High performance architectural precast concrete wall system

Abstract

A construction panel comprising a rigid insulation layer having an interior surface and an exterior surface, an outer concrete wythe secured to the exterior surface of the insulation layer, an inner concrete wythe secured to the interior surface of the insulation layer, a grid system which ties the outer concrete wythe to the inner concrete wythe and a capillary tube system located within the construction panel wherein liquid is passed through the tubing in order to increase or decrease the temperature of the construction panel.

What is claimed is: 
     
         1 . A method of manufacturing a pre-cast construction panel comprising the steps of:
 preparing an inner wythe mold/form and an outer wythe mold/form;   inserting one or more capillary tube sections into the concrete mix located in one or more molds/forms;   preparing one or more types of concrete to use in the molds/forms resulting in one or more concrete mixes;   pouring the concrete mix into the molds/forms;   compacting the concrete mix within each form/mold using a vibrating tool;   placing a piece of rigid insulation between the inner wythe mold/form and the outer wythe mold/form to ensure that the inner wythe and the outer wythe are secured to the rigid insulation;   securing a grid system which ties the outer concrete wythe to the inner concrete wythe;   allowing the concrete mix to cure for a period of time;   connecting a water supply to the one or more capillary tube sections;   pumping water through the one or more capillary tube sections to further cure the inner wythe and outer wythe for a period of time;   removing the molds/forms resulting in a completed construction panel.   
     
     
         2 . The method of  claim 1  further comprising the step of preparing and placing welded wire mesh, and/or rebar into the one or more molds/forms prior to pouring the concrete mix into the molds/forms. 
     
     
         3 . The construction panel of  claim 1  wherein the rigid insulation layer has a thickness in the range of 12 to 40 cm, the outer concrete wythe has a thickness in the range of 12 to 40 cm, and the inner concrete wythe has a thickness in the range of 12 to 40 cm. 
     
     
         4 . The construction panel of  claim 1  wherein the outer concrete wythe and the inner concrete wythe are constructed of a geo-polymer concrete. 
     
     
         5 . The construction panel of  claim 1  wherein the grid system is selected from the group including a carbon fiber grid, steel grid, or a combination thereof. 
     
     
         6 . The construction panel of  claim 1  wherein the capillary tube system is located within the inner concrete wythe. 
     
     
         7 . The construction panel of  claim 1  wherein the capillary tube system is separated into two or more zones which allow for the passage of liquids having different temperatures to pass through each zone simultaneously. 
     
     
         8 . The construction panel of  claim 1  further comprising a photovoltaic panel system operationally associated with the capillary tube system which functions to assist in heating and/or cooling the interior or exterior of the structure. 
     
     
         9 . A building or structure made from a plurality of precast construction panels according to  claim 1  of the instant invention. 
     
     
         10 . The building or structure of  claim 9  wherein both the interior walls and the exterior walls include precast construction panels according to  claim 1  of the instant invention. 
     
     
         11 . The building or structure of  claim 9  wherein the rigid insulation layer extends from the walls to the floor(s) of the building or structure. 
     
     
         11 . The building or structure of  claim 9  wherein the rigid insulation layer extends from the walls to the ceiling(s) of the building or structure. 
     
     
         12 . A pre-cast construction panel comprising:
 a rigid insulation layer having an interior surface and an exterior surface;   an outer concrete wythe secured to the exterior surface of the insulation layer;   an inner concrete wythe secured to the interior surface of the insulation layer;   a grid system which ties the outer concrete wythe to the inner concrete wythe; and   a capillary tube system located within the construction panel;   wherein the capillary tube system is comprised of one or more collector pipes each having a diameter in the range of 25 to 40 mm and a plurality of capillary tubes having a diameter in the range of 6 to 10 mm and extending from the collector pipes as a series of loops;   wherein liquid is passed through the capillary tube system in order to increase or decrease the temperature of the construction panel;   one or more temperature sensors embedded within one or both of the concrete wythes;   wherein the temperature sensors are incorporated into a building monitoring and control system which allows the building monitoring and control system to pass liquid through the capillary tube system in order to increase or decrease the temperature of the construction panel in order to increase or decrease the temperature of a room or structure.   
     
     
         13 . The construction panel of  claim 12  wherein the rigid insulation layer has a thickness in the range of 12 to 40 cm, the outer concrete wythe has a thickness in the range of 12 to 40 cm, and the inner concrete wythe has a thickness in the range of 12 to 40 cm. 
     
     
         14 . The construction panel of  claim 12  wherein the outer concrete wythe and the inner concrete wythe are constructed of a geo-polymer concrete. 
     
     
         15 . The construction panel of  claim 12  wherein the grid system is selected from the group including a carbon fiber grid, steel grid, or a combination thereof. 
     
     
         16 . The construction panel of  claim 12  wherein the capillary tube system is located within the inner concrete wythe. 
     
     
         17 . The construction panel of  claim 12  wherein the capillary tube system is separated into two or more zones which allow for the passage of liquids having different temperatures to pass through each zone simultaneously. 
     
     
         18 . The construction panel of  claim 12  further comprising a photovoltaic panel system operationally associated with the capillary tube system which functions to assist in heating and/or cooling the interior or exterior of the structure.