MXPA01010747A - Insulated wall construction and forms and methods for making same - Google Patents

Abstract

A form assemblage for making concrete and other building walls is disclosed. The form assemblage includes interlocking interior and exterior wall panels (1a-c, 2a-c) that are connected at a predetermined spacing with panel connectors (7a, 7b) that interlock with the interior wall panels (2a-c) and the exterior wall panels (1a-c). The panel connectors (7a, b) have means (303a-d) for holding insulating foam panels (12a-c) at a position intermediate to the interior and exterior wall panels (1a-c, 2a-c). Cavities between the insulating foam panels (12a-c) and the exterior and/or interior wall panels (1a-c, 2a-c) can be filled with concrete or other load-bearing materials. In certain aspects, the form assemblage can be used as a wall structure without the use of the load-bearing material.

Description

CONSTRUCTION OF ISOLATED WALLS AND FORMS AND METHOD TO MAKE THE SAME DECLARATION WITH RESPECT TO FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT The research and development that leads to the invention described and claimed herein was not federally sponsored.

BACKGROUND OF THE INVENTION This invention relates to a method for making walls for buildings, in particular concrete walls or similar material made using shapes for configuring the wall. A common method for building walls for houses and other buildings is to prepare shapes that outline the configuration of the wall, pour concrete or other curable material into the shape, and then allow the material to harden to complete the wall. The forms are often plywood, particle board or other wood, steel or aluminum product, and are usually removed when the wall is completed. Frequently, the forms can not be reused and must be discarded or consumed in some other application of lesser value. In addition, assembling and disassembling the forms is laborious and slow. A wall made by the above method must frequently be isolated. This is particularly true if the wall is a construction above zero degrees, but it is also true in many areas for construction below zero degrees. An example of the latter is a home basement, which can be used as a living space, or a basement in a home or office building, in which thermal insulation not only provides comfort but also helps reduce the structural damage that It is created by the temperature cycles. In the method described above, the insulation is added as a separate construction step. In addition, the insulation can only be installed on the external surfaces of the wall. A common method to do this is to build a series of uprights inside the wall, place insulation in the space created between the uprights, and then cover the uprights with a material, such as albarrada or gypsum to form an interior wall surface . For aesthetic and comfort reasons, it is often desirable to cover the exposed surfaces of the wall. When the wall is made in the manner described above, this is accomplished in subsequent operations. The application of albarrada or gypsum, as described in the previous paragraph, are examples of this. In the case of an exterior wall, a facade such as brick, lining boards, stucco or the like is frequently joined. It has been proposed to build concrete walls using plastic forms. Among such propositions is that described in U.S. Pat. 5,706,620, 5,729,944 and WO publications. 97/32092, 97/32095, 94/1 8405, 94/21 867 and 95/331 06, all for De Zen. De Zen describes a wall construction based on prefabricated, interlocking plastic sectional shapes, with a roughly rectangular cross-section. A series of these shapes are connected to make a shape for a wall, and then filled with concrete to complete the wall. The shapes can be adapted, such that they contain a layer of insulating foam on the inner or outer surface, as shown, for example, in WO publications. 97/32092 and 97/32095. Due to the design of the shapes, the insulating foam is generally restricted to a type of empty-in-place, which tends to undergo dimensional changes as it ages. As a result of these dimensional changes, the integrity of the insulating layer is sometimes lost. Even more significantly, the insulating layer often distorts the plastic form by itself. This distortion can interfere with the ability of adjacent shapes to interlace easily. Still another problem is that the shapes are often bulky, because they have rectangular cross sections. It would be desirable to provide a non-expensive, easily assembled form for making concrete walls and other load bearing materials. Preferably, such a shape is easily adaptable to a variety of wall sizes and configurations and allows easy installation of services and openings. In addition it would be desirable to provide a method for making a wall, in which the wall could be constructed and isolated in a simple step; ' and preferably, in which aesthetically and functionally pleasing interior and / or exterior surfaces could also be provided.

BRIEF DESCRIPTION OF THE DIAMETERS Figure (Fig.) 1 is a partial cutaway view of an aspect of the invention. Fig. 2A is a top plan view of a wall panel of the invention. Figs. 2B and 2C are top perspective views of a wall panel of the invention. Fig. 3A is a top plan view of a panel connector for use in the invention. Fig. 3B is a front view of a panel connector for use in the invention. Fig. 3C is a perspective view of the upper part of a panel connector for use in the invention. Fig. 4 is a top plan view of a portion of a shaped assembly of the invention. Fig. 5 is a top plan view of a corner portion of a shaped assembly of the invention.

