Title:
Method and system for supporting insulating panels in an insulated concrete wall structure
Kind Code:
A1


Abstract:
A method and system for supporting insulating panels in an insulated concrete wall structure, wherein the wall structure has at least two insulating panels positioned relative to each other to form a cavity for receiving uncured concrete to form a wall. The system comprises at least two supporting panels, each disposed on each side of the wall structure to support the insulating panels. Each of the supporting panels has a planar member and an intruding member extended from the planar member. The intruding member intrudes inwardly toward the cavity so as to allow a mechanical linkage to link the supporting panels in order to maintain the relative position between the insulating panels when uncured concrete is poured into the cavity. Preferably, the supporting panel is made of a foldable sheet so that the sheet is folded to form the intruding member.



Inventors:
Mckay, Harry (Scarborough, CA)
Application Number:
10/442735
Publication Date:
11/25/2004
Filing Date:
05/21/2003
Assignee:
MCKAY HARRY
Primary Class:
International Classes:
E04B2/86; (IPC1-7): E04G17/06
View Patent Images:



Primary Examiner:
KATCHEVES, BASIL S
Attorney, Agent or Firm:
Paul A. Levitsky (Fairfield, CT, US)
Claims:

What is claimed is:



1. A method for supporting insulating panels in an insulated concrete wall structure, wherein at least a first insulating panel and a second insulating panel are positioned relative to each other defining a cavity for receiving uncured concrete to form a wall having opposing surfaces, and wherein each of the first and second insulating panels has an inner side and an outer side with the inner sides facing the cavity, the inner sides substantially defining the opposing surfaces of the wall, said method comprising the steps of: (a) providing a first support panel adjacent to the outer side of the first insulating panel and a second support panel adjacent to the outer side of the second insulating panel, the first support panel having a first longitudinal axis and the second support panel having a second longitudinal axis substantially parallel to the first longitudinal axis, wherein: (i) the first support panel comprises a first intruding member intruding inwardly toward the cavity, the first intruding member having a longitudinal axis substantially parallel to the first longitudinal axis of the first support panel, and (ii) the second support panel comprises a second intruding member intruding inwardly toward the cavity, and the second intruding member having a longitudinal axis substantially parallel to the second longitudinal axis of the second support panel; and (b) providing a mechanical linkage linking the first intruding member to the second intruding member so as to maintain the relative position between the first and second insulating panels.

2. The method of claim 1, wherein: (a) the first support panel defines a first plane and the first intruding member comprises a first elongated strip extending from the first plane, and (b) the second support panel defines a second plane and the second intruding member comprises a second elongated strip extending from the second plane.

3. The method of claim 2, wherein the first elongated strip has a plurality of first securing means and the second elongated strip has a plurality of second means, and wherein the mechanical linkage comprises a plurality of ties, each secured to one of said first securing means and one of said second securing means.

4. The method of claim 3, wherein the plurality of first securing means are spaced apart from each other, distributed substantially along the longitudinal axis of the first intruding member, and the plurality of second securing means are spaced apart from each other, distributed substantially along the longitudinal axis of the second intruding member.

5. The method of claim 1, further comprising the step of: providing a third insulating panel adjacent to the outer side of the first insulating panel, and a fourth insulating panel adjacent to the outer side of the second insulating panel.

6. The method of claim 1, wherein each of the first and second insulating panels has a top portion, said method further comprising the steps of: (a) providing a third support panel adjacent to the outer side of the first insulating panel near the top portion of the first insulating panel, and a fourth support panel adjacent to the outer side of the second insulating panel near the top portion of the second insulating panel, wherein (i) the third support panel comprises a third intruding member intruding inwardly toward the cavity, and (ii) the fourth support panel comprises a fourth intruding member intruding inwardly toward the cavity; and (b) providing a further mechanical linkage linking the third intruding member to the fourth intruding member so as to further maintain the relative position of the first and second insulating panels.

7. The method of claim 6, wherein: (a) the third intruding member comprises a channel for covering at least a part of the top portion of the first insulating panel, and (b) the fourth intruding member comprises a further channel for covering at least a part of the top portion of the second insulating panel.

