U.S. patent application number 09/896045 was filed with the patent office on 2002-02-14 for plastic module for insulated concrete waffle wall.
Invention is credited to Batch, Juan R..
Application Number | 20020017070 09/896045 |
Document ID | / |
Family ID | 26909859 |
Filed Date | 2002-02-14 |
United States Patent
Application |
20020017070 |
Kind Code |
A1 |
Batch, Juan R. |
February 14, 2002 |
Plastic module for insulated concrete waffle wall
Abstract
A foamed plastic module for building an insulated concrete wall
structure by stacking the modules together until the desired
configuration of the structure is completed, and when the form is
filled, a concrete monolithic waffle wall structure having foam
insulation permanently attached to the opposed wall surfaces to
form the inner and outer wall surfaces of an enclosure is realized.
The module is made of foamed plastic material, such as expanded
polystyrene, for example, and is built in a pressure molding
apparatus. Each module comprises a rigid form block of a generally
rectangular configuration having a hollow interior of a particular
predetermined configuration formed between spaced apart confronting
sidewalls to form a cement waffle wall. The side walls of the
module are secured one to the other by a plurality of spaced
tension members. The tension members can be formed of metal or
plastic material. When formed of plastic, the tension members can
have plastic rebar seats into which reinforcing steel can be
snapped and held in position. Regardless of being metal or plastic,
the tension members are positioned at evenly spaced centers,
including across adjoining modules, whereby the flanges thereof can
be more easily located. Location of the recessed flanges is also
accomplished by incorporation of molded raised vertical lines or
depressed divets centered over the flanges and visible externally
on the surface of the waffle wall module. The interlocking tongue
and groove features of a conventional module have been modified to
increase the nominal base width of the tongue and groove to be at
least equal to the nominal height or depth of the tongue and
groove, respectively, whereby the strength of the tongue is
substantially increased and without increasing the lever arm of the
tongue. These aspects provide synergistic benefits when employed
together. The configuration of the new invention side panels is
such, that the two ends of a module are only half cores, creating
full cores when subsequent modules are placed in running bonds.
This saves at least one tension member per module over conventional
waffle wall formwork of similar size and dimension and hundreds of
dollars per structure. When stacked vertically employing per-molded
corner modules, the tension members, and internal horizontal and
vertical core elements of the waffle wall are all evenly
aligned.
Inventors: |
Batch, Juan R.; (Odessa,
TX) |
Correspondence
Address: |
Juan R. Batch
Box 3089
Odessa
TX
79760
US
|
Family ID: |
26909859 |
Appl. No.: |
09/896045 |
Filed: |
June 28, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60215246 |
Jun 30, 2000 |
|
|
|
Current U.S.
Class: |
52/309.11 ;
52/309.12; 52/426; 52/562; 52/742.14 |
Current CPC
Class: |
E04B 2/8617 20130101;
E04B 2002/867 20130101 |
Class at
Publication: |
52/309.11 ;
52/309.12; 52/426; 52/562; 52/742.14 |
International
Class: |
E04B 001/16; E04G
011/06 |
Claims
1. A module comprising: first and second foam panels each having
inner and outer surfaces, said panels arranged in spaced parallel
relation with their inner surfaces facing each other; and when said
panels are filled with concrete and stacked vertically and in
running bonds, the resultant structure is a series of vertical
posts and horizontal beams with webs between cores forming a
monolithic waffle shaped wall; certain modules containing first and
second foam panels are "L" shaped forming corner modules with left
and right hand corners; there is at least one tension member
traversing said panels and anchored into said side walls, the
tension member made of either polypropylene plastic or sheet
metal;
2. The module of claim 1 wherein said waffle wall tension members
are at evenly spaced centers within the module and adjoining
modules; tension members have a polygonal shape with opposed faces,
similar top and bottom, and opposed sides; each tension member
includes a unitary piece of stamped sheet metal or molded
polypropylene plastic anchored within the panels, and extending
perpendicular to the walls face; the flanges of the tension member
are parallel to the inner and outer wall surfaces of the module,
each flange terminating in a free end, the free end being a
stiffener; at least one stiffener rib extends parallel across the
face of the tension member and terminates prior to the vertical
flange imbedded in the polystyrene plastic on opposing sides; said
tension member has preferably one hole located in the center of the
unit whose size is at least 1/3 the height of the metal or plastic
in this area of the tension member; the tension member hole is
approximate equal-distant between the vertical flanges; said
tension member has at least one stamped crescent shaped rebar
support seat stamped into the top and bottom of the tension member
located equal-distant form the tension member side flanges; a
plurality of stamped approximately 90 degree tabs located in
vertical lines just internal to the vertical flanges and within the
molded polystyrene plastic help retain the unitary sheet metal
tension member within the plastic side walls of the module;
3. The module of claim 2 wherein said waffle wall tension members
are spaced away from the ends of the module about one-half the
distance of the desired spacing of the subsequent tension members;
i.e. six inches as opposed to one foot for subsequent tension
members) whereby each tongue and groove end of a waffle module,
completes a half core of the adjoining module; the tongue and
groove end of modules when placed in running bonds, completes a
full and virtually similar dimensioned core of the adjacent module,
all equal distant and aligned with one another horizontally and
vertically.