BRIEF DESCRIPTION OF THE INVENTION In a first aspect, this invention is a wall construction comprising an assembly so as to have cavities that are filled with a load bearing material. The shape assembly comprises (1) an interior wall surface comprising a plurality of interlocked interior wall panels, each panel having a first interlocking means in at least one panel edge and a second interlocking means in at least one border of the panel, the first and second interlocking means being on opposite panel edges, the first interlocking means of an inner wall panel being locked with the second interlocking means of an adjacent inner wall panel, said inner wall panels having the minus a first panel connector interlock means located on an internal surface thereof; (2) an outer wall surface separated from said inner wall surface, said outer wall surface comprising a plurality of interlocking outer wall panels, each panel having a third interlocking means in at least one panel edge and a fourth half of interlocking in at least one panel edge, the third and fourth interlocking means being on opposite panel edges, the first interlocking means of an outer wall panel being locked with the second interlocking means of an adjacent outer wall panel, said outer wall panels having at least one second panel connector interlock means located on an internal surface thereof; (3) a plurality of panel connectors, each panel connector having a body with an inner wall panel interlock means at one end, locked with a first panel connector interlock means of an interior and middle wall panel of interlocking outer wall panel at an opposite end locked with a second interlocking means of panel connector of an outer wall panel, wherein said panel connectors further contain at least one insulating foam panel support means in said body between said inner wall panel interlock means and said outer wall panel interlock means, and (4) a plurality of insulating foam panels located between and substantially parallel to said inner wall surface and said inner surface. outer wall, and between each consecutive pair of panel connectors, said insulating foam panels being held in position by said insulating panel support means e of foam in said connectors of consecutive panels. The foam assembly contains a plurality of cavities joined by an insulating foam panel, the consecutive panel connectors which hold said insulating foam panel in place, and at least one of said inner wall surface or outer wall surface. The cavities are filled with a material that supports load. The wall construction of this aspect of the invention provides a simplified wall construction and structural advantages. Because interior wall panels, exterior wall panels and panel connectors are locked, a form for the construction of a wall can be assembled quickly and easily. By varying the width and configuration of the wall panels, the walls can be easily constructed in most of the desired configurations. Similarly, the thickness of the wall is easily manipulated as desired when selecting wider or narrower panel connectors. Services, such as plumbing, electricity, telephone and the like, are easily installed. The openings, such as for doors and windows are easily provided. In addition, the construction and insulation of the wall can be carried out in a simple construction step. Because insulating foam panels are built into the wall construction, it is usually not necessary to separately install additional thermal insulation after the wall is finished. The position of the insulating foam panels inside the wall can be easily adjusted by modifying the panel connectors accordingly. This allows the builder to install the insulating foam panels in place on the wall where they have the greatest benefit for the particular climate, soil and other conditions that exist where the wall construction is made. Additionally, the interior wall panels and exterior wall panels will ordinarily become permanently attached to the wall structure, and if desired, will form the exposed internal and external surfaces of the finished wall. In preferred embodiments, these wall panels can be designed to provide aesthetic details, so that it becomes unnecessary to cover the wall panels with a facade or other finish, in order to have an aesthetically acceptable surface. In particularly preferred embodiments- the interior wall panels become the final, exposed interior walls of the building, and an additional interior finish, such as anchoring or the like, can be avoided. In a second aspect, this invention is a method for making a wall construction. In the method, a shape mount is made as described in the first aspect. Then, the cavities in the form assembly are filled with a material that supports empty-in-place loading. A third aspect of this invention is assembly in the manner described in the first aspect. The shape assembly of the third aspect can be used with or without a load bearing material to form a freestanding wall or a wall for a building. When used without a load bearing material, the form mounting is suitable by itself to make the walls ceilings of light structures, such as garages, tool sheds, light storage buildings and the like. Of course, the shape mounting of this aspect can be filled with a load bearing material as discussed with respect to the first aspect. A fourth aspect of this invention is a wall panel comprising a thermoplastic or thermoplastic structural foam sheet having two opposite edges, one of said opposite edges having a means of interlocking for interlocking with a reciprocal interlock means of a second panel of wall, the opposite edge having a reciprocal interlock means for interlocking with a means of interlocking a third wall panel, and said wall panel having at least one panel connector interlock means on one side. A fifth aspect of this invention is a panel connector comprising an elongate body having opposite edges, a means for interlocking the wall panel along said edges for engagement with a wall panel, and a panel support means. of insulating foam located on either side of said body between said opposite edges.

DETAILED DESCRIPTION OF THE INVENTION Fig. 1 illustrates a portion of a wall construction according to the invention. The wall construction includes a plurality of exterior wall panels 1 a, 1 b and 1 c and interior wall panels 2 a, 2 b and 2 c. The adjacent outer wall panels 1 a and 1 b are connected when locked at a connection point designated 3 in the drawing. The exterior wall panels 1 by 1 c are similarly connected at the connection point 4. The adjacent interior wall panels 1 a, 2 b and 2 c are connected in series at the seams 5 and 6. Note that the terms "exterior "e" interior "are used herein as short expressions for opposite sides of the wall construction. It is not necessary for the construction of walls to be an exterior wall of a building. The wall construction can be a freestanding wall, such as a boundary wall or retaining wall. Alternatively, it can be an interior wall in a building, such as to create separate rooms. The wall construction does not have to be vertical. For example, the wall construction of this invention can be used as a floor, roof, roof or other horizontal or angled structural component. The panel connectors 7a and 7b connect the inner and outer wall panels. In the embodiment shown, the panel connector 7a is connected to the wall panels 1 a and 2 a when locked thereto at the connection points 8 and 9, respectively. Similarly, the panel connector 7b is connected to the wall panels 1b and 2b when they are locked with them at the connection points 10 and 1 1. The panel connectors 7a and 7b have insulating foam panel support means 303a, 303b, 303c and 303d for supporting insulating foam panels 12a, 1 2b and 12c in a fixed position between the outer wall surfaces defined by wall panels exterior 1 a, 1 b and 1 c and interior wall surfaces defined by interior wall panels 2 a, 2 b and 2 c. As shown, the insulating foam panels 12a, 12b and 12c are positioned in a preferred manner between and separated from the outer and inner wall surfaces. However, it is within the scope of the invention that the foam panels are held in any position intermediate the exterior and interior wall surfaces, including adjacent any of the exterior or interior wall surfaces. Figs. 2A-2C further illustrate a wall panel for use in this invention. Wall panels used on the exterior and interior of the wall construction of the invention may, and preferably have, the same general cross-sectional design, although they may differ in several aspects as shown below. In Figs. 2A-2C a wall panel '2 having an outer side 201 and an inner side 202 is shown. As used herein, "internal" means the side towards the center of the wall construction and "external" means the side Looking away from the center of the wall construction. Along a vertical edge of the wall panel 2 is a means of interlock 203, and a reciprocal interlock means 204 is located along the opposite vertical edge. The interlocking means 203 and 204 are designed to fit together, so that when two adjacent wall panels are assembled to form the wall construction of the invention, the interlock means 203 of a wall panel is locked with the wall means. reciprocal interlock 204 of the adjacent wall panel. As shown, the interlock means 203 is in the shape of an arrow, and the reciprocal interlock means 204 is in the form of a receptacle for receiving and holding the arrow-shaped interlock means 203. However, the configurations of the interlock means 203 and 204 are not critical, as long as they correspond in structure, so that the panels of adjacent walls can be adjusted or slid into a locking relationship and the resulting interconnection is strong enough to hold them together when the construction or load-bearing material is subsequently put on the wall. In this way, the interlock means 203 and 204 may take the form of a rib and a slot, respectively, or may have any other interlocking configuration. It is also within the scope of the invention that the interlock means 203 and the reciprocal interlock means 204 are designed so that a separate part can be adjusted or slid over them to secure adjacent wall panels together.