8. The method of claim 7, wherein: (a) the third intruding member further comprises a lip section extending from the channel inwardly toward the cavity, the lip section comprises a plurality of third securing means, and (b) the fourth intruding member further comprises a further lip section extending from the further channel inwardly toward the cavity, the further lip section comprising a plurality of fourth securing means, and wherein (c) the further mechanical linkage comprises a plurality of ties, each secured to one of said third and fourth securing means.

9. The method of claim 1, wherein each of the first and second insulating panels has a bottom portion, said method further comprising the steps of: (a) providing a third support panel adjacent to the outer side of the first insulating panel near the bottom portion of the first insulating panel, and a fourth support panel adjacent to the outer side of the second insulating panel near the bottom portion of the second insulating panel, wherein (i) the third support panel comprises a third intruding member intruding inwardly toward the cavity, and (ii) the fourth support panel comprises a fourth intruding member intruding inwardly toward the cavity; and (b) providing a further mechanical linkage linking the third intruding member to the fourth intruding member so as to further maintain the relative position of the first and second insulating panels.

10. The method of claim 9, wherein (a) the third intruding member comprises a channel for covering at least a part of the bottom portion of the first insulating panel, and (b) the fourth intruding member comprises a further channel for covering at least a part of the bottom portion of the second insulating panel.

11. The method of claim 10, wherein: (a) the third intruding member further comprises a lip section extending from the channel inwardly toward the cavity, the lip section comprises a plurality of third securing means, and (b) the fourth intruding member further comprises a further lip section extending from the further channel inwardly toward the cavity, the further lip section comprising a plurality of fourth securing means, and wherein (c) the further mechanical linkage comprises a plurality of ties, each secured to one of said third and fourth securing means.

12. The method of claim 6, wherein each of the first and second insulating panels has a bottom portion, said method further comprising the steps of: (a) providing a fifth support panel adjacent to the outer side of the first insulating panel near the bottom portion of the first insulating panel, and a sixth support panel adjacent to the outer side of the second insulating panel near the bottom portion of the second insulating panel, wherein (i) the fifth support panel comprises a fifth intruding member intruding inwardly toward the cavity, and (ii) the sixth support panel comprises a sixth intruding member intruding inwardly toward the cavity; and (b) providing another mechanical linkage linking the fifth intruding member to the sixth intruding member so as to further maintain the relative position of the first and second insulating panels.

13. The method of claim 12, and wherein: (a) the fifth intruding member comprises a channel for covering at least a part of the bottom portion of the first insulating panel, and (b) the sixth intruding member comprises a further channel for covering at least a part of the bottom portion of the second insulating panel.

14. A support system for supporting insulating panels in an insulated concrete wall structure, wherein at least a first insulating panel and a second insulating panel are positioned relative to each other defining a cavity for receiving uncured concrete to form a wall having opposing surfaces, and wherein each of the first and second insulating panels has an inner side and an outer side with the inner sides facing the cavity, the inner sides defining the opposing surfaces of the wall, said support system comprising: (a) a first support panel disposed adjacent to the outer side of the first insulating panel, the first support panel having a first longitudinal axis, wherein the first support panel comprises a first intruding member intruding inwardly toward the cavity, the first intruding member having a longitudinal axis substantially parallel to the first longitudinal axis of the first support panel; (b) a second support panel disposed adjacent to the outer side of the second insulating panel, the second support panel having a second longitudinal axis, wherein the second support panel comprises a second intruding member intruding inwardly toward the cavity, the second intruding member has a longitudinal axis substantially parallel to the second longitudinal axis; and (c) means for linking the first intruding member to the second intruding member across the cavity so as to maintain the relative position between the first and second insulating panels.

15. The system of claim 14, wherein (a) the first support panel defines a first plane and the first intruding member comprising a first elongated strip extending from the first plane, and (b) the second support panel defines a second plane and the second intruding member comprising a second elongated strip extending from the second plane.

16. The system of claim 15, wherein the first elongated strip has a plurality of first securing means and the second elongated strip has a plurality of second securing means, and wherein the linking means comprises a plurality of ties, each secured to one of said first securing means and one of said second securing means.

17. The system of claim 16, wherein each tie has two end hooks, and each of the first and second securing means comprises an aperture for engaging with one of said hooks.

18. The system of claim 15, wherein each of the first and second panels is made of a foldable sheet and a portion of the sheet is folded to form the respective intruding member.