4. The module of claim 3 wherein said tension members are
identified externally on said first and second panels of the
module, by raised visual alignment lines or recessed divets within
the polystyrene plastic module; said alignment lines or divets are
located approximate to the center of the imbedded 1.5 inch flange
which has its face parallel to the external surface of the module;
said alignment lines and tension members are equal-distant
horizontally throughout the modules, and align vertically with
subsequent stacking of the modules.
5. The module in claim 4 wherein (4) tension members can be
utilized within the module, (traditional waffle wall formwork of
similar dimension and size, use 5 members); adjusting the position
the tension member in the formwork to the area of maximum foam
bridging and minimum concrete interference, while adding to the
strength of the vertical and horizontal core.
6. Method of claim 5 wherein the module configuration has been
substantially changed to now terminate in half cores; cores within
the module have been elongated to retain strength within the core
yet have the core approximately 1/2 inch narrower; reduction in
core diameter while increasing amount of foam bridging across
tension member, without appreciably increasing overall width of the
module; repositioning the end tension member to 1/2 the distance of
the desired one foot dimension, resulting in equal spacing on all
tension members; tension member positioned in the module where it
receives resistance to thermal transfer through the module;
7. The module of claims 1 and 6 wherein said "L" shaped corner
modules have approximately 90 degree angles, right and left mirror
images, of at least three tension members per module, with ends
terminating in similar configuration to the straight modules with
half cores and modified tongue and groove arrangements; each corner
module when stacked it automatically displaces adjoining formwork
establishing proper stagger, and alignment of the waffle wall
system.
8. The module of claim 1 and 7 wherein said "L" shaped corner
module has an additional polygonal shaped member made of steel or
polypropylene plastic; said member is imbedded into module surface
at the corner of the module; this member is molded or bent at an
initial 90 degree angle, fitting vertically into the corner; this
polygonal member extends as a flat sheet down both sides of the
module for a predetermined distance, (approximately 2 inches)
turning 45 degrees, it continues into the corner core of the
module, terminating in the cavity; the polygonal 45 degree member
has perforations within the member which allow for foam bridging
throughout the member thus securing it into the foam plastic; once
concrete is placed in the module, and cured, the corner piece is
secure; sheetrock, siding, and other construction materials can be
screwed to the imbedded corner tension member;
9. The module of claim 8 and claim 1 wherein the modules side
panels all terminate in tongue and groove arrangements located at
the ends top and bottom of the module; the tongue runs parallel to
the form at the top and down the left or right hand sides of the
panels, and the grooves run parallel across the bottom of the form
and up the opposite side of the form as the tongue; this
arrangement results in tongues at one end of the block and on top
of the module side panels, and grooves at the other end of the
module and on the bottom of the module side panels; the tongues on
the top of the module are wider than they are high; the grooves on
the bottom are wider than they are recessed into the module,
usually by a factor of 1.5 i.e. tongue 1 inch wide, groove 0.50
high; the tongue and grooves at the ends of the module which
interlock modules in running bonds are of essentially equal
dimension, i.e. 1 inch by 1 inch.
10. Method of claim 7 whereby either plastic or sheet metal tension
members can be molded within the module utilizing the same molding
apparatus; design of mold apparatus to use removable inserts to
replace the space left or needed when either plastic (thick) or
metal tension members (thin) are molded; said inserts are anchored
to the tension member insertion slots located in the center core
web member of the tool centering the appropriate tension member
within the mold apparatus; through addition or subtraction of
dimensionally predetermined Teflon and metal inserts within the
mold it is possible to produce multi-user modules some devoid of
tension members altogether and using foam bridging to retain the
two side panels.
