Wall and Method

This is a divisional of U.S. patent application Ser. No. 19/093,991 filed Mar. 28, 2025, which is a divisional of U.S. patent application Ser. No. 18/199,211 filed May 18, 2023, which is a nonprovisional of U.S. provisional patent application Ser. No. 63/344,508 filed May 20, 2022, all of which are incorporated by reference herein.

The present invention is related to the production of panels and the construction of building structures. More specifically, the present invention is related to the production of panels and the construction of building structures utilizing a 3D wire mesh panel enveloped with a structural material, such as concrete, which can be precast, or produced on-site at a desired location.

This section is intended to introduce the reader to various aspects of the art that may be related to various aspects of the present invention. The following discussion is intended to provide information to facilitate a better understanding of the present invention. Accordingly, it should be understood that statements in the following discussion are to be read in this light, and not as admissions of prior art.

Panels for construction are widely used. However, due to their size into their weight equipment and labor is needed to transport them as well as to place them in a desired location and position. Furthermore, in many construction building applications, sound dampening and thermal insulation as well as fire retardation need to be considered. A panel which is lighter in weight, transportable or able to be produced on site at a desired location and position, which also provides for sound dampening, thermal insulation and fire retardation, it is desired.

The present invention pertains to a wall. The wall comprises a 3D wire mesh panel having a core with a 3D wire mesh matrix extending through and out the core and having a front side, a rear side, a top side, a bottom side, a left side, and a right side. The wall comprises structural material disposed about the panel covering the front side, the rear side, the top side, the bottom side, the left side, and the right side. The wall may comprise a foam form positioned about the 3D panel with the structural material disposed between the panel and foam form.

The present invention pertains to a method for producing a wall. The method comprises the steps of partially filling a form with uncured concrete. There is the step of positioning a 3D wire mesh panel onto the uncured concrete in the form. There is the step of allowing the panel to settle into the uncured concrete so there is uncured concrete below and around all sides of the panel and the uncured concrete bonds with the panel. There is the step of pouring additional uncured concrete onto the panel in the form to cover over the panel. There is the step of letting the uncured concrete about the panel cure. There is the step of separating the panel with the cured concrete about the panel from the form.

The present invention pertains to a method for producing a wall. The method comprises the steps of positioning a 3D wire mesh panel vertically at a desired location. The panel has a core with a 3D wire mesh matrix extending through and out the core. There is the step of building a foam form about the panel. There is the step of pouring a structural material between the panel and foam form. There is the step of letting the structural material harden about the panel.

Referring now to the drawings wherein like reference numerals refer to similar or identical parts throughout the several views, and more specifically tothereof, there is shown wall. The wallcomprises a 3D wire mesh panelhaving a corewith a 3D wire mesh matrixextending through and out the coreand having a front side, a rear side, a top side, a bottom side, a left side, and a right side. The wallcomprises structural material disposed about the panelcovering the front side, the rear side, the top side, the bottom side, the left side, and the right side.

Each side may be flat, and the structural material is concrete. The wallmay include an openingextending through the front sideand rear sideand concrete over the front sideand rear sidewhich defines a window or a door. The wallmay be freestanding and transportable. The wallmay include a formpositioned about the top side, bottom side, right side, and left side, and in contact with the concrete covering the top side, bottom side, right side, and left side. The formdefines an outer borderof the wall. The wallmay have dimensions of about 4′×′×″, and may weigh less than 4,600 lbs. with no openingsand may support loads of more than 50000 lbs. The wallmay include eyesextending from the front sidefor lifting the wall.

In an alternative embodiment, as shown in, the wallmay include a formpositioned about the panelwith the structural material disposed between the paneland form. The formmay include a front foam sheetdisposed adjacent to and in spaced relationship with the front sideand a rear foam sheetdisposed adjacent to and in spaced relation with the rear side. The wallmay include a right end boardand a left end boardadjacent to and in spaced relationship with the right sideand the left side, respectively. The wallmay include bracingpositioned about the formto hold the formin place. The wallof this embodiment is produced using a 3D panel, 2″ or 4″ foam sheets, pencil rods, 2″×4″ boards for the bracing. Spacerof the desired thickness are installed between the foam sheets and the paneland are removed during the pouring process.

By using this wall, and the methods described herein, it will create a large savings in the construction building cost and eliminate labor costs for end results. Contractors are able to precast on site or at other locations with little waste of materials. Once the wallis formed, the foam sheets can be left in place for applying the finish desired to the foam, being stucco, brick, stone, etc. The foam can also be removed for a smooth surface finish. The panelgives the wallthe proper strength for building requirements and for insulation value to the building. The foam formgives extra insulation value, both temperature and sound, and extends the burn rating time to the structure. Pouring a 2″ or 4″ thickness of concrete, on both sides of the form, can be used to produce the wall.