19. The system of claim 14, wherein each of the first and second insulating panels has a top portion, said system further comprising: (a) a third support panel disposed adjacent to the outer side of the first insulating panel near the top portion of the first insulating panel, the third support panel comprising a third intruding member intruding inwardly toward the cavity; (b) a fourth support panel disposed adjacent to the outer side of the second insulating panel near the top portion of the second insulating panel, the fourth support panel comprising a fourth intruding member intruding inwardly toward the cavity; and (c) means for linking the third intruding member to the fourth intruding member across the cavity so as to further maintain the relative position between the first and second panels.

20. The system of claim 19, wherein: (a) the third intruding member comprises a channel for covering at least a part of the top portion of the first insulating panel, and (b) the fourth intruding member comprises a further channel for covering at least a part of the top portion of the second insulating panel.

21. The system of claim 14, wherein each of the first and second insulating panels has a bottom portion, said system further comprising: (a) a third support panel disposed adjacent to the outer side of the first insulating panel near the bottom portion of the first insulating panel, the third support panel comprising a third intruding member intruding inwardly toward the cavity; (b) a fourth support panel disposed adjacent to the outer side of the second insulating panel near the bottom portion of the second insulating panel, the fourth support panel comprising a fourth intruding member intruding inwardly toward the cavity; and (c) means for linking the third intruding member to the fourth intruding member across the cavity so as to further maintain the relative position between the first and second panels.

22. The system of claim 21, wherein (a) the third intruding member comprises a channel for covering at least a part of the bottom portion of the first insulating panel, and (b) the fourth intruding member comprises a further channel for covering at least a part of the top bottom of the second insulating panel.

23. The system of claim 19, wherein each of the first and second insulating panels has a bottom portion, said system further comprising: (a) a fifth support panel disposed adjacent to the outer side of the first insulating panel near the bottom portion of the first insulating panel, the fifth support panel comprising a fifth intruding member intruding inwardly toward the cavity; (b) a sixth support panel disposed adjacent to the outer side of the second insulating panel near the bottom portion of the second insulating panel, the sixth support panel comprising a sixth intruding member intruding inwardly toward the cavity; and (c) means for linking the fifth intruding member to the sixth intruding member across the cavity so as to further maintain the relative position between the first and second panels.

24. A support panel for use in a support system supporting insulating panels in an insulated concrete wall structure, wherein at least two insulating panels are positioned relative to each other defining a cavity for receiving uncured concrete to form a wall, and wherein each of insulating panels has an inner side and an outer side with the inner sides facing the cavity, the inner sides substantially defining the opposing surfaces of the wall, said support panel comprising: (a) a substantially planar member for allowing said support panel to be positioned relative to the outer side of one of said insulating panels, the substantially planar member having a longitudinal axis, and (b) an intruding member having a further longitudinal axis substantially parallel to the longitudinal axis of the planar member and extended from the planar member, so as to allow said intruding member to intrude inwardly toward the cavity, wherein the intruding member has securing means for receiving a linking means to mechanically link to an intruding member of another support panel.

25. The support panel for claim 24, wherein the linking means comprises a plurality of ties, each having two end hooks, and wherein the securing means comprises a plurality of apertures each capable of receiving one of said hook for achieving said linking.

26. The support panel of claim 24 wherein said substantially planar member is made of a foldable sheet and a part of the sheet is folded to form said intruding member.

27. The support panel of claim 24, wherein each of the insulating panels has an end portion, and wherein the intruding member comprises a channel for covering at least a part of the end portion of one of the insulating panels.

28. The support panel of claim 27, wherein the intruding member further comprises a lip section for disposing said securing means, the lip section extending from the channel of the intruding member away from the planar member.

Description:

FIELD OF THE INVENTION

[0001] The present invention relates generally to a poured concrete wall system and, more particularly, to a supporting system to support insulating panels in an insulated concrete wall system.

BACKGROUND OF THE INVENTION

[0002] A poured concrete wall is usually formed from uncured concrete poured in a cavity defined by two substantially flat panels. The flat panels can be made of wood or metal, and they are usually removed from the wall after the poured concrete is cured. Alternatively, flat panels can be made of foam and they are permanently kept with the concrete wall to form an insulated concrete wall system.

