [0015]      FIG. 8  shows an outside prospective view of a construction panel with attaching features  
         [0016]      FIG. 9  shows an inside prospective view of a construction panel with angle faces  
         [0017]      FIG. 10  shows an inside prospective view of a construction panel with curved features  
         [0018]      FIG. 11  shows a prospective view of the corner post  
         [0019]      FIG. 12  shows an inside prospective view of a narrow construction panel  
         [0020]      FIG. 13  shows an outside prospective outside view of the construction panel with compartments  
         [0021]      FIG. 14  shows the enlarged inside partial view of construction panel with compartments  
         [0022]      FIG. 15  shows a side view of joined construction panel  
         [0023]      FIG. 16  shows an enlarged partial section view of joined construction panel  
         [0024]      FIG. 17  shows an enlarged partial view of the joined construction panel  
         [0025]      FIG. 18  shows a plan view of a construction panel in mold base  
         [0026]      FIG. 19  shows an exploded side view of a construction panel with mold base  
         [0027]      FIG. 20  shows an exploded prospective view of a construction panel with mold base  
         [0028]      FIG. 21  shows an enlarged partial inside view of a completed construction panel  
         [0029]      FIG. 22  shows a prospective view of the handling tool  
         [0030]      FIG. 23  shows another prospective view of the handling tool  
         [0031]      FIG. 24  shows a prospective view of the partial structure with handling tool  
         [0032]      FIG. 25  shows a partial prospective view of the wall showing bracket  
         [0033]      FIG. 26  shows a partial prospective view of the wall showing cleat  
         [0034]      FIG. 27  shows a partial prospective view of the wall showing floor bolting  
         [0035]      FIG. 28  shows an inside prospective view of a construction panel  
         [0036]      FIG. 29  shows an enlarged partial inside view of a completed construction panel  
         [0037]      FIG. 30  shows another inside prospective view of a partial structure  
         [0038]      FIG. 31  shows the top view of the construction panel  
         [0039]      FIG. 32  shows the inside view of the construction panel  
         [0040]      FIG. 33  shows the side view of the construction panel  
         [0041]      FIG. 34  shows a prospective view of the construction panel  
         [0042]      FIG. 35  shows the inside view of the wall  
         [0043]      FIG. 36  shows the top view of the wall  
         [0044]      FIG. 37  shows the side view of the wall  
         [0045]      FIG. 38  shows a prospective view of the wall 
     
    
     DETAILED DESCRIPTION  
       [0046]     Referring to the drawings and initially to  FIG. 1  there is shown a  1  a basic construction panel according to the invention. This mostly rectangular construction panel has bottom flange  2 , top flange  3 , and a planar surface  5  opposite a inside surface  6  having connecting features which are arrayed hook  4  protrusions with a hook opening  9  on a plain perpendicular to inside surface  6  and having an engaging surface  10  on the inside of the engaging paw  11 . Stiffener ribs  7  are also arrayed on inside surface  6 . Construction panels are usually, but not limited to, poured concrete and having a mesh reinforcing  12  of steel. Expanded aggregates and aerated concretes rites are extensively used when casting construction panels. This panel has a panel length  13 , a panel width  14  and two thicknesses expressed as, overall thickness  16  over the hook  4  and effective thickness  15  which is approximately half of a finished wall thickness. If required for aesthetic purposes planar surface  5  may be a texture surface  17 . Shown in  FIG. 6 , construction panel  20  configured for a door opening  23  showing the door jab  22  and door header  21 .  
         [0047]     In  FIG. 7  construction panel  30  is configured to a window opening construction panel  30  having usual window opening  33  surrounded by window sill  33 , window header  32  and frame  34 . Construction panel  40  as shown in  FIG. 8  is used to connect walls both exterior and interior through connecting feature  41  as shown to be a tendon. The corner construction panel  50  of this invention is shown in this  FIG. 9  whereby the panel is cast having two plane surfaces at angle  52  and inside surfaces  6  are intersected with a fillet  51  to prevent stress rises. Yet another construction panel is demonstrated with curved construction panel  60  having curve  61 . A corner post  70  is shown having tendons  71 .  FIG. 12  shows a reduced width construction panel  80  used primarily to set the stagger of the joints along the wall and for short walls. A composite construction panel  90  is used in  FIG. 13  to demonstrate various compartments as, electrical compartment  91 , plumbing compartment  92 , wall outlet compartment  93  and wall switch compartment  94 .  
         [0048]     A primary assembly  100  is shown in  FIG. 15  when two construction panels are rotated 180 degrees and the hook  4  are nested with paw  11  inserted into hook opening  9  and contacted along surface  101  and thereby bonded  102 . FIG. is a partial section through primary assembly  100  while  FIG. 17  is an enlarged partial section of primary assembly  100  showing gap  104  provided for fastener entry and cavity  103  to be foam insulation filled.  
         [0049]     All construction panels previously shown have been simplified and shown without foam in place.  FIG. 18  shows the casting of a construction panel  1  in a mold platen  123  as an assembly  120  with  FIG. 19  showing the mold assembly exploded. A foam mold  121  with inserts  122  for demonstration removed from openings in foam mold  121 .  FIG. 20  is a prospective view of a mold assembly  120 .  
         [0050]      FIG. 22  is a tool  150  used to place construction panels of all configurations whereby completed construction panel  130  is held in clamp  154  when knobs  155  are screwed inward. The clamp  154  is free to pivot about axis  153  of carriage  156  that is free to move laterally on slides  152  supported by frame  151 . Tool  150  has openings on the bottom to provide the entry of a pallet jack or fork truck.  FIG. 22  is another view of tool showing complete construction panel  130 . Wall stiffness is achiever with joint stagger  329   FIG. 24  is a prospective view of a partial structure  300  showing the above described construction panels in place on footer  302  while  FIG. 27  shows construction panels secured to the footer using external threaded fastener  320  extending through bar  322  and clamped by a internal threaded fastener.  FIG. 25  is a partial view of the top of the wall shows a bracket with an external threaded fastener extending through a hole and having an internal threaded fastener proving a clamp. Electrical conductors  303  are provided with a construction panel and stored as a service loop  304 . Plumbing and air conduit  306  is also provided with construction panel.  FIG. 28  is a prospective view of the complete construction panel  130  showing hook  4  and cavity  131  arrayed on inside while  FIG. 29  is an enlarged partial view that is rotated slightly for a better view of hook  4  and cavity  131 .  FIG. 32  shows the inside view of the small construction panel  370 ,  FIG. 31  is a top view while  FIG. 33  is a side view. A prospective view is seen with  FIG. 34 .  FIG. 35  is a side view of a partial wall assembly  380  having a course pitch  372  and vertical joints stagger while  FIG. 36  is a top view.  FIG. 37  is a partial view of a vertical section followed by  FIG. 39 , a prospective view.