Description
[0001] This is a continuation of a previous filing enclosed dated
Jun. 30, 2000 with expiration date Jun. 30, 2001. This invention
relates to foamed plastic modules for use in building insulated
concrete waffle walls of a building.
BACKGROUND OF INVENTION
[0002] The objective of using a concrete waffle wall construction
with a plurality of insulated form modules is to obtain a wall that
is more cost effective because it uses less concrete than flat wall
concrete systems yet sufficiently strong for residential and many
light commercial applications.
[0003] Apparatuses are known for building an insitu insulated
concrete waffle wall by the use of a plurality of modules stacked
together to provide a continuous concrete form which results in a
unitary wall structure when the interior thereof is filled with
concrete. The resultant structure is a concrete monolithic waffle
wall structure with foam insulation permanently attached to the
inner concrete waffle wall and forming the inner and outer wall
surfaces thereof. Accordingly, a plurality of the modules are
easily assembled into a concrete building form to provide a new and
inexpensive method of building a rugged monolithic waffle wall of a
building enclosure. The module per se provides a building component
by which the method of this invention can be carried out.
[0004] All of the previous prior art attempts to employ waffle wall
systems in the building of an insitu insulated concrete waffle wall
have employed the use of tension members placed or molded across
the module at even intervals terminating at both ends of the
module. Usually this would require five tension members be present
to secure adequately a four foot long module from failure during
concrete placement. Often due to the inadequacy of the tongue and
groove and the distance between tension members within the module,
end tension members in convention waffle wall assemblies are vital
to module structural integrity.
[0005] These prior embodiments used end tension members for the
purpose of strengthening the module ends so during concrete
placement module failure would not occur. In addition end tension
members provided a fastening surface for materials such as brick
ties, sheetrock, siding, etc.
[0006] At least one prior art embodiment U.S. Pat. No. 5,566,518 )
dated Oct. 22, 1996 Martin et al. attempted to remove these
undesirable end tension members by placing the tension member in
the center of the core of the module with the resulting
problems:
[0007] 1. Insufficient foam bridging around the tension member made
it ineffective structurally when concrete was placed in the
formwork.
[0008] 2. Not changing the basic design of the formwork shifting
the maximum concrete point of pressure to the place in the formwork
of maximum foam bridging around the tension member results in high
failure rates of the module.
[0009] 3. Placing a tension member in the center of the concrete
core tends to weaken the core and the structural integrity of the
overall structure.
[0010] 4. The overall thickness of the modules polystyrene
retaining the concrete was left unchanged leading to high failure
rates of prior embodiments.
[0011] If you will note in the present invention embodiment
contained in this application, I have changed the basic design of
the form. In the invention I have removed the problematic position
of the end tension member away from the end module position.
Successfully accomplishing this has virtually eliminated the
problem of voids being created by two tension members being close
to one another when modules are placed in running bonds. In
addition unrestricted flow of concrete during concrete placement is
realized. Problems associated with concrete voids were; compromise
of wall integrity, compromise of fire resistance, creation of
insect breading ground, and possible failure of the structure. I
have transferred this tension member to a place of maximum strength
and maximum foam bridging within the module. As a result of this
strategic positioning of the tension member and the basic design
changes of the module, I have achieved a formwork that works
well.
[0012] Previous "prior art" attempts to employ waffle wall systems
using conventional tension member arrangements also had the
undesirable drawback that when the forms were stacked end to end
(which is necessary for the construction of the wall) it inevitably
presented the aforementioned situation of two tension members being
in very close proximity to one another. Structurally two tension
members in such close proximity are unnecessary, a waste of
numerous tension members within the wall once the concrete is
placed, and creates confusion for the sheetrock installers
attempting to align the tension members. In view of the above, it
was necessary to create a waffle wall that would (1) structurally
hold the concrete during concrete placement, (2) have a tension
member arrangement that would allow for smooth flow of concrete
through the form eliminating the potential for voids (3) have the
tension members so oriented, that when the forms were placed end to
end and vertically, the tension members would be on even centers
and aligned, for the continuous efficient attachment of sheetrock
and other uniformly dimensioned construction materials, when view
from the outside of the form. (4) Invent a means to identify the
recessed tension member within the module allowing for the
efficient identification of the recessed attachment flange of the
tension member. (5) reduce the use of at least one tension member
over convention modules (saving the cost of one tension member per
module) while maintaining or enhancing the structural strength of
the wall (6) Create a tongue and groove locking system that would
effectively reduce failures in shipping, handling, and during
placement of concrete in the wall system.