In Figs. 2A-2C, the interlock means 203 is bent towards the inner side 202 of the wall panel 2, so that a flat outer surface is formed having only a vertical seam when the wall panel 2 is locked with an adjacent wall panel , as shown in Fig. 1. For aesthetic reasons, it is generally preferred that the interlocking means 203 and 204 be designed so as to provide a flat external surface, in particular on the inner side of the wall construction. It is particularly advantageous that the connection points between adjacent wall panels are visible from the outside of the wall only as a thin seam, the outer surfaces of the wall panels forming together an uninterrupted flat surface, except for the seam. The wall panel 2 also has at least one internal panel connector interlock means 205 for connecting the wall panel 200 to a panel connector (e.g., connectors 7a and 7b shown in Fig. 1). Although not critical to the invention, the panel connector 205 interleaving means preferably has approximately the same design and dimensions as either the interlock means 203 or the reciprocal interlock means 204. This allows the means of Panel connector 205 interlock is used to connect the wall panel 2 to another wall panel in a perpendicular relationship, thereby allowing a corner to be formed. This is illustrated in Fig. 5. As with the interlock means 203 and reciprocal interlock means 204, the panel connector interlock means 205 can be of any convenient configuration, as long as it is locked with a panel connector to form a connection that is strong enough to hold them together when the load-bearing material is subsequently placed on the wall. The various interlock means 203, 204 and 205 preferably extend the full height of the wall panel 2, as shown in Figs. 2B-2C. This allows maximum strength and stability of the connections of the wall panel 2 to adjacent wall panels and to panel connectors. In addition, having a full length interlock means allows the wall panel 2 to be easily prepared in an extrusion process, as discussed more fully below. However, it is within the scope of the invention to use interlock means 203, 204 and 205 that do not extend over the full height of the wall panel 2. For example, the interlock means 203 or 204 may intermittently run at along the edges of the wall panel 2, or may extend only in part along the vertical edges of the wall panel 2. The wall panel may also contain optional structures, such as a conduit for services, such as data , telephone, cable, electricity, plumbing, heating, ventilation, air conditioning and the like. One such vertically oriented conduit is shown at 206 in Figs. 1 and 4. Preferably, the conduit 206 is not filled with the load bearing material when the wall construction is constructed, so that the services running through the conduit 206 can be easily accessed for repair, service or replacement. Although the conduit 206 is shown in a vertical orientation, the conduits can be oriented horizontally or even diagonally if desired. The panel connectors are the second main component of the wall construction of the invention. Figs. 3A, 3B and 3C illustrate a panel connector 7 for use in the invention. The panel connector 7 has a body 301 having a wall panel interlocking means 302 at the opposite vertical edges. The panel connector 7 has a width Wc. The wall panel interlock means 302 is adapted to be locked with the corresponding panel connector interlock means 205 (shown in Figs 2A-2C) on the inner and outer wall panels. On each side of the body 301, between the wall panel interlocking means 302, insulating foam panel support means 303 are found. As shown, the insulating foam panel support means 303 is positioned approximately in the center of the width Wc of the connector panel 7. However, the insulating foam panel support means 303 can be varied anywhere along the width of the panel connector, depending on whether it is desired to place the insulating foam within the wall construction. For example, the insulating foam panel support means 303 may be positioned such that the insulating foam is almost adjacent to either the inner wall panel or the outer wall panel in the final construction. The preferred location of the insulating foam panel support means 303 along the width Wc of the panel connector 7 will depend on several factors. These factors include structural considerations, local climate and building codes, and any special requirements that must be met by the wall. Thermal insulating considerations favor placing the insulating foam panel support means 303 near the outer edge of the panel connector 7. However, to protect the insulating foam panels 1 2 from environmental attack, such as by weathering, impact or agents biological, such as termites or other insects, it may be desirable that the insulating panel support means 303 be located somewhat internally of the outer edge of the panel connector 7, so as to form a cavity (such as the cavities 401). by 401 c in Figure 1) that can be filled with the load-bearing material, between the insulating foam panel 12 and the outer wall panel 1. However, in some cases, it may be desired to locate the insulating panel support means 303 near the inner edge of the panel connector 7. It is also within the scope of the invention that the panel connectors 7 contain two or more supporting means. of insulating panel 303 on either side of the body 301. This allows to build a wall construction containing two or more layers of insulating foam. For example, a construction can be made having an insulating foam layer adjacent to the inner wall surface, defined by interior wall panels 2 and a second layer of insulating foam separated from the interior wall surface defined by the exterior wall panels 1. (see Fig. 1). As seen with the wall panels, the interlock means 302 preferably extends by substantially the full vertical length of the panel connector 7, to provide maximum force. Having a full length, 303 insulating foam bracket interlock means makes it easier to make a panel connector 7 via an extrusion process.

As shown, the insulating foam panel support means 303 for supporting the insulating foam panels, are formed integrally with the panel connector 7. However, it is not essential. The insulating foam panel support means 303 can be manufactured separately from the panel connector 7 and fixed thereto, for example, at a construction site as the wall construction is being assembled. For example, the insulating foam panel support means 303 can be designed with a hook or latch that fits over the top and / or bottom of the body 301 and holds the insulating foam panel support means 303 in place. Alternatively, although less preferable, the insulating foam panel support means 303 can be attached to the panel connector 7 by glue, nails, screws, lamination or any other suitable technique. It is also shown in Figs. 3A, 3B and 3C optional supports 304. The supports 304 are useful, for example, for supporting reinforcing means, such as rebars and the like in the three-dimensional space until the construction material is cast in place and hardened. As shown in Fig. 3A, the support 304 can be positioned so that the reinforcing means is oriented vertically. In Fig. 3C, the supports 304 permute horizontal orientation of the reinforcing means. Note that supports 304 can have other uses besides supporting a reinforcing medium. For example, supports 304 can also support plumbing, drainage, air fans, power, cable, data and telephone lines, heating, ventilation, air conditioning and the like.