[0003] Insulated concrete wall structures and method for producing such structures are known in the art. For example, U.S. Pat. No. 6,438,917 B2, issued Aug. 27, 2002 to Richard Kubica (hereinafter referred to as “Kubica”) discloses an insulated concrete wall structure wherein a wall forming system is used to define a cavity for receiving uncured concrete in order to form a concrete wall. In particular, the wall forming system of Kubica comprises a pair of insulating panels positioned spaced apart to form the cavity and to define the wall surfaces. Each of the insulating panels is supported by a metal wall form. The wall form has a plurality of sidewalls, which are extended outwardly from the insulating panel and are substantially perpendicular to the concrete wall surface. The sidewalls have a plurality of holes to receive a plurality of connecting pins so that a plurality of wall ties can be used to engage with the connecting pins so as to allow the metal wall form on one side of the cavity to be mechanically linked to the metal wall form on the other side of the cavity. U.S. Pat. No. 6,401,413 B1, issued Jun. 11, 2002 to Michael Niemann (hereinafter referred to as “Niemann”) discloses a concrete form wall building system, wherein a pair of polystyrene sidewalls are anchored to a footing with angle irons in order to form a cavity for receiving uncured concrete. In a different embodiment, Niemann discloses a wall building system wherein a plurality of vertically oriented divisional members are attached to the sidewalls. These divisional members form a plurality of channels for receiving the uncured concrete. U.S. Pat. No. 6,363,683 B1 issued Apr. 2, 2002 to James Moore, Jr. (hereinafter referred to as “Moore”), discloses an insulated concrete form wherein two side panels are used to form a cavity for receiving uncured concrete. A plurality of web members are attached or formed on the side panel of Moore. The web members on the side panel on one side of the cavity can be connected to the web members on the side panel on the other side of the cavity by a plurality of connectors.

[0004] The concrete wall forms in prior art are complex in design and in manufacturing. It is advantageous and desirable to provide a method and system for supporting the insulating panels in an insulated concrete wall structure that is simple and cost effective.

SUMMARY OF THE INVENTION

[0005] It is an object of the present invention to provide a simple method and system to support insulating panels that are used to form a cavity for receiving uncured concrete to form a wall. The object can be achieved by a supporting panel having an elongated planar member and an elongated intruding member extended from the planar member. Furthermore, the supporting panel can be made of a foldable sheet and part of the sheet is folded to form the intruding member.

[0006] Thus, the first aspect of the present invention provides a method for supporting insulating panels in an insulated concrete wall structure. The method provides for use of at least a first insulating panel and a second insulating panel positioned relative to each other, thus defining a cavity for receiving uncured concrete to form a wall having opposing surfaces. Each of the first and second insulating panels has an inner side and an outer side with the inner sides facing the cavity; the inner sides substantially defining the opposing surfaces of the wall.

[0007] The method itself comprises several steps. The first of these calls for providing a first support panel adjacent to the outer side of the first insulating panel and a second support panel adjacent to the outer side of the second insulating panel. The first support panel has a first longitudinal axis and the second support panel has a second longitudinal axis substantially parallel to the first longitudinal axis. Additionally, the first support panel comprises a first intruding member intruding inwardly toward the cavity and having a longitudinal axis substantially parallel to the first longitudinal axis of the first support panel. The second support panel comprises a second intruding member intruding inwardly toward the cavity, and has a longitudinal axis substantially parallel to the second longitudinal axis of the second support panel. The method further provides for a mechanical linkage which links the first intruding member to the second intruding member so as to maintain the relative position between the first and second insulating panels.

[0008] The first support panel defines a first plane and the first intruding member comprises a first elongated strip extending from the first plane. The second support panel defines a second plane and the second intruding member comprises a second elongated strip extending from the second plane. The first elongated strip has a plurality of first securing means and the second elongated strip has a plurality of second securing means. The mechanical linkage comprises a plurality of ties, each secured to one of the first securing means and one of the second securing means. Further, the plurality of first securing means are spaced apart from each other, distributed substantially along the longitudinal axis of the first intruding member. The plurality of second securing means are spaced apart from each other, distributed substantially along the longitudinal axis of the second intruding member.

