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 on rigid plastic inserts molded into the sheet base extend from each of the base surfaces. Each of the protrusions has a narrow waist into which concrete flows to anchor the concrete onto the sheet. Narrow ducts extend through the insulation sheet.

1 . An insulation sheet comprising: 
 a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;    b) a plurality of rigid inserts embedded in said sheet base;    c) each of said inserts including an embedded section embedded in said sheet base and protrusions extending away from said opposed base surfaces; and    d) each of said protrusions having a distal surface and a waist that is narrower than said distal surface.    
   
   
       2 . The insulation sheet of  claim 1  wherein each of said inserts includes an anchor to retain said insert in said sheet base.  
   
   
       3 . The insulation sheet of  claim 1  wherein said sheet includes ducts that extend through said insulation sheet.  
   
   
       4 . 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.  
   
   
       5 . An insulation sheet comprising: 
 a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;    b) a plurality of rigid inserts embedded in said sheet base;    c) each of said inserts including an embedded section embedded in said sheet base, an anchor to retain said insert in said sheet base, and protrusions extending away from said opposed base surfaces;    d) each of said protrusions having a distal surface and a waist that is narrower than said distal surface; and    e) said sheet including ducts that extend through said insulation sheet.    
   
   
       6 . The insulation sheet of  claim 5  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.  
   
   
       7 . 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 rigid inserts embedded in said sheet base;    c) each of said inserts including an embedded section embedded in said sheet base and protrusions extending away from said opposed base surfaces; and    d) each of said protrusions having a distal surface and a waist that is narrower than said distal surface.    
   
   
       8 . The insulation sheet of  claim 7  wherein said sheet includes ducts that extend through said insulation sheet.  
   
   
       9 . The insulation sheet of  claim 7  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.  
   
   
       10 . 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 rigid inserts embedded in said sheet base, each of said inserts including an embedded section embedded in said sheet base and protrusions extending away from said opposed base surfaces, and each of said protrusions having a distal surface and a waist that is narrower than said distal surface;    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.    
   
   
       11 . The method of  claim 10  wherein said sheet includes ducts that extend through said insulation sheet.  
   
   
       12 . The method of  claim 10  wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.