In yet another embodiment, as shown in, the wallmay include an enclosureenveloping, positioned around and in spaced relationship with the right foam sheet and left foam sheet, and wherein the structural material is also disposed between the enclosureand the front foam sheetand rear foam sheet.shows an overhead view of the enclosure, which can be comprised of plywood sheets, adjacent to and in spaced relationship with the right foam sheet and left foam sheet. Spacersare used to maintain the desired distance between the plywood sheetsand the right and left foam sheets. The right end boardand left end boardcontact the ends of the plywood sheetsto close off the enclosureso none of the poured uncured concrete can escape through the right and left sides. Uncured concreteis poured into the enclosurethrough the top side so it flows between the plywood sheetsand the right and left foam sheets and the paneland the right end and a left end boards to capture the right and left foam sheets in the uncured concretepoured about the panel.shows an overhead view of a wallformed from the formand enclosureofwith a partial cutaway view of the cured concrete.

The present invention pertains to a method for producing a wall. The method comprises the steps of partially filling a formwith uncured concrete. There is the step of positioning a 3D wire mesh panelonto the uncured concretein the form. There is the step of allowing the panelto settle into the uncured concreteso there is uncured concretebelow and around all sides of the paneland the uncured concretebonds with the panel. There is the step of pouring additional uncured concreteonto the panelin the formto cover over the panel. There is the step of letting the uncured concreteabout the panelcure. There is the step of separating the panelwith the cured concreteabout the panelfrom the form.

There may be the step of preparing the panel. There may be the step of preparing the formto receive the panel. The preparing the panelstep may include the step of clipping joints and seamsof the panel. The preparing the panelstep may include the step of adding U shaped mesh to an outer edge of the panel. The preparing the panelstep may include the step of clipping and cutting a window or door or openingin the panel.

The preparing the formstep may include preparing inner borderswithin a perimeter of the formwhere the inner bordersconformwith a window or door or openingin the panel. After the pouring step, there may be the step of finishing or stamping the uncured concrete. The allowing step may include the step of vibrating the panelso the panelsettles into the uncured concrete. After the pouring step, there may be the step of screeding the uncured concrete.

The panelmay have a corewith a 3D wire mesh matrixextending through and out the core. The panelmay provide sound dampening and temperature insulation. The corepay me formed of styrene foam.

The present invention is a precast wallthat is significantly lighter than existing precast walls, but just as capable of meeting all the current requirements in commercial and residential buildings. For example, a rectangular shaped wallof the present invention with no openingat 4′×20′×8″, would weigh less than 4,600 lbs., or even less than 4,000 lbs., or even less than 3,700 lbs., or even weigh as little as about 3,200 lbs. In comparison, a wall of the same size but precast completely with concrete and no panelor any coreor wire mesh matrix, would weigh about 6,000 lbs.

Furthermore, the precast wallhas a sound dampening coreembedded in the panelwith the styrene foam used to make the panels. The precast wallprovides an additional source of insulation that is not currently available.

The ability to utilize the techniques of forming and pouring in place, and additionally the ability to utilize the engineered wallto precast onsite or offsite described herein allows for a wallthat offers more to a customer in terms of use and the ability to move. The customer can utilize smaller equipment to move and handle, plus the added benefit of sound and insulation.

The precast wall/tilt up wall would be cast either onsite by the contractor or could be constructed off site and shipped to the site. Both approaches would be performed the same way. With reference to, first, the precast formor box would already be built to the specification of the project. Second, the panelswould be installed in the precast form. This would consist of clipping all the joints and seams, adding U shaped mesh to the outer edge of the panelsand clipping, then cutting any window/door or openingin the panel. Once this is complete, any additional engineering specs would be installed per the engineered construction plans for that specific project. Third, the precast panelwould then be lifted out of the formand positioned to the side to allow the uncured concreteto be poured into the precast form. Once the uncured concreteis placed in the form, the panelis then picked up and put back into the form. At this point, the panelwould be vibrated in to make sure the panelsare settled into the uncured concreteto get the correct coverage of concrete around the panelto get the correct bond from the panelto the concrete. Fourth, the final layer or top portion of uncured concretewould be poured over the panelto the desired thickness required by the project and then it would be screeded off. The uncured concretewould then be either flat finished or stamped depending upon the project. Fifth, once the concrete has cured about the precast panel, the now formed wallwould then be lifted out of the formand either shipped to the job site or placed as either a precast panelor tilt up panelbased on the job.

shows an empty form. The size and configuration of the formis based on the ultimate wall that will be produced. The formis made by outer boardsconnected together in a configuration that matches the configuration of the wallwhich is being produced to define an outer border. The outer boardsare held in place by slatsplaced against the outsideof the outer boards. For any opening, such as a door or a window, there are inner boardsthat are placed in the interiorof the perimeter of the formdefined by the outer boardsto define an inner border. The inner boardsare connected together in a configuration that matches the configuration of the openingof the wall. The inner boardsare held in place by slatsplaced against the insideof the inner boards.