[0009] Optionally, the method further comprises the step of providing a third insulating panel adjacent to the outer side of the first insulating panel, and a fourth insulating panel adjacent to the outer side of the second insulating panel. Advantageously, the method further comprises several steps. These include, providing a third support panel adjacent to the outer side of the first insulating panel near the top portion of the first insulating panel, and a fourth support panel adjacent to the outer side of the second insulating panel near the top portion of the second insulating panel.

[0010] The third support panel comprises a third intruding member intruding inwardly toward the cavity. The fourth support panel comprises a fourth intruding member intruding inwardly toward the cavity as well. An additional step of the method, calls for providing a further mechanical linkage linking the third intruding member and to the fourth intruding member so as to further maintain the relative position of the first and second insulating panels. The further mechanical linkage comprises a plurality of ties, each secured to one of said third and fourth securing means.

[0011] The third intruding member comprises a channel for covering at least a part of the top portion of the first insulating panel, and the fourth intruding member comprises a further channel for covering at least a part of the top portion of the second insulating panel. The third intruding member further comprises a lip section extending from the channel inwardly toward the cavity; the lip section comprising a plurality of third securing means. The fourth intruding member further comprises a lip section extending from the channel inwardly toward the cavity, and comprising a plurality of fourth securing means.

[0012] Advantageously, the method further comprises the step of providing a fifth support panel adjacent to the outer side of the first insulating panel near the bottom portion of the first insulating panel, and a sixth support panel adjacent to the outer side of the second insulating panel near the bottom portion of the second insulating panel. The fifth support panel comprises a fifth intruding member intruding inwardly toward the cavity; and, the sixth support panel comprises a sixth intruding member intruding inwardly toward the cavity. Another mechanical linkage is provided for linking the fifth intruding member to the sixth intruding member so as to further maintain the relative position of the first and second insulating panels.

[0013] The fifth intruding member comprises a channel for covering at least a part of the bottom portion of the first insulating panel. The sixth intruding member comprises a further channel for covering at least a part of the bottom portion of the second insulating panel.

[0014] A second aspect of the present invention provides a support system for supporting insulating panels in an insulated concrete wall structure, wherein at least a first insulating panel and a second insulating panel are positioned relative to each other to define a cavity for receiving uncured concrete to form a wall having opposing surfaces. Each of the first and second insulating panels has an inner side and an outer side with the inner sides facing the cavity, the inner sides defining the opposing surfaces of the wall.

[0015] The support system comprises a first support panel disposed adjacent to the outer side of the first insulating panel, the first support panel having a first longitudinal axis and comprising a first intruding member intruding inwardly toward the cavity. The first intruding member has a longitudinal axis substantially parallel to the first longitudinal axis of the first support panel.

[0016] The support system additionally, comprises a second support panel disposed adjacent to the outer side of the second insulating panel, and having a second longitudinal axis, wherein the second support panel comprises a second intruding member intruding inwardly toward the cavity. The second intruding member has a longitudinal axis substantially parallel to the second longitudinal axis.

[0017] The system further comprises means for linking the first intruding member to the second intruding member across the cavity so as to maintain the relative position between the first and second insulating panels.

[0018] The first support panel defines a first plane and the first intruding member comprises a first elongated strip extending from the first plane. The second support panel defines a second plane and the second intruding member comprises a second elongated strip extending from the second plane. The first elongated strip has a plurality of first securing means and the second elongated strip has a plurality of second securing means. The securing means comprises a plurality of ties, each secured to one of the securing means. Each tie has two end hooks, and each of the first and second securing means comprises an aperture for engaging with one of the hooks.

[0019] Preferably, each of the first and second panels is made of a foldable sheet and a portion of the sheet is folded to form the respective intruding member. Advantageously, the system further comprises a third support panel disposed adjacent to the outer side of the first insulating panel near the top portion of the first insulating panel. The third support panel comprises a third intruding member intruding inwardly toward the cavity. Additionally, the system comprises a fourth support panel disposed adjacent to the outer side of the second insulating panel near the top portion of the second insulating panel; the fourth support panel comprising a fourth intruding member intruding inwardly toward the cavity. The system further comprises means for linking the third intruding member to the fourth intruding member across the cavity so as to further maintain the relative position between the first and second panels.

[0020] The third intruding member comprises a channel for covering at least a part of the top portion of the first insulating panel. The fourth intruding member comprises a further channel for covering at least a part of the top portion of the second insulating panel.

