Low Density Concrete Wall Panel With Reinforced Insulation Members

Abstract

An insulated wall panel is provided that employs a plurality of spaced insulated members that define cavities within the body of the wall panel. The insulation panels that form the cavities may be constructed of a reinforced insulating material, such as expanded polystyrene. The insulated wall panels may include a reinforcing mesh, preferably fiberglass coated with PVC embedded within the body of the EPS foam during fabrication. The strengthened EPS foam blocks have the advantage of being lightweight and very durable, thereby reducing handling damage, for example.

1 . A reinforced foam shell adapted for use with a low density manufactured concrete wall panel, comprising:
 a low density foam core comprising an upper end, a lower end and lateral edges positioned therebetween and having an exterior surface and an interior surface to define a predetermined depth;   a first and a second lateral wall extending downwardly from said lateral edges and extending substantially between said lower end and said upper end to define a substantially hollow portion positioned within the confines of the first wall and the second wall core; and   a mesh material positioned within the low density foam material to provide enhanced strength to the low density core.   
   
   
       2 . The reinforced foam shall of  claim 1 , further comprising a lip extending around a perimeter edge of said low density foam core proximate to said interior surface. 
   
   
       3 . The reinforced foam shall of  claim 2 , wherein said lip includes a least one rib with a cross-sectional profile adapted to support a reinforcing rod. 
   
   
       4 . The reinforced foam shell of  claim 12 , further comprising at least one structural rib positioned between said lateral edges of said foam core within said substantially hollow portion. 
   
   
       5 . The reinforced foam shell of  claim 4 , wherein said at least one structural rib has a cut-out portion adapted to receive a utility; 
   
   
       6 . The reinforced foam shell of  claim 2 , wherein the mesh material comprises at lest one of a polypropylene, a carbon fiber, a polyethylene, a fiberglass and metal material. 
   
   
       7 . The reinforced foam shell of  claim 1 , further comprising at least one spacer extending outwardly along said lateral edges, wherein a defined space is formed between the lateral edges when one reinforced foam core is positioned adjacent a second reinforced foam core along the lateral edges. 
   
   
       8 . The reinforced foam shell of  claim 1 , wherein said shell has an open bottom. 
   
   
       9 . The reinforced foam shell of  claim 1 , further comprising at least one plurality of plastic nailers positioned proximate to said upper end and said lower end. 
   
   
       10 . The reinforced foam shell of  claim 1 , wherein said mesh material extends between said upper end and said lower end. 
   
   
       11 . A method of manufacturing a reinforced foam material having a predetermined shape, comprising:
 providing a mold with a predetermined shape;   positioning a reinforcing material at a predetermined location within said mold;   injecting a heated foam material into the mold; and   bending said foam material to said reinforcing material.   
   
   
       12 . The method of  claim 1 , wherein the low density foam material is comprised of an EPS material. 
   
   
       13 . The method of  claim 1 , wherein said reinforcing material is placed in tension within the mold. 
   
   
       14 . The method of  claim 1 , wherein said reinforcing material is comprised of at least one of a fiberglass, a polypropylene, a polyvinyl chloride, and a carbon fiber material. 
   
   
       15 . The method of  claim 14 , wherein said reinforcing material is a fiberglass material coated with a polyvinyl chloride material. 
   
   
       16 . An insulative wall panel comprising:
 a concrete exterior face wall having an upper edge, a lower edge, and lateral edges therebetween;   a plurality of reinforced cavity formers interconnected to said exterior face wall; and   a plurality of ribs extending from said concrete exterior face wall, wherein said plurality of ribs are reinforced with a reinforcing rod and are interconnected to said concrete exterior face wall with a carbon fiber stirrup.   
   
   
       17 . The insulative wall panel of  claim 16 , further comprising a footer on said lower edge; and
 a bearing pad for engagement with a building foundation interconnected adjacent to said lower edge of said face wall.   
   
   
       18 . The insulative wall panel of  claim 16 , further including a carbon fiber stirrup interconnected to said reinforcing rod and said concrete exterior face wall. 
   
   
       19 . The insulative wall panel of  claim 16 , further comprising a wood strip interconnected to at least one of said plurality of ribs and said reinforced cavity formers, said wood strip being oriented generally parallel to said plurality of ribs. 
   
   
       20 . The insulative wall panel of  claim 16 , wherein said plurality of reinforced cavity formers include a channel for receipt of a utility conduit.