shows the 3D wire mesh panel. The panelhas a 2 inch or a 4-inch-thick foam corewith a welded wire mesh matrixextending through and out the core. The opening, in this case a door or a window, has been cut out of the panel. U shaped wire meshis wrapped about all open edgesof the panelto close off the sides of the panel. Flat wire mesh patchesare attached to any seamsin the panel. The seamsare formed from smaller 3D wire mesh panelswhich are positioned aside each other, with the flat wire mesh patchespositioned over the adjacent sides of the smaller 3D wire mesh panels. The flat wire mesh patchesare wired to the adjacent smaller panelsto join the seamsor welded or brazed to the adjacent smaller panelsto join the seams. There are also tilt up eyesextending from the surface of the wire mesh matrix. An example of a 3Dwire mesh panelthat can be used can be purchased from Strata Worldwide located in Sandy Springs Georgia and is called the EVG-3D® Panel, which comprises a 3D welded wire mesh matrix, fitted with an expanded and non-flammable polystyrene core. The strength and rigidity of the panelresults from inner diagonal truss wires welded to both mesh layers on each side.

shows the initial placement of uncured concreteinto the formfrom a first pour of uncured concrete. The initial placement of the uncured concreteinvolved pouring uncured concreteinto the formuntil the uncured concreteis about 2 inches thick throughout the insideof the form.

shows the placement of the panelonto the uncured concretein the formfrom the initial placement of the uncured concrete. The panelis then vibrated into the uncured concrete. A concrete pencil vibrator is used to help settle the panelin the uncured concrete.

shows the placement of the uncured concretefrom the second pour onto the top of the panelalready in the form. The second pour of the uncured concreteprovides about 2 inches of uncured concretein addition to the uncured concretefrom the first pour. The panelin the uncured concreteis again vibrated and then finished.

shows the finished wallwith the cured concreteabout the panel. The formis then removed from the wallso the wallis then ready to be ultimately used in the structure being created with the wall.

shows the finished wallseparated from the form.

In regard to an alternative embodiment, the present invention pertains to a method for producing a wall. The method comprises the steps of positioning a 3D wire mesh panelvertically at a desired location. The panelhas a corewith a 3D wire mesh matrixextending through and out the core. There is the step of building a foam formabout the panel. There is the step of pouring a structural material between the paneland foam form. There is the step of letting the structural material harden about the panel.

shows the panelbeing prepared to receive the uncured concrete. The coreis in the center with the wire mesh of the 3D wire mesh matrixshown on the front sideand the rear sideof the core. The right sideof the coreis shown in. The front foam sheetis adjacent to the front sidewith a spacerpositioned between the front sideand the front foam sheetand the rear foam sheetis adjacent to the rear sidewith spacerpositioned between the rear sideand the rear foam sheet. Barsextend out from the front foam sheet, and also the rear foam sheet(not shown). The barsare used to attach the bracingto the formto hold the formand the paneltogether while the uncured concreteis poured and then allowed to cure. The barsextend through the foam sheets and the panel.

shows a perspective overhead view of the panelbeing prepared to receive the uncured concrete. The coreis in the center with the 3D wire mesh matrixextending through the coreand on the front and rear sideof the core. In, the top sideand the rear sideof the coreare shown. There are spacersdisposed between the paneland the front and rear foam sheets. The right end boardis shown in place along the right sideto close off the formso no uncured concreteand escape.

shows a perspective right sideview of the panelbeing prepared to receive the uncured concrete. Some of the bracingis in place to hold the formto the panel.

shows a perspective view of the formpositioned about the paneland held in place by bracing. The bottom sideof the panelcan rest on spacersso uncured concretecan flow under the bottom sideand cover the bottom side.

shows a perspective view of the formpositioned about the paneland held in place by even more bracingthan shown in.

shows a finished wallthat is separated from the formwhich is freestanding and positioned vertically.

shows a perspective top view of the top sideof the paneland formafter the uncured concretehas been poured into the formand has had time to cure.

is an overhead view of the wallseparated from the formwith the concrete cured and showing the width of the wallbeing 10 inches.

The wallacts as a sound barrier due to the core. The wallcan be precast traditionally or onsite. Equipment required to move, and set would be significantly less due to the lower weight of the wallcompared to existing walls. Overall cost would be less due to overall concrete consumption. The wallis used in general civil construction, such as office builds, large commercial applications, etc. In residential construction, the wallmay be precast utilizing the foam formonsite. By keeping the foam form, its presence as part of the walls allows for even better insulation, and creates a base to apply brick, stucco, stone etc. This allows for less labor to formand strip forms, added R value, better sound barrier, and in short, a lower cost to the end user in materials and labor cost.

Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described by the following claims.