The supports 304 may be made separately from the panel connector 300 and subsequently joined thereto, but for reasons of cost and ease of production of the panel connector 300, they are preferably formed integrally on the panel connector 300. When the supports 304 are made separately from the panel connector 300, the joining means is not critical. Similarly, the position of supports 304 may be varied as required by the parameters of the particular job. The supports 304 may also be in the form of cuts sized and properly positioned on the body 301 of the panel connector 7. FIG. 4 illustrates how to assemble the wall panels, panel connectors and insulating foam panels to make a shape of a small section of a wall construction. The outer wall panels 1 a and 1 b are locked at the connection point 3, the interlocking means 203 a of the outer wall panel 1 b with the reciprocal interlocking means 204 a of the outer wall panel 1 a engaging. In a similar manner, the wall panels 2a and 2b are locked via interlock means 203b of the inner wall panel 2b and reciprocal interlock means 204b of the inner wall panel 2a at the connection point 5. Although not shown, the exterior wall panels 1 a and 1 b and interior wall panels 2 a and 2 b can all be connected in series with additional wall panels in a similar manner, to extend the exterior and interior surfaces of the wall to any desired length. In Fig. 4, the panel connector 7a is positioned in interlocking relationship with the outer wall panel 1 a and inner wall panel 2 a, holding the respective wall panels at a predetermined distance from each other, which corresponds to the overall desired thickness of the construction of wall. The panel connector 7a has a latching means 302a which engages as a latch with the reciprocal interlocking means 205a on the outer wall panel 1 a, and a second interlock means 302c which similarly engages the interlock means reciprocal 205c on the inner wall panel 2a. The panel connector 7b is positioned in an analogous manner between the outer wall panel 1b and the inner wall panel 2b, the interlock means 302b and 302d being coupled with reciprocal muting means 205b and 205d, respectively, in an interlock relationship. The insulating foam panels 12a, 12b and 12c are positioned approximately parallel to, and between, the outer and inner wall panels, and are held in such a position by the insulating panel support means 303a, 303b, 303c and 303d that are Fixed to the panel connectors 7a and 7b. In Fig. 4, the various exterior wall panels, interior wall panels, panel connectors and insulating foam panels define a series of cavities 401 a, 401 b, 401 c, 401 d, 401 e and 401 f. In the finished wall construction of this invention, these cavities are filled with load bearing material. In Fig. 1, the cavities 401 c and 401f are shown filled with a load bearing material 13a and 13b, respectively, in such a manner. Similarly, the cavities 401 b and 401 e are shown in Fig. 1 partially filled with load-bearing material, as they might appear in the middle of the process of placing a load-bearing, emptied material in the cavities where it is caused that harden As shown in Figs. 3B and 3c, the body 301 may contain holes 305. The holes 305 are a preferred feature that allows the load bearing material to flow from a cavity through and from one end of the panel connector 7 to an adjacent cavity to form a continuous body of material that supports load. This is illustrated in Fig. 1, in which the load bearing material 1 3c in the cavity 401 e has flowed from one end to the other of a hole in the panel connector 7a to join with the load bearing material in the cavity adjacent to the left. The holes 305 are, therefore, advantageously large enough so that a load-bearing material, cast-in-place, emptied into a cavity on one side of the panel connector 7, can easily pass through the holes for filling and joining with the load bearing material in the adjacent cavity on the other side of the panel connector. As illustrated, the body 301 contains only two large holes 305. However, the holes 305 may be smaller than as illustrated in FIGS. 3B and 3C, and a greater number of holes 305 may be present. In the embodiment shown in Figs. 1 and 4, the outer cavities of the insulating foam panels 12a-c (ie, the cavities 401 ac) are approximately equal in thickness (exterior to interior) to those interior cavities of the insulating foam panels (i.e., cavities) 401 df). The relative thicknesses of the outer cavities 401 ac and the interior cavities 401 df are determined by the placement of the insulating foam panels 12a-c, which in turn are determined by the placement of the insulating foam panel support means 303a -d in the bodies of the panel connectors 7a and 7b. It is within the scope of this invention to position the insulating foam panels anywhere between the interior wall panels and the exterior wall panels, including adjacent any of the interior or exterior wall panels. For example, when the insulating foam panel is adjacent to the outer wall panels, the corresponding cavities 401 a-c will be reduced in thickness to zero or almost zero, and the cavities 401 d-f will be correspondingly increased in thickness. In such a case, filling exterior cavities to the insulating foam panels with load bearing material can provide little structural benefit, and all the load bearing material can be put in place in the interior cavities for the insulating foam panels. However, it is preferred that the insulating foam panels be positioned between and separated from the outer wall panels and inner wall panels, forming cavities on either side of the insulating foam panels sufficiently thick to provide a structural benefit when filling the cavities with material that supports load. Preferably, the cavities outside the insulating foam panels and outside the insulating foam panels are all at least 2.5 centimeters (cm) thick. The cavities outside the insulating foam panels are more preferably 