Lightweight Concrete Wall Panel With Metallic Studs

Abstract

A wall panel is provided that is comprised of a plurality of spaced foam insulative blocks. Between each block is a metal stud that spans the height of the wall panel and provides sufficient strength to counteract any compressive loads the wall panel may encounter. The presence of the insulation panels provides large surface areas for the receipt of a thin layer of cementious or gypsum based material that is adapted to receive nails and be easily cut. In addition, the decreased weight of the exterior wall allows for the omission of reinforcing internal structure within the exterior wall which is found in the prior art, thereby providing a lightweight and easy to fabricate wall.

1 . A wall panel with metallic studs comprising:
 an exterior layer comprised of at least one of a cementious or gypsum based material;   a plurality of generally parallel spaced foam blocks positioned on said layer of cementious or gypsum based material, each foam block having an upper end, a lower end and two lateral sides extending therebetween, wherein one lateral side further comprises a lip extending therefrom that defines a space between adjacent foam blocks;   a plurality of metallic framing members each with an upper end and a lower end, at least one said plurality of metallic framing members positioned within the space between the adjacent foam blocks; and   a fastening device interconnecting said metallic framing members to said exterior layer.   
   
   
       2 . The wall panel of  claim 1  wherein said wall panel is adapted to be cut with a hand saw. 
   
   
       3 . The wall panel of  claim 1  wherein said plurality of foam blocks are adhered to said plurality of frame members to increase bonding strength. 
   
   
       4 . The wall panel of  claim 1  wherein said plurality of foam blocks include a passageway therethrough and said plurality of frame members include apertures that are adapted to receive utility wiring or plumbing. 
   
   
       5 . The wall panel of  claim 1 , further comprising a first channel interconnected to said upper ends of said plurality of spaced metallic framing members. 
   
   
       6 . The wall panel of  claim 1 , wherein said fastening device is comprised of a stamped flat metal member coated with nylon and is adapted for attachment to said plurality of frame members with at least one of screws, rivets, welds and adhesives. 
   
   
       7 . The wall panel of  claim 1 , further comprising a bonding agent positioned between said layer of cementious or gypsum material and said foam blocks. 
   
   
       8 . The wall panel of  claim 1 , further comprising a second channel interconnected to said lower ends of said plurality of spaced framing members. 
   
   
       9 . The wall panel of  claim 1 , further comprising at least one bore formed through at least a portion of at least one of the framing members and at least one of the foam blocks opposite from the exterior layer for aiding in the bonding of a second exterior layer comprised of at least one of a cementious or gypsum based material. 
   
   
       10 . The wall panel of  claim 1 , wherein the exterior layer comprises concrete. 
   
   
       11 . The wall panel of  claim 1 , wherein the exterior layer comprises SHEETCRETE™ by Oldcastle Precast, Inc. 
   
   
       12 . The wall panel of  claim 1 , wherein the exterior layer comprises glasscrete. 
   
   
       13 . A low density wall panel, comprising:
 a first exterior layer comprised of at least one of a cementious or gypsum based material;   a foam block positioned on the first exterior layer, the foam block having a front surface and a rear surface, the front surface being in contact with the first exterior layer;   a plurality of studs embedded in the foam block, wherein each stud includes first and second portions, the first portion being adjacent the front surface of the foam block and the second portion being generally opposite the first portion; and   at least one fastener extending into the foam block and the first exterior layer.   
   
   
       14 . The wall panel of  claim 13 , wherein at least one bore is formed through the foam block and the second portion of at least one of the plurality of studs for aiding in the bonding of a second layer of at least one of a cementious or gypsum based material to the foam block opposite from the first exterior layer. 
   
   
       15 . The wall panel of  claim 13 , wherein the front surface of the foam block includes at least one cutout for aiding in the bonding of the first exterior layer to the foam block. 
   
   
       16 . The wall panel of  claim 15 , wherein the cutout includes a dovetail-shaped cutout. 
   
   
       17 . The wall panel of  claim 13 , wherein the fastener includes a head, an abutment portion, and a protruding portion; wherein when the protruding portion is mounted in the foam block, the abutment portion contacts the front surface of the foam block and the head is mounted in the exterior layer. 
   
   
       18 . The wall panel of  claim 17 , wherein the protruding portion is threaded. 
   
   
       19 . The wall panel of  claim 13 , wherein the fastener includes a head and a protruding portion; wherein when the protruding portion is mounted in the foam block, the head is mounted in the exterior layer. 
   
   
       20 . The wall panel of  claim 19 , wherein the protruding portion is threaded.