Lightweight concrete composite wall panels

Abstract

Unitary lightweight concrete composite wall panels include a frame filled with lightweight composite concrete. The wall panels may be used in the construction of either interior or exterior walls, and a wall panel may be configured as a load bearing or non load bearing. The size of a wall panel ranges from an individual wall panel forming a portion of a wall to a wall panel spanning an entire wall length, thereby furnishing a single complete wall. A wall panel may further be configured to support either a window or door.

1 . A unitary lightweight concrete composite wall panel, comprising: 
 a frame; and    lightweight concrete composite disposed within the frame.    
   
   
       2 . The unitary lightweight concrete composite wall panel according to  claim 1 , wherein upon curing the lightweight concrete composite adheres to the frame, thereby forming the wall panel.  
   
   
       3 . The unitary lightweight concrete composite wall panel according to  claim 1 , further comprising at least one reinforcing bar disposed within the lightweight concrete composite.  
   
   
       4 . The unitary lightweight concrete composite wall panel according to  claim 3 , wherein the frame comprises apertures that receive the at least one reinforcing bar therethrough to secure the at least one reinforcing bar to the frame.  
   
   
       5 . The unitary lightweight concrete composite wall panel according to  claim 1 , wherein the frame comprises at least a first side, a second side, and a third side.  
   
   
       6 . The unitary lightweight concrete composite wall panel according to  claim 5 , wherein the first side, the second side, and the third side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite.  
   
   
       7 . The unitary lightweight concrete composite wall panel according to  claim 1 , wherein the frame comprises a top end, a bottom end, a first side, and a second side.  
   
   
       8 . The unitary lightweight concrete composite wall panel according to  claim 7 , wherein the top end, the bottom end, the first side, and the second side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite.  
   
   
       9 . The unitary lightweight concrete composite wall panel according to  claim 1 , wherein the frame further comprises a first support member coupled to the top end and the bottom end.  
   
   
       10 . The unitary lightweight concrete composite wall panel according to  claim 9 , wherein the frame further comprises at least one second support member coupled to one of the first side or the second side and the first support member.  
   
   
       11 . The unitary lightweight concrete composite wall panel according to  claim 1 , wherein the frame defines an opening that supports a window frame therein.  
   
   
       12 . The unitary lightweight concrete composite wall panel according to  claim 1 , wherein the frame defines an opening that supports a door frame therein.  
   
   
       13 . The unitary lightweight concrete composite wall panel according to  claim 1 , wherein the frame comprises a header, a first side, and a second side.  
   
   
       14 . The unitary lightweight concrete composite wall panel according to  claim 13 , wherein the frame further comprises a footer.  
   
   
       15 . The unitary lightweight concrete composite wall panel according to  claim 13 , wherein the header, the first side, and the second side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite.  
   
   
       16 . The unitary lightweight concrete composite wall panel according to  claim 1 , further comprising at least one conduit disposed within the lightweight concrete composite.  
   
   
       17 . The unitary lightweight concrete composite wall panel according to  claim 16 , wherein the at least one conduit includes at least one opening communicating exterior to the wall panel.  
   
   
       18 . The unitary lightweight concrete composite wall panel according to  claim 16 , wherein the at least one conduit includes at least one end connected to an electrical box disposed within the lightweight concrete composite.  
   
   
       19 . The unitary lightweight concrete composite wall panel according to  claim 16 , wherein the at least one conduit receives electrical wiring therethrough.  
   
   
       20 . The unitary lightweight concrete composite wall panel according to  claim 16 , wherein the at least one conduit comprises plumbing piping.  
   
   
       21 . The unitary lightweight concrete composite wall panel according to  claim 16 , wherein the at least one conduit comprises an air duct.  
   
   
       22 . A form for facilitating the curing of lightweight concrete composite into wall panels, comprising: 
 a bottom assembly that supports a frame of the wall panel therein; and    a cap that seats on the bottom assembly, whereby, upon curing, the lightweight concrete composite adheres to the frame, thereby forming the wall panel.    
   
   
       23 . The form for facilitating the curing of lightweight concrete composite into wall panels according to  claim 22 , wherein the bottom assembly comprises: 
 walls; and    mating assemblies that couple the walls, thereby forming the desired shape that is assembled and disassembled.    
   
   
       24 . The form for facilitating the curing of lightweight concrete composite into wall panels according to  claim 23 , wherein the walls comprise: 
 two sidewalls located opposite and parallel to each other; and    two endwalls located opposite and parallel to each other.    
   
   
       25 . The form for facilitating the curing of lightweight concrete composite into wall panels according to  claim 22 , further comprising a mating assembly that couples the bottom assembly with the cap.  
   
   
       26 . The form for facilitating the curing of lightweight concrete composite into wall panels according to  claim 22 , further comprising an insert that shortens the form to produce smaller blocks.