2.5 to 1.2 cm thick. The interior cavities to the insulating foam panels are, more preferably from 5.1 to 25.4 cm and even more preferably from 7.6 to 20.3 cm in thickness. The wall construction of this invention is made by connecting the outer wall panels, inner wall panels, wall connectors and insulating foam sections together to make a fitting of desired shape, size and thickness. The shape mounting is usually built on a sub-structural, such as a foundation or a lower level wall or floor. The reinforcing means, such as reinforcing bars advantageously extend, from the substructure upwards towards the cavities enclosed by the form assembly. When reinforcing means are desired, those means are also normally placed in place between the inner and outer wall panels. For example, Figs. 1 and 4 show optional reinforcement bars (rebars) 32a, 32b, 33a, 33b and 33c, the rebars 32a-b being oriented in a horizontal direction and the rebars 33a-c oriented in a vertical direction. In the embodiment shown, the rebar 32b is shown attached to the panel connector 7a by the support 304e. The rebar 33a is attached to the panel connector 7a by the support -304a. The rebars 33b and 33c are joined to a panel connector 7b by the supports 304b and 304c, respectively. In addition, the unused support 304d is shown attached to the panel connector 7a in FIG. 4. Although the rebars are illustrated in Fig. 1, another reinforcing means can be replaced by the rebars or can be used in place of them. These alternative reinforcing means include sills, screens, meshes and the like. In all cases, the use of such reinforcing means is optional. In most cases, local building codes will dictate whether such reinforcing means are required. The corners can be made in several ways. A less preferred way is to cut exterior and / or interior wall panels as necessary to form a corner. Using the preferred structural foam wall panels, the individual panels can be glued or cemented together to form any desired configuration. Another less preferred method is to bend panels of individual exterior and / or interior walls to the desired configuration. Using the preferred structural foam wall panels, this can be easily achieved by heating the wall panels to the softening temperature of the polymer from which the wall panels are made, bending the wall panel into the desired shape, and then allowing the panel to cool below the softening temperature of the polymer. A more preferred way to form a corner involves using one or more specially designed interlocking wall panels. Fig. 5 shows an example of a corner made with such specially designed interlocking wall panels. In Fig. 5, the exterior wall panel 1 d has the same design as the exterior wall panel 2 in Fig. 2a. The wall panel 1 d has a reciprocal interlock means 204c, which is available to be locked with an adjacent wall panel (not shown) and the interlock means 203c, which is locked with the interlock means 205e in the panel of exterior wall 501. The wall panel 1 d also has internal interlock means 205f which is locked with the panel connector 507. The exterior wall panel 501 also has a means of interlock 203d which is connected to the reciprocal interlock means 204d of the wall panel adjacent exterior 1 e. As shown, the outer wall panel 501 demonstrates an advantage achieved when the interlocking means 302 in the panel connectors 7 (see Fig. 3), is designed to be adjusted with the reciprocal interlock means 204 of the wall panels 2 (see Fig. 2). In that case, the outer wall panel 501 can be prepared from the wall panel 2, simply by cutting the wall panel 2 along the edge of the interlock means 205e and discarding the unnecessary portion. In Figure 5, the removed and discarded portion of a wall panel 2 is shown in dotted lines to the left of the remaining exterior wall panel 501. The inner wall panel 6502 has the body 202a, the interlock means 203e and the reciprocal interlock means 204f. The interlock means 203e is coupled with the reciprocal interlock means 504 of the panel connector 507. The reciprocal interlock means 204f is available to be locked with an adjacent wall panel (not shown). The length of the inner wall panel 502 is advantageously selected in conjunction with that of the outer wall panel 1 d, so that the interlock means 204c and 204f are aligned. In Fig. 5, the panel connector 507 has the body 301 a. at each end of the body 301 a are crisscrossing means 302e and 302f for coupling with reciprocating interlocking means 205f of the outer wall panel 1 d and 204e of the outer wall panel 1 f. The insulating foam panel support means 303e and 303f are located on either side of the body 301 a, and are located in the body 301 a between the interlock means 302 e and 302 f. With respect to the features just described, the panel connector 507 can be very similar or identical to the panel connector 7 as shown in Fig. 3. However, the panel connector 507 contains an additional reciprocal muting means 504 proximate a body end 301 a and oriented at right angles close to the interlock means 302f. The reciprocal interlock means 504 is adapted to engage the interlock means 203e of the inner wall panel 502. Also in FIG. 5, the insulating foam panels 1 2d and 1 2e are held in place by the insulating foam panel support means 303e and 303f, respectively, of the panel connector 507. The insulating foam panel 12f is held in place by means of support of corresponding insulating foam panel in a panel connector that is not shown. The insulating foam panel 1 2f can be cut at the point where the insulating foam panel 1 2e intersects, or it can be extended, as shown, over the entire wall to the exterior wall panel 1 d. If desired, the optional support 1 2g can be used to help hold the insulating foam panel 12f in place. The optional support 12f may be a board or a piece of insulating foam, for example. Insulating foam panels 1 2e and 12f can be secured with one another to provide additional structural integrity.