[0021] Advantageously, the system further comprises a fifth support panel disposed adjacent to the outer side of the first insulating panel near the bottom portion of the first insulating panel. The fifth support panel comprises a fifth intruding member intruding inwardly toward the cavity. The system further comprises a sixth support panel disposed adjacent to the outer side of the second insulating panel near the bottom portion of the second insulating panel, the sixth support panel comprising a sixth intruding member intruding inwardly toward the cavity; and, means for linking the fifth intruding member to the sixth intruding member across the cavity so as to further maintain the relative position between the first and second panels.

[0022] The third aspect of the present invention provides a support panel for use in a system supporting insulating panels in an insulated concrete wall structure, wherein at least two insulating panels are positioned relative to each other defining a cavity for receiving uncured concrete to form a wall. Each of the insulating panels has an inner side and an outer side with the inner sides facing the cavity, the inner sides substantially defining the opposing surfaces of the wall. The support panel comprises a substantially planar member having a longitudinal axis, so as to allow the support panel to be positioned relative to the outer side of one of the insulating panels. The panel has an intruding member having a further longitudinal axis substantially parallel to the longitudinal axis of the planar member and extending from the planar member, so as to allow said intruding member to intrude inwardly toward the cavity. The intruding member has securing means for receiving a linking means to mechanically link to an intruding member of another support panel. The securing means comprises a plurality of apertures.

[0023] Preferably, the substantially planar member is made of a foldable sheet and a part of the sheet is folded for forming said intruding member. The intruding member can be an elongated strip extended from the middle section of the planar member. The intruding member can be an elongated member extended from either the top or the bottom of planar member, and the intruding member comprises a channel for covering the top or the bottom end of an insulating panel. Here too, the intruding member further comprises a lip extended from the channel so as to allow a mechanical linkage to link the intruding member of the supporting panel to the intruding member of another supporting panel position on the other side of the cavity.

[0024] The present invention will become apparent upon reading the description taken in conjunction with FIGS. 1 to 5.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is an isometric view illustrating a section of the insulated concrete wall structure, according to the present invention.

[0026] FIG. 2A is a front view of an intermediate support panel.

[0027] FIG. 2B is a top view of the intermediate support panel.

[0028] FIG. 3A is a front view of a bottom support panel.

[0029] FIG. 3B is a top view of the bottom support panel.

[0030] FIG. 4A is a front view of a top support panel.

[0031] FIG. 4B is a top view of the top support panel.

[0032] FIG. 5 is a top view of an insulated concrete wall structure having two walls joined at a corner.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Beginning with FIG. 1, there is shown the insulated concrete wall structure 1 of the present invention comprising a wall (not shown) sandwiched between two insulating panels 20. Each insulating panel 20 comprises an inner insulation sheet 22 and an outer insulation sheet 24. The insulating panels 20 are positioned relative to each other defining a cavity 10 between the two facing inner insulation sheets 22 for receiving uncured concrete in order to form a wall within the cavity 10. In order to maintain the relative position between the insulating panels 20 when the uncured concrete is poured into the cavity, it is advantageous to use one or more support panels to support the insulating panels 20. Preferably, one or more intermediate support panels 30 are used to support the insulating panels 20 in the middle section of the wall structure 1. As shown in FIG. 1, each of the intermediate support panels 30 comprises a substantially planar member 32 covering the length of the wall structure 1. Thus, the planar member 32 is elongated in shape, having a longitudinal axis 130. In the illustrating example of FIG. 1, the wall structure 1 is vertical and the longitudinal axis 130 of the planar member 32 is substantially perpendicular to the vertical axis. Each of the support panels 30 comprises an intruding member 34 extended from the planar member 32 and intruding inwardly toward the cavity 10 so that the intruding member 34 can be mechanically linked to the intruding member 34 in another support panel 30 on the other side of the cavity 10. As can be seen from FIG. 1, the intruding member 34 is an elongated strip extended from the planar member 32. The intruding member 34 has a longitudinal axis 136 (see FIG. 2b) substantially parallel to the longitudinal axis 130 of the planar member 32. The support panels 30 on both sides of the cavity 10 are mechanically linked by a plurality of ties 60, which are mechanically engaged with the intruding members 34.

