Wall panel apparatuses and methods

Abstract

Apparatuses and methods for a wall panel having a support element and an insulation element.

1 . A wall panel, comprising:
 a support element;   an insulation element to be adjacent the support element; and   a footer element integral with the support element.   
   
   
       2 . The wall panel of  claim 1 , the footer element to be adjacent the insulation element. 
   
   
       3 . The wall panel of  claim 1 , the support element comprising one or more ribs. 
   
   
       4 . The wall panel of  claim 3 , the one or more ribs each to be reinforced. 
   
   
       5 . The wall panel of  claim 1 , the support element comprising a first mating portion and a second mating portion. 
   
   
       6 . The wall panel of  claim 1 , further comprising a support shelf. 
   
   
       7 . The wall panel of  claim 1 , further comprising a beam pocket. 
   
   
       8 . The wall panel of  claim 1 , further comprising a window opening. 
   
   
       9 . The wall panel of  claim 1 , further comprising a door opening. 
   
   
       10 . The wall panel of  claim 1 , wherein the wall panel is to form an inside corner. 
   
   
       11 . The wall panel of  claim 1 , wherein the wall panel is to form an outside corner. 
   
   
       12 . The wall panel of  claim 1 , further comprising a first end surface of the support element and a second end surface of the support element, the first end surface and the second end surface each including one or more attachment holes. 
   
   
       13 . The wall panel of  claim 12 , the attachment holes on each of the first end surface and second end surface to secure the wall panel to another wall panel. 
   
   
       14 . The wall panel of  claim 1 , further comprising one or more locator elements. 
   
   
       15 . The wall panel of  claim 14 , wherein the locator elements are anchor bolts. 
   
   
       16 . The wall panel of  claim 1 , further comprising a header adjacent the support element. 
   
   
       17 . The wall panel of  claim 16 , further comprising at least one locator element protruding from the header. 
   
   
       18 . The wall panel of  claim 1 , wherein the insulation element includes EPS foam. 
   
   
       19 . The wall panel of  claim 1 , wherein the panel body comprises high compressive strength concrete. 
   
   
       20 . The wall panel of  claim 1 , wherein the wall panel includes an exterior finish. 
   
   
       21 . The wall panel of  claim 20 , wherein the exterior finish is a spray coating. 
   
   
       22 . The wall panel of  claim 1 , further comprising a slab tie embedded at least partially in the footer element. 
   
   
       23 . The wall panel of  claim 1 , wherein the footer element is formed with a slab-locating groove. 
   
   
       24 . The wall panel of  claim 23 , wherein the slab-locating groove is V-shaped. 
   
   
       25 . The wall panel of  claim 1 , further comprising one or more mechanical connection elements and one or more panel securing holders, each of the one or more mechanical connection elements disposed around a different one of the one or more panel securing holders. 
   
   
       26 . A process for forming a wall panel, comprising:
 disposing an insulation element in a mold;   inserting a casting material in the mold to integrally form a support element and a footer element adjacent to the insulation element.   
   
   
       27 . The process of  claim 26 , wherein the inserting of the casting material in the mold is further to integrally form a header with the support element. 
   
   
       28 . The process of  claim 26 , further comprising forming a sealant groove in the support element. 
   
   
       29 . The process of  claim 26 , wherein the support element is to be adjacent to the insulation element such that the support element and the insulation element interlock. 
   
   
       30 . The process of  claim 26 , further comprising forming one or more ribs in the support element. 
   
   
       31 . The process of  claim 26 , further comprising forming a first mating portion and a second mating portion in the support element. 
   
   
       32 . The process of  claim 26 , further comprising disposing one or more locator elements in the mold before inserting the casting material in the mold. 
   
   
       33 . The process of  claim 26 , further comprising forming a support shelf on the wall panel. 
   
   
       34 . The process of  claim 26 , further comprising forming a beam pocket in the wall panel. 
   
   
       35 . The process of  claim 26 , further comprising forming at least one of a door and a window in the wall panel. 
   
   
       36 . The process of  claim 26 , further comprising forming one or more attachment holes in the support element. 
   
   
       37 . The process of  claim 26 , further comprising curing the wall panel and applying an exterior finish to the wall panel. 
   
   
       38 . A wall panel, comprising
 a support element;   an insulation element disposed adjacent the support element; and   a header element formed integral with the support element.   
   
   
       39 . The wall panel of  claim 38 , wherein the support element comprises a first mating portion, the sealant groove formed in the first mating portion. 
   
   
       40 . A wall panel, comprising:
 a support element having a sealant groove formed therein; and   an insulation element disposed adjacent the support element.   
   
   
       41 . A wall panel, comprising:
 a support element;   an insulation element to be disposed adjacent the support element; and   one or more nailers disposed in the insulation element.   
   
   
       42 . The wall panel of  claim 41 , the one or more nailers secured to the support element. 
   
   
       43 . The wall panel of  claim 41 , further comprising a header and a footer, the one or more nailers secured to the header and the footer. 
   
   
       44 . The wall panel of  claim 43 , wherein the header and footer are integral with the support element. 
   
   
       45 . A wall panel, comprising:
 a support element having one or more ribs, the one or more ribs protruding from the support element in a bowed out shape; and   an insulation element disposed adjacent the one or more ribs.   
   
   
       46 . A wall panel, comprising:
 a support element;   an insulation element to be adjacent the support element; and   a support shelf integral with the support element.   
   
   
       47 . An insulation element for a wall panel, comprising:
 one or more rib voids; and   one or more rib rebar seats disposed in each of the one or more rib voids.   
   
   
       48 . The insulation element of  claim 47 , wherein the one or more rebar seats disposed in each of the one or more rib voids includes three rebar seats. 
   
   
       49 . The insulation element of  claim 47 , further comprising one or more mechanical chases. 
   
   
       50 . The insulation element of  claim 47 , further comprising one or more nailer voids. 
   
   
       51 . An insulation element for a wall panel, comprising:
 a top surface; and   one or more panel securing holders adjacent the top surface.   
   
   
       52 . The insulation element of  claim 51 , wherein the one or more panel securing holders includes two panel securing holders. 
   
   
       53 . The insulation element of  claim 51 , further comprising one or more knockouts protruding from the top surface. 
   
   
       54 . The insulation element of  claim 53 , further comprising one or more mechanical chases, each of the one or more knockouts positioned above a different one of the one or more mechanical chases. 
   
   
       55 . An insulation element for a wall panel, comprising:
 a bottom surface; and   one or more footer rebar seats adjacent the bottom surface.   
   
   
       56 . The insulation element of  claim 55 , wherein the one or more footer rebar seats includes two rebar seats.