Other variations of the above system for making corners will be apparent to those skilled in the art. The separation of the panel connectors is primarily chosen to provide the wall panel system and panel connector assembled and locked with sufficient strength to support the subsequent location of load bearing material without separating the panels and connector from each other and without distortion unacceptable. When making lightweight structures using the wall construction of the invention, in which no load-bearing material is used, the separation of the panel connectors is chosen to provide the unfilled foam assembly with the necessary structural strength. The separation of the panel connectors at intervals of 15.2 to 91.4 cm is generally adequate, a separation of 20.3 to 61.0 cm being preferred, and a separation of 25.4 to 61.0 cm being preferred. Using wall panels as shown in Figs. 2A-2C, which contain only a simple interlock means 205 for connection to a panel connector, the width of the wall panel will correspond to the spacing between the panel connectors. However, the wall panels can be easily made by having two or more interlock means 205 for connection to a corresponding number of panel connectors. In that case, the overall width of the wall panel can be increased. This has the effect of decreasing the number of seams that are visible on the external and internal surfaces of the completed wall construction, where the adjacent wall panels are located.

The cross-sectional thickness of the wall construction is determined by the width Ww (Fig. 3A) of panel connectors. Accordingly, the width Wc is chosen so that the thickness of the wall construction is sufficient to provide the required structural strength. Similarly, the cross-sectional thickness of cavities formed by the wall panels, panel connectors and insulating foam panels (shown as 401 af in Fig. 4), depends on the width Wc of the panel connectors and the placement relative of insulating panel support means 303a-along the body 301 of the panel connectors 7a and 7b. In order to build a basement wall for a simple one or two storey home, the overall thickness of the wall construction is advantageously 20.3 to 40.6 cm, preferably 20.3 to 30.5 cm. For walls above zero degrees in a plant structure, or the walls of an upper floor in a multi-storey structure, the overall thickness of the wall construction is advantageously 1 0.2 to 30.5 cm. At the height of the wall construction is mainly a matter of choice for the builder. It is contemplated that the wall construction of this invention is especially useful for building basement walls and walls above zero degrees in approximately one-story increments. In this way, heights from about 1.2 meters or greater, preferably 2.1 meters, more preferably 2.4 meters, to 4.6 meters, preferably 3.6 meters, more preferably 3.0 meters, are particularly suitable. In general, the height of the wall panels will be the same as that of the wall construction. If higher heights are desired, this can be achieved by lifting a second form mount above a completed wall construction, and repeating the construction process until the desired height is obtained. The services can be routed through the assembly as desired or required. As mentioned before, the conduits as shown in reference numeral 206 in Figs. 1 and 4, can be attached to the interior or exterior wall panels in order to provide routes through which services can be routed. When such conduits are used, the actual routing of most services can be done either before or after the load bearing material is placed in the cavities defined by the wall panels, insulating foam panels and panel connectors. However, it is usually preferred to route certain services such as plumbing, drains and heating, ventilation and / or air conditioning ducts before the load bearing material is put in place. Such services may be installed using customary techniques, and may be attached to wall panels and / or panel connectors as desired, using, for example, supports (e.g., 304a-d) or other suitable means. Of course, the holes may be made in interior wall panels, exterior wall panels or both, through which the services are delivered as necessary to the interior or exterior of the wall construction. In addition, the openings for any desired advantage, door and the like, can be made by cutting appropriately dimensioned and positioned holes through the assembled panel system, before adding the load bearing material. If desired, these openings can be made in place, or they can be pre-cut into the wall panels at the point of manufacture. The periphery of the opening is then framed before emptying the load-bearing material. The pre-fabricated window or door seats can be, and preferably are, used for this purpose. Advantageously, the framing adheres to the material bearing the load. After the wall construction is completed, the door or window trim can be attached to the frame and cut as desired. If desired, other structural or functional components may be added to the shape assembly, such as, for example, a barrier sheet or film for moisture or vapor. For convenience, the moisture or vapor barrier film may be attached to the interior surface of either or both of the interior and exterior wall panels or to either or both sides of the insulating foam panels prior to assembling the form fitting. Other structural or functional components include, for example, protruding screws or other fasteners for attachment to roof, eaves, roof, trusses and the like.; cuts for beams, rafters and the like, rods or protruding reinforcing rods, and the like. Once the form assembly is completed, any required aperture is framed and the necessary services are routed, and a load-bearing material can be placed in its place. In preferred embodiments, the load bearing material is emptied into place and subsequently hardened. If the wall is thick or high, or if a particularly dense load bearing material is used, it may be desirable to empty the load-bearing material in the frame in discrete portions, typically 1 5.2 to 91.4 cm in depth, and allowing Each of these portions hardens before emptying the portion that follows. This minimizes the distortion of the interior and exterior wall panels due to the weight of the construction material. If desired, external supports can be used to prop up the exterior wall panels, interior wall panels or both, while the load-bearing material is put in place. The exterior and interior wall panels can be made of any material that has sufficient rigidity to withstand the stresses placed on it during the construction of the wall, without breaking or becoming significantly distorted. In this way, the wall panels can be made of a wide variety of materials that are sufficiently rigid. These include, for example, gypsum wall board (albarrada), plywood and unexpanded plastics, such as polyvinyl chloride (PVC), polypropylene, polyethylene terephthalate (PET), polycarbonate (PC), polycarbonate polymer blends. acrylonitrile / butadiene / styrene (PC-ABS), high density polyethylene, polyacrylates, such as polymethyl methacrylate, rigid polyurethane, rigid polyisocyanurate and fiberglass or other compounds. However, the outer and especially inner wall panels are advantageously made of a thermoplastic or thermoplastic cellular material, commonly known as a "structural foam".

A structural foam is a cellular material made of a rigid organic polymer having a density as described below. The use of a structural foam has several advantages. First, it can be easily extruded or molded in a variety of configurations. Second, a sheet of structural foam of a given weight is thicker than a sheet of unexpanded polymer sheet of the same overall weight. The increased thickness increases its rigidity per unit weight. In the case of an interior wall panel which will ultimately form the exposed inner surface of the wall construction, a structural foam exhibits some improved insulating ability in relation to a non-expanded polymeric sheet. As a result, the wall tends to feel a little warmer to the touch when the interior wall panel is made from a structural foam. The density of the structural foam and its construction material are selected so that it substantially maintains its configuration and dimensions under the stresses to which it is subjected during the construction of the wall. Suitable polymers from which structural foam can be made include those previously identified as non-expanded plastics. Reinforcing materials, such as glass, polymer or carbon fibers, glass or ceramic chips or inorganic fillers, may be incorporated into the structural foam if desired. The structural foam advantageously has a density from 240 kilogram / cubic meter (kg / m3), preferably 320 kg / m3, more preferably 400 kg / m3 to 801 kg / m3, preferably 721 kg / m3, more preferably 641 kg / m3. A structural foam wall panel is advantageously from about 1, preferably about 2 mm in thickness, to about 25, preferably about 15, more preferably about 10 mm in thickness. As the exterior and interior wall panels will often become a permanent device for wall construction, it is preferred to adapt the external surfaces of the wall panels to provide aesthetic or functional characteristics. For example, the outer surface of the outer wall panel can be textured to provide the appearance of more conventional exterior building materials, such as with a brick pattern, a pattern of lining boards, a stucco pattern or the like. The outer surface of the interior wall panel can also be textured, such as with a pattern of simulated wood grains, a geometric pattern, a brick pattern or any other aesthetically desirable surface pattern. In addition, the interior or exterior wall panels can be colored or otherwise colored to any predetermined color. If desired, a sheet or other decorative external sample surface may be laminated or otherwise adhered to the interior wall panel. Similarly, panel connectors can be made from a wide variety of materials, with thermoplastic or thermosetting resins being preferred construction materials. It is particularly preferred that the panel connectors are made of a thermoplastic or thermoplastic structural foam as described with respect to the wall panels.

