Building Component Construction System Utilizing Insulated Composite Wall Panels and Method For in situ Assembly

Abstract

A wall panel construction for in situ assembly includes a plurality of parallel elongate molded foam insulation forms uniformly spaced from each other to form elongate substantially parallel channels between each two adjacent molded foam insulation forms. Elongate attachment members extend along the channels proximate to the inner end surfaces. Concrete ribs fill voids between adjacent molded foam insulation forms to fill said channels to form load-supporting concrete columns extending along the length directions of the molded foam insulation forms. A sheathing panel abuts outer end surfaces. Fasteners attach the elongate attachment members and sheathing panel to the ribs, the inner end surfaces defining a plane substantially parallel to the sheathing panel suitable for attachment to a sheet of plaster board to cover the molded foam insulation forms when incorporated into a building structure. A building structure and method of assembling the wall panels are also described.

1 . A wall panel comprising an elongate, generally rectangular foam form having four corners and two spaced parallel lateral edges extending along the length direction of said foam form, at least one of said parallel edges being provided with means for forming at least one void or channel; rigid members embedded in said foam form at said corners at the longitudinal ends of said at least one void or channel; anchor means extending from said rigid members into said at least one void or channel; a wall board substantially coextensive with and secured to said foam form to form an exterior side of the wall panel and, together with said foam form, define said at least one void or channel; and concrete within said at least one void or channel embedding and securing said anchor means whereby said rigid members can be used as attachment points for structural members to be attached to the wall panel. 
     
     
         2 . A wall panel as defined in  claim 1 , wherein means for forming a void or channel is provided at each of both of said lateral edges. 
     
     
         3 . A wall panel as defined in  claim 1 , wherein foam form defines inner and outer surfaces and an outwardly extending flange at said inner surface that encapsulates said rigid members and at least partially defines said at least one void or channel with said wall board attached to said exterior or outer surface. 
     
     
         4 . A wall panel as defined in  claim 3 , wherein said foam form extends outwardly at said at least one of said parallel edges from said outer to said inner surface to form with said flange a portion of a trapezoid, whereby positioning two foam forms coextensively to butt associated flanges forms with said wall board a void or channel having a trapezoidal cross-section. 
     
     
         5 . A wall panel as defined in  claim 1 , further comprising cross steel straps each extending between corners at opposing longitudinal ends of opposing lateral edges of said foam form and secured at each end to said rigid members. 
     
     
         6 . A wall panel as defined in  claim 1 , further comprising anchors projecting from said wall board into said voids or channels and are encased within said concrete. 
     
     
         7 . A wall panel as defined in  claim 1 , wherein said foam form includes an opening for a window between said parallel edges. 
     
     
         8 . A wall panel as defined in  claim 1 , further comprising a steel assembly attached at a top of said wall panel to said rigid members. 
     
     
         9 . A wall panel as defined in  claim 1 , wherein said foam form is molded with said rigid members. 
     
     
         10 . A method of forming a wall panel comprising the steps of forming an elongate, generally rectangular foam form having four corners and two spaced parallel lateral edges extending along the length direction of said foam form, at least one of said parallel edges being provided with means for forming at least one void or channel; embedding rigid members in said foam form at said corners at the longitudinal ends of said at least one void or channel; extending anchors from said rigid members into said at least one void or channel; filling said at least one void or channel with concrete and embedding and securing said anchor means within said concrete; and attaching a wall board substantially coextensive with and secured to said foam form to form an exterior side of the wall panel, whereby said rigid members can be used as attachment points for structural members to be attached to the wall panel. 
     
     
         11 . A method as defined in  claim 10 , wherein means for forming a void or channel is provided at each of both of said lateral edges. 
     
     
         12 . A method as defined in  claim 10 , wherein foam form defines inner and outer surfaces and forming an outwardly extending flange at said inner surface to form said at least one void or channel with said wall board attached to said exterior or outer surface. 
     
     
         13 . A method as defined in  claim 12 , wherein said foam form extends outwardly at said at least one of said parallel edges from said outer to said inner surface to form with said flange a portion of a trapezoid, and positioning two foam forms coextensively to butt associated flanges to form with said wall board a void or channel having a trapezoidal cross-section. 
     
     
         14 . A method as defined in  claim 10 , further comprising adding cross steel straps each extending between corners at opposing longitudinal ends of opposing lateral edges of said foam form and secured at each end to said rigid members. 
     
     
         15 . A method as defined in  claim 10 , wherein said rigid members are molded into said foam forms. 
     
     
         16 . A method as defined in  claim 10 , wherein an opening is formed within said foam form for a window between said parallel edges. 
     
     
         17 . A method as defined in  claim 10 , further comprising the step of positioning a steel assembly at a top of said wall panel and securing said steel assembly to said rigid members. 
     
     
         18 . A method as defined in  claim 10 , wherein said foam form is molded with said rigid members. 
     
     
         19 . A method of simultaneously forming a plurality of wall panels comprising the steps stacking a plurality of foam forms in a production rack, each foam form being generally rectangular having four corners and two spaced parallel lateral edges extending along the length direction of each foam form, a wall board substantially coextensive with and secured to each of said foam forms to form an exterior side of each wall panel, at least one of said parallel edges being provided with means for forming at least one void or channel, and rigid members embedded in each of said foam forms at said corners at the longitudinal ends of said at least one void or channel with anchors extending from said rigid members into said at least one void or channel, said foam forms being stacked to arrange said voids or channels of all of said foam forms in non-horizontal orientations to position one end of each void or channel at a higher elevation relative to the other end of each of said voids or channels; and filling of said voids or channels of all of said forms by pouring concrete into said one ends to embed and secure said anchor means within said concrete while forming concrete ribs within said voids or channels. 
     
     
         20 . A method as defined in  claim 19 , wherein said foam forms are stacked to orient said voids or channels in substantially vertical directions.