[0034] Preferably, the support panel 30 is made of a piece of sheet metal, which is folded in the center section to form the intruding member 34. As such, the intruding member 34 is integral to the planar member 32. The support panel 30 is simple to produce.

[0035] It should be noted that it is not necessary to support the entire surface of the insulating panels 20 by the support panels 30. For example, only one pair of support panels 30 is used to support the insulating panels 20 on both sides of the wall structure 1, as shown in FIG. 1. Depending on the height of the wall structure, more support panels 30 may be needed for supporting the insulating panels 20.

[0036] According to the present invention, the support panels can be of different embodiments. Preferably, a pair of top support panels 40 is used to support the insulating panels 20 at the top part of the wall structure 1, and a pair of bottom support panels 50 is used to support the insulating panels 20 at the bottom part of the wall structure 1.

[0037] The side view of an intermediate support panel 30 is shown in FIG. 2A. In this exemplary embodiment, the height of the upper half of the planar member 32 is equal to that of the lower half. The top view of the intermediate support panel 30 is shown in FIG. 2b. As shown, a plurality of holes 36 are distributed along the length of the intruding member 34, so as to allow the intruding member 34 of the intermediate support panel 30 to be mechanically linked to the intruding member 34 of another intermediate support panel 30 on the other side of the cavity 10 by one or more ties 60 (see FIG. 1). The intruding member 34 has a longitudinal axis 136 along its length.

[0038] The side view of a top support panel 40 is shown in FIG. 3A. As shown, the top support panel 40 has a planar member 42 and an intruding member 44 extended from the top portion of the planar member 42. Furthermore, the intruding member 44 is folded to form a cover section 47 and a lip section 48. Advantageously, the width of the cover section 47 is sufficient to accommodate the top part of the inner insulation sheet 22 (see FIG. 1). The top view of the top support panel 40 is shown in FIG. 3B. As shown, a plurality of holes 46 are provided on the lip section 48 of the intruding member 44, so as to allow the intruding member 44 of the top support panel 40 to be linked to the intruding member 44 of another top support panel 40 on the other side of the cavity 10 by one or more ties 60 (see FIG. 1).

[0039] The side view of a bottom support panel 50 is shown in FIG. 4A. As shown, the bottom support panel 50 has a planar member 52 and an intruding member 54 extended from the bottom portion of the planar member 52. Furthermore, the intruding member 54 is folded to form a channel section 57 and a lip section 58. Advantageously, the width of the channel section 57 is sufficient to accommodate the bottom part of the inner insulation sheet 22 (see FIG. 1). The top view of the bottom support panel 50 is shown in FIG. 4B. As shown, a plurality of holes 56 are provided on the lip 58 of the intruding member 54, so as to allow the intruding member 54 of the bottom support panel 50 to be linked to the intruding member 54 of another bottom support panel 50 on the other side of the cavity 10 by one or more ties 60 (see FIG. 1).

[0040] When a wall structure 1 has two walls joined at a corner, it is advantageous to provide an inner corner support 70 and an outer corner support 80, as shown in FIG. 5. Advantageously, the corner supports 70, 80 are made of sheet metal, and the sheet metal is folded into the desired shape.

[0041] The tie 60, as shown in FIG. 1, is a rod shaped member having two hooks formed at two ends. The hooks can be engaged in a hole in the intruding member of a support panel and a hole in the intruding member of another support panel on the other side of the cavity to provide a mechanical linkage between these two support panels. It should be noted that, the holes (36, 46, 56) on an intruding member (34, 44, 54) can be replaced by a plurality of pins or hooks, for example, so as to allow the tie 60 to be engaged with such pins and hooks in order to provide a mechanical link between two support panels. Likewise, the tie 60 can be replaced by a strip of suitable material with two holes on its ends to engage with the pins or hooks on the intruding members of two supporting members. Furthermore, when a support panel is made of a sheet of foldable material, it is preferable that the sheet is folded to form the intruding member. However, the support panel can be molded into shape if it is made of a moldable material, such as plastic. It is also possible that the intruding member is made separately from the planar member and then attached to the planar member to form a supporting member, for example.

[0042] Thus, although the invention has been described with respect to a preferred embodiment thereof, it will be understood by those skilled in the art that the foregoing and various other changes, omissions and deviations in the form and detail thereof may be made without departing from the scope of this invention.