The structural foam wall panel and preferred panel connectors can be made by any suitable process, such as by injection molding or extrusion. An extrusion process tends to be inexpensive and is advantageous from that point of view. However, some shapes and configurations are difficult to produce in an extrusion process, and must be added to the wall panels in a subsequent operation. Any load bearing material that will provide adequate strength and rigidity can be used. In simpler or less expensive wall constructions, the load bearing material can be, for example, wood, stone, earth, sand, metal and the like. These are advantageously used in a particulate form, so that they can be easily emptied in the assembly in a manner as a free filling. However, this invention is particularly adapted for use with a load bearing material, which is emptied into place after the system of wall panels, insulating foam panels and panel connectors is assembled and then hardened. Accordingly, any of the many forms of cement, such as Portland cement, aluminous cement and hydraulic cements are suitable, as are clays capable of hardening, such as adobe, mortar and mixtures capable of hardening from clay and cement. Generally, it is preferred for reasons of cost and properties to use concrete, which is an aggregate of a material such as gravel, pebbles, sand, broken stones, slag, or ashes, in a matrix capable of hardening, usually mortar or a cement form, such as Portland cement, aluminous or hydraulic. In general, any concrete or aggregate that is useful for preparing load-bearing building walls is suitable for use with this invention. In the preferred wall construction made using a load-bearing material, capable of hardening, the outer and inner wall panels are advantageously permanently attached to the wall construction by the panel connectors and by adhering to the load bearing material hardened Preferably, the load bearing material also adheres to the insulating foam sections, so that the overall wall structure has physical integrity through its thickness from the outside to the inside. The panel connectors can contribute, in some cases, to this physical integrity, although it is anticipated that the main cross-sectional force (from outside to inside) of the wall construction is created by adhering the load-bearing material to the walls. Exterior and interior wall panels and insulating foam panels. Of course, this can be complemented if desired, using any suitable means. For example, the insulating foam panels and internal surfaces of the wall panels may contain projections or other irregularities which become embedded in the hardened load bearing material, thereby providing a mechanical coupling to complement the adhesion. The insulating foam panels can be made from any cellular insulating material that is sufficiently rigid to substantially maintain its configuration during the construction of the wall. Preferably, the insulating foam panel is a cellular polymeric foam. It can be made from a thermosetting or thermoplastic polymer. Suitable polymers include polyethylene (including low density polyethylene (LDPE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE) and substantially linear ethylene interpolymers), polypropylene, polyurethane, polyisocyanurate, ethylene-acetate copolymers of vinyl, polyvinyl chloride, phenol-formaldehyde resins, ethylene-styrene ether polymers and polyvinyl aromatic resins, especially polystyrene. Mixtures of any of two or more of the foregoing or mixtures of any of the foregoing with another polymer or resin are suitable. Polystyrene, rigid polyurethane, polyisocyanurate and phenolic resins are preferred, with polystyrene and polyisocyanurate being especially preferred. The insulating foam panel is preferably a closed cell foam having at least 60%, preferably at least 80%, more preferably at least 90% closed cells. The insulating foam panel advantageously has a density of 1 2.8 kg / m3, preferably 16.0 kg / m3, more preferably 1 9.2 kg / m3 to 96.1 kg / m3, preferably up to 3.0 kg / m3, more preferably up to 32.0 kg / m3. May have a skin on its larger surface, which can act as a barrier to moisture. The thickness of the insulating foam panel can vary depending on the amount of insulating effect desired. Normally, the insulating foam panel will be from 1.3 cm, preferably 2.5 cm, to 15.2 cm, preferably 5.1 cm thick. The thickness of the insulating foam layer will often be determined by local insulation needs and local building codes. In most cases, using a thicker insulating foam layer will improve the thermal insulating properties of the wall construction. Many insulating foam panels are made using a volatile blowing agent that escapes from the foam over time and is replaced by air. During this aging process, the foam frequently undergoes dimensional changes due to changes in the internal cell gas pressures as the blowing agent escapes and the air permeates the cells. After this process is long completed, the dimensions of the foam stabilize. An advantage of this invention is that it allows the use of insulating foam panels that are previously manufactured and aged, and therefore, are dimensionally stable. As discussed above, the invention is particularly suitable for use with a load-bearing material that fills the cavities created in the form-fitting between the inner and outer wall panels, the insulating foam panels and the panel connectors. However, the shape assembly of this invention can be adapted for other uses. An alternative mounting of this invention includes locked interior and exterior wall panels, as described above, which are locked with and separated by panel connectors. In this assembly alternatively, the insulating foam panel support means described above, may be omitted from the panel connectors. A form fitting of this type is adapted for use in light applications, such as garages, tool sheds and storage buildings. The space between the inner wall surface and the outer wall surface can be left empty, or filled with a load bearing material, as discussed above. Alternatively, a thermal insulating foam material can be placed in the space between the inner and outer wall surfaces. A second mounting alternatively retains the insulating foam panel support means, but the width Wc of the panel connectors is such that the insulating foam panels substantially fill the space between the inner wall surface and the wall surface. Exterior. Again, this alternative foam assembly is particularly suitable for light applications as discussed above.

The shape assembly of this invention is easily adapted to manufacture pre-cast wall panels that can be transported to a construction site and connected together to build a finished wall.

This provides the advantage of reducing the amount of work required at the construction site. One advantage of using structural foam interior wall panels is that the structural foam can form the exposed, final "sample" surface of the interior wall. In this way, it is not necessary to build an additional interior sample surface. As discussed above, seams normally appear at the juncture of adjacent inner wall panels and adjacent outer wall panels. If desired, the seams can be filled with a variety of filling materials, such as, mastic, wood fillings, plastic fillings and the like. For preferred structural foam wall panels, plastisol formulations, which are usually solutions of synthetic resins in a suitable solvent, are especially useful for filling in seams to provide a smooth finish. If desired, the interior and exterior wall panels may be painted, stained, papered or otherwise decorated, to provide any desired final appearance.

Claims (18)

