Insulation sheet structure and concrete sandwich wall panel assembly constructed therewith

Abstract

An insulation sheet for concrete sandwich wall panels comprising a sheet base composed substantially of expanded cellular foam and having opposed base surfaces. Protrusions integral with the sheet base extend from each of the base surfaces from a footprint at the base surface to a distal surface away from the base surface. Each of the protrusions has a cross-sectional shape such that a width of the distal surface is greater than a width of the footprint, that is, mushroom-shaped. Narrow ducts extend through the insulation sheet. Optionally, the protrusion distal surfaces are rounded.

1 . An insulation sheet comprising: 
 (a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;    (b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface; and    (c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint.    
   
   
       2 . The insulation sheet of  claim 1  wherein said distal surfaces have shapes and the smallest of said distal surfaces is larger than the largest area between said distal surfaces.  
   
   
       3 . The insulation sheet of  claim 1  wherein said distal surfaces are rounded.  
   
   
       4 . The insulation sheet of  claim 1  wherein said sheet includes ducts that extend through said insulation sheet.  
   
   
       5 . The insulation sheet of  claim 1  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.  
   
   
       6 . An insulation sheet comprising: 
 (a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;    (b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface;    (c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint;    (d) said distal surfaces being rounded and having shapes, the smallest of said distal surfaces being larger than the largest area between said distal surfaces; and    (e) said sheet including ducts that extend through said insulation sheet.    
   
   
       7 . The insulation sheet of  claim 6  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.  
   
   
       8 . A concrete sandwich assembly comprising a first concrete layer, a second concrete layer, and an insulation sheet therebetween, said insulation layer comprising: 
 (a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;    (b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface; and    (c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint.    
   
   
       9 . The insulation sheet of  claim 8  wherein said distal surfaces have shapes and the smallest of said distal surfaces is larger than the largest area between said distal surfaces.  
   
   
       10 . The insulation sheet of  claim 8  wherein said distal surfaces are rounded.  
   
   
       11 . The insulation sheet of  claim 8  wherein said sheet includes ducts that extend through said insulation sheet.  
   
   
       12 . The insulation sheet of  claim 8  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.  
   
   
       13 . A concrete sandwich assembly comprising a first concrete layer, a second concrete layer, and an insulation sheet therebetween, said insulation layer comprising: 
 (a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;    (b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface;    (c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint;    (d) said distal surfaces being rounded and having shapes, the smallest of said distal surfaces being larger than the largest area between said distal surfaces; and    (e) said sheet including ducts that extend through said insulation sheet.    
   
   
       14 . The insulation sheet of  claim 13  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.  
   
   
       15 . A method of constructing a concrete sandwich assembly comprising the steps of: 
 (a) providing an insulation sheet comprising a sheet base composed substantially of expanded cellular foam and having opposed base surfaces, a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface, each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint;    (b) pouring a first concrete layer into a form;    (c) pushing said protrusions of a first of said opposed base surfaces of said insulation sheet into said first concrete layer; and    (d) pouring a second concrete layer onto a second of said opposed base surfaces of said insulation sheet.    
   
   
       16 . The method of  claim 15  wherein said distal surfaces have shapes and the smallest of said distal surfaces is larger than the largest area between said distal surfaces.  
   
   
       17 . The method of  claim 15  wherein said distal surfaces are rounded.  
   
   
       18 . The method of  claim 15  wherein said sheet includes ducts that extend through said insulation sheet.  
   
   
       19 . The method of  claim 15  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.