Pre-cast rain screen wall panel

Abstract

A prefabricated rain screen wall panel is provided comprising inner and outer concrete panels secured together by shear connectors. Intermediate members provide insulation, a drainage channel and a vapour barrier.

1 . A prefabricated assembly comprising:
 a) inner and outer concrete panels;   b) an intermediate drainage panel positioned adjacent the outer concrete panel and having an inner face and an outer face and a plurality of drainage channels provided on a face thereof, the outer face is adjacent an inner face of the outer panel;   c) an intermediate insulation panel positioned adjacent the intermediate drainage panel;   d) a vapour barrier positioned between the intermediate insulation panel and the inner concrete panel; and,   e) a plurality of shear connectors, each having a first portion, a second portion and an intermediate portion extending between the first and second portions, the first portion provided in the inner concrete panel and the second portion provided in the second concrete panel.   
     
     
         2 . The prefabricated assembly comprising of  claim 1  wherein the drainage channels are provided on the inner face of the intermediate drainage panel. 
     
     
         3 . The prefabricated assembly comprising of  claim 1  wherein the inner face of the intermediate drainage panel is adjacent an outer face of the intermediate insulation panel. 
     
     
         4 . The prefabricated assembly comprising of  claim 1  wherein the vapour barrier is positioned between an inner face of the intermediate insulation panel and an outer face of the inner concrete panel. 
     
     
         5 . The prefabricated assembly comprising of  claim 1  wherein the first and second portions are configured to be secured in the concrete panels. 
     
     
         6 . The prefabricated assembly comprising of  claim 1  wherein the intermediate portion extends at an angle to each of the first and second portions. 
     
     
         7 . The prefabricated assembly comprising of  claim 1  wherein the intermediate drainage panel comprises insulation material. 
     
     
         8 . The prefabricated assembly comprising of  claim 1  further comprising rebar provided in each of the inner and outer concrete panels and the first portions are secured to rebar in the inner concrete panel and the second portions are secured to rebar in the outer concrete panel. 
     
     
         9 . The prefabricated assembly comprising of  claim 1  wherein the intermediate drainage panel has an absence of internal channels. 
     
     
         10 . A prefabricated assembly comprising:
 a) inner and outer concrete panels;   b) first and second intermediate panels positioned between the inner and outer concrete panels, one of the first and second intermediate panels having a plurality of drainage channels provided on a face thereof, each of the intermediate panels having an inner face and an outer face;   c) a vapour barrier positioned between the inner and outer concrete panels; and,   d) a plurality of shear connectors, each having a first portion, a second portion and an intermediate portion extending between the first and second portions, the first portion provided in the inner concrete panel and the second portion provided in the second concrete panel.   
     
     
         11 . The prefabricated assembly comprising of  claim 10  wherein the drainage channels are provided on the inner face of the first intermediate panel. 
     
     
         12 . The prefabricated assembly comprising of  claim 10  wherein the inner face of the first intermediate panel is adjacent an outer face of the second intermediate panel. 
     
     
         13 . The prefabricated assembly comprising of  claim 10  wherein the vapour barrier is positioned between an inner face of the second intermediate panel and an outer face of the inner concrete panel. 
     
     
         14 . The prefabricated assembly comprising of  claim 10  wherein the first and second portions are configured to be secured in the concrete panels. 
     
     
         15 . The prefabricated assembly comprising of  claim 10  wherein the intermediate portion extends at an angle to each of the first and second portions. 
     
     
         16 . The prefabricated assembly comprising of  claim 10  further comprising rebar provided in each of the inner and outer concrete panels and the first portions are secured to rebar in the inner concrete panel and the second portions are secured to rebar in the outer concrete panel. 
     
     
         17 . The prefabricated assembly comprising of  claim 10  wherein the intermediate drainage panel has an absence of internal channels. 
     
     
         18 . A method of preparing a prefabricated panel comprising:
 a) providing a first concrete panel having first portions of shear connectors provided therein, the shear connectors having intermediate portions extending outwardly from the concrete panel;   b) providing a vapour barrier in overlying relation to the first concrete panel, the intermediate portions extending through the vapour barrier;   c) providing an insulation panel in overlying relation to the vapour barrier, the intermediate portions extending through the insulation panel;   d) providing a drainage panel in overlying relation to the insulation panel, the intermediate portions extending through extending through the drainage panel; and,   e) providing a second concrete panel in overlying relation to the drainage panel, the intermediate portions extending to the outer panel, wherein second portions of shear connectors are provided in the second concrete panel.   
     
     
         19 . The method of  claim 18  wherein step (a) further comprises providing rebar in the first concrete panel and step (e) further comprises providing rebar in the second concrete panel. 
     
     
         20 . The method of  claim 19  wherein step (a) further comprises securing the first portions to the rebar in the first concrete panel and step (e) further comprises securing the second portions to the rebar in the rebar in the second concrete panel. 
     
     
         21 . The method of  claim 18  further comprising shipping the prefabricated panel to a construction site.