1. REIVI DICACIONES 1 . A wall construction comprising (A) a mounting so as to have (1) an inner wall surface comprising a plurality of interlocked interior wall panels (1 a, 1 b), each panel having a first interlock means ( 203a) in at least one panel edge and a second interlocking means (204a) in at least one panel edge, the first and second interlocking means being on opposing panel edges, the first interlock means of a panel being interlocked. inner wall with the second interlocking means of an adjacent inner wall panel, said inner wall panels having at least one first panel connector interlocking means (205a, 205b) located on an internal surface thereof; (2) an outer wall surface separated from said inner wall surface, said outer wall surface comprising a plurality of interlocking outer wall panels (2a, 2b), each panel having a third interlock means (203b) in at least one a panel edge and a fourth interlocking means (204b) on at least one panel edge, the third and fourth interlocking means being on opposite panel edges, the third interlocking means of an outer wall panel locking with the fourth interlocking means of an adjacent outer wall panel, said outer wall panels having at least a second panel connector interlocking means (205c, 205d) located on an internal surface thereof; (3) a plurality of panel connectors (7a, 7b), each panel connector having a body with an inner wall panel interlock means (302a, 302b) at one end, locked with a first connector interlock means panel (205a, 205b) of an inner wall panel and outer wall panel interlock means (302c, 302d) at an opposite end locked with a second panel connector interlock means (205c, 205d) of a panel of outer wall, wherein said panel connectors further contain at least one insulating foam panel support means (303) in said body between said inner wall panel interlock means and said outer wall panel interlock means, and (4) a plurality of insulating foam panels (12) located between and substantially parallel to said inner wall surface and said outer wall surface, and between each consecutive pair of panel connectors, said panels being supported. insulating puma in position by said foam insulating panel support means in said consecutive panel connectors, wherein said foam assembly forms a plurality of cavities, each joined by an insulating foam panel, the adjacent panel connectors which they hold said insulating foam panel in place, and at least one said inner wall surface or outer wall surface, and (B) a load bearing material (1 3) that fills said cavities.
2. 2. The wall construction of claim 1, wherein said load bearing material is capable of hardening.
3. 3. The wall construction of claim 1, wherein at least one of (a) said inner wall panels, (b) said outer wall panels, and (c) said panel connectors, are made of a structural foam.
4. The wall construction of claim 1, wherein said insulating foam panels are disposed proximate to at least one of said inner wall surface and said outer wall surface.
5. The wall construction of claim 2, wherein said load bearing material, capable of hardening, comprises concrete.
6. The wall construction of claim 3, wherein said inner and outer wall panels comprise a structural foam of polyvinyl chloride.
7. The wall construction of claim 1, wherein said inner and outer wall panels comprise a structural foam reinforced with fiber.
8. 8. A method for making a wall construction comprising (a) locking a plurality of interior wall panels (1 a, 1 b) to form an inner wall surface, each panel having a first interlock means (203a) at least on one panel edge and a second interlock means (204a) on at least one panel edge, the first being and second interlocking means on opposite panel edges, the first interlocking means of an inner wall panel is locked with the second interlocking means of an adjacent inner wall panel, said inner wall panels having at least one first half of panel connector interlock (205a, 205b) located on an internal surface thereof; (b) locking a plurality of outer wall panels (2a, 2b) to form an outer wall surface, each panel having a third interlock means (203b) at least one panel edge and a fourth interlocking means (204b) ) on at least one panel edge, with the third and fourth interlocking means being on opposite panel edges, the third interlocking means of an outer wall panel is locked with the fourth interlocking means of an adjacent outer wall panel, said outer wall panels having at least one second panel connector interlocking means (205c, 205d) located on an internal surface thereof; (c) locking the inner wall surface and the outer wall surface by means of a plurality of panel connectors (7a, 7b), each panel connector having a body with inner wall panel interlock means (302a, 302b) ) at an end locked with a first panel connector interlocking means (205a, 205b) of an inner wall panel and outer wall panel interlock means (302c, 302d) at an opposite end locked with a second means of panel connector interlock (205c, 205d) of an outer wall panel, wherein said panel connectors further contain at least one insulating foam panel support means (303) located in said body between said panel interlock means of interior wall and said means of interlock of outer wall panel; and (d) mounting a plurality of insulating foam panels (12) between and substantially parallel to said inner wall surface and said outer wall surface, and between each adjacent pair of connectors by means of said insulating panel support means. of foam in said adjacent panel connectors, thereby forming a plurality of cavities, each joined by an insulating foam panel, to the adjacent panel connectors which support said insulating foam panel in place, and at least one of said interior wall surface or exterior wall surface, and (e) filling said cavities with a load bearing material (13).
9. 9. The method of claim 8, wherein said load bearing material is capable of hardening.
10. The method of claim 8, wherein at least one of (a) said inner wall panels, (b) said outer wall panels, and (c) said panel connectors, are made of a structural foam. eleven .
11. The method of claim 8, wherein said insulating foam panels are disposed proximate to at least one of said inner wall surface and said outer wall surface.
12. The method of claim 9, wherein said load bearing material capable of hardening comprises concrete.
13. The method of claim 10, wherein said inner and outer wall panels comprise a polyvinyl chloride structural foam.
14. The method of claim 8, wherein said inner and outer wall panels comprise a structural foam reinforced with fiber.
15. 15. The wall construction of claim 1, wherein at least one of the inner wall surface and the outer wall surface comprises a thermoplastic or thermoplastic structural foam sheet.
16. 16. The wall construction of claim 1, wherein the foam has a density of 400 to 721 kilograms per cubic meter.
17. 17. The wall construction of claim 1, wherein an exposed, external surface of at least one of the inner wall surface and the outer wall surface is decorated, colored or laminated, to provide an aesthetic sample surface.
18. 18. A mounting assembly comprising (a) an interior wall surface comprising a plurality of interlocked interior wall panels (1 a, 1 b), each panel having a first interlock means (203 a) in at least one panel edge and a second interlocking means (204a) in at least one panel edge, the first and second interlocking means being on opposite panel edges, the first interlocking means of an inner wall panel being locked with the second means of enclosing an adjacent inner wall panel, said inner wall panels having at least one first panel connector interlocking means (205a, 205b) located on an inner surface thereof; (b) an outer wall surface separated from the inner wall; said inner wall surface, said outer wall surface comprising a plurality of interlocking outer wall panels (2a, 2b), each panel having a third interlocking means (203b) in at least one panel edge yu n fourth interlock means (204b) on at least one panel edge, the third and fourth interlock means being on opposing panel edges, the third interlock means of an outer wall panel locking with the fourth interlock means of a adjacent exterior wall panel, said outer wall panels having at least one second panel connector interlocking means (205c, 205d) located on an internal surface thereof; (c) a plurality of panel connectors (7a, 7b), each panel connector having a body with an inner wall panel interlock means (302a, 302b) at one end, locked with a first connector interlock means panel (205a, 205b) of an inner wall panel and outer wall panel interlock means (302c, 302d) at an opposite end locked with a second panel connector interlock means (205c, 205d) of a panel of outer wall, wherein said panel connectors further contain at least one insulating foam panel support means (303) in said body between said inner wall panel interlock means and said outer wall panel interlock means.