Modular insulated concrete wall panel system

Abstract

The present invention provides a modular insulated concrete wall panel system comprising at least one assembled panel, each assembled panel comprising a precast concrete panel and one or more insulation panels. The concrete panel has an outer frame and plurality of vertical ribs that engage with corresponding channels on the insulation panels. There is also provided a method of forming a modular concrete wall panel system of the present invention, comprising the steps of: providing the at least one preformed insulating panel laid horizontally with the vertical channels facing in an upward direction; pouring concrete around the at least one preformed insulating panel such that the concrete fills the channels in the insulating panel, thereby forming the concrete panel rib elements; and allowing the concrete panel to set and cure.

We claim: 
     
         1 . An insulated concrete wall panel system comprising at least one assembled panel, the at least one assembled panel comprising:
 a concrete panel comprising:
 a first face and a second face; 
 an outer frame extending around a periphery of the first face of the panel, the outer frame being formed from a top frame element extending from the top edge of the first face, a bottom frame element extending from the bottom edge of the first face, and first and second vertical frame elements extending between respective ends of the top and bottom frame elements; and 
 at least one rib element extending between the top and bottom frame elements on the first face of the panel; 
   wherein the outer frame elements and the at least one rib element form cavities on the first face of the concrete panel; and   at least one insulation panel comprising:
 a first face and a second face, the first face of the insulation panel being configured to conform to corresponding cavities on the concrete panel, each said insulation panel comprising on said first face at least one vertical channel, each said vertical channel being configured to receive a respective rib element on the concrete panel. 
   
     
     
         2 . The system of  claim 1 , wherein the concrete panel comprises two or more rib elements extending between the top and bottom frame elements on the first face of the concrete panel, and each said at least one insulation panel comprises two vertical channels on the first face of the insulation panel. 
     
     
         3 . The system of  claim 2 , further comprising a first end insulation panel and a second end insulation panel. 
     
     
         4 . The system of  claim 1 , wherein the concrete panel further comprises a connector slot at each corner of the outer frame, the system further comprising a connector element configured to engage the connector slots on two adjacent concrete panels to hold the two concrete panels together in abutting arrangement. 
     
     
         5 . The system of  claim 4 , wherein the connector element has a generally tapered shape and is provided with shoulder bumps. 
     
     
         6 . The system of  claim 1 , wherein the insulation panels further comprise one or more vertical electrical chases extending through the length of each insulation panel. 
     
     
         7 . The system of  claim 1 , wherein the insulation panels further comprise one or more horizontal electrical chases extending through the width of each insulation panel. 
     
     
         8 . The system of  claim 1 , wherein the insulation panels further comprise one or more channel slides on the second face of the insulation panel, the channel slides being configured to receive metal channel slides to facilitate attachment of drywall or eternal fixtures. 
     
     
         9 . The system of  claim 1 , wherein the insulation panels are formed from expanded polystyrene. 
     
     
         10 . A method for forming the insulated concrete wall panel system as defined in  claim 1 , comprising the steps of:
 providing the at least one preformed insulating panels laid horizontally with the vertical channels facing in an upward direction;   pouring concrete around the at least one preformed insulating panel such that the concrete fills the channels in the insulating panel, thereby forming the concrete panel rib elements; and   allowing the concrete panel to set and cure.   
     
     
         11 . The method of  claim 10 , further comprising the step of finishing the second face of the concrete panel to create the outer layer of the concrete wall panel system. 
     
     
         12 . The method of  claim 10 , further comprising the step of providing an exterior finish selected from stucco finish, painted finish, faux brick finish, stone finish or simulated wood finish.