[0013] This newly configured module with open ends and no end
fastener such as conventional waffle wall forms will also have
corner modules incorporated with like configuration. The main
difference in the corner forms will be the ends of the forms will
change directions 90 degrees to accommodate wall directional
changes at the end of the waffle wall. These corners will be both
right and left in nature or mirror images. The corners will be
configured in such a manner that when stacked one on top the other,
they will naturally align the module cores, tension members, and
the horizontal and vertically spaced raised polystyrene alignment
lines or recessed divets as viewed on the outside of the
module.
[0014] The configuration of the module, along with modifications in
the mold that makes the module, allow for the manufacture of both
plastic and metal tension members being molded alternately within a
module, or separately within a particular module. Previous to this
invention it was necessary to have separate molds for the
manufacture of the modules. If you were building in an area that
plastic tension members were not allowed or preferred you could not
switch to metal without manufacturing from a separate mold capable
of manufacturing metal modules. The molds are very costly and
re-hanging another mold for production takes valuable time away
from production. The advantages of the newly configured module are:
1. Will use one less tension member per module, (2) simplify
hanging sheetrock, (3) adapt itself to molding multiple types of
tension members within the same mold, (4) eliminate propensity to
create voids in the concrete due to the removal of two tension
members in close proximity at the ends of adjacent modules, (5)
have an integral corner piece to align the system during
construction, (6) save hundreds of dollars per building eliminating
one tension member per module, (7) because of tongue and groove
modifications, reduced damage in handling and shipping were
realized, along with gains in structural integrity during the
construction phase.
[0015] The waffle wall module is built in a pressure mold using
foamed plastic material, such as expanded polystyrene. Each module
comprises a rigid, rectangular block having a hollow interior of a
particular configuration formed between spaced apart confronting
sidewalls.
[0016] The module further includes opposed ends and a top opposed
bottom, and provides a concrete form within which there can
advantageously be realized a concrete structure having spaced
parallel vertical load bearing columns tied together by spaced
horizontal sheer members, all of which is achieved after the
concrete has been poured into the assembled modules.
[0017] The inner and outer walls of the module are secured one to
the other by a plurality of spaced, vertically arranged, tension
members. Each tension member is preferably made of a single
perforated bent-up sheet of thin metal.
[0018] Opposed ends of the tension member terminate in flanges
arranged perpendicular to the wall faces of the tension member and
parallel respective to the inner and outer wall surfaces of the
module. The flanges each have a flange face embedded within the
polystyrene near the inner and outer wall surfaces thereof. A self
tapping screw can be screwed into the flange face using an electric
screwdriver to directly attach the paneling or other materials to
the wall surface of either side of the structure.
[0019] Preferably, one large hole in the tension member is located
between the flanges for flow of wet concrete therethrough in order
to tie the opposed confronting module walls together and to the
concrete structure. The upper marginal end of the tension member
preferably has at least one cutout formed therein that results in a
crescent shaped rebar seat that is connected to the upper and lower
end of the flanges by a web member.
[0020] A plurality of tabs are preferably formed below the
reinforcing steel support seat near the flanges, for example, an
inner and an outer row of tabs bent perpendicular respective to the
tension member faces. Preferably, the inner and outer row of tabs
are bent about 90 degrees along a common plane or line for
anchoring the outer marginal edge portion of the tension member
within the polystyrene foam plastic of the module. Hence the tabs
of each double row are oppositely bent toward one another in order
to align tabs along a vertical line.
[0021] The outer edges of the walls of the module are in the form
of tongue-and-groove construction for fastening the modules
together in an interlocking manner at the top, bottom and lower
edges thereof. However, several problems (in addition to the ones
previously mentioned) have still been encountered with the typical
plastic modules used in the construction of an insulated waffle
wall.
[0022] For example, it has become increasingly desirable to be able
to use plastic, rather than metal, tension members for the modules
used in the construction of an insulated concrete waffle wall. Some
of these changes have been simply the personal preferences of the
client and others have been code specific for either metal or
plastic in certain municipalities. Plastic is desirable for its
corrosion resistance and lower thermal transfer as opposed to
metal, although its behavior in fire and its propensity to transfer
accumulative loads down the wall unlike metal limit its load caring
capacities when items such as shelving or sheetrock are screwed
onto the wall. Plastic material allows and requires a substantially
different structure for the tension member. However, a conventional
module is designed to accept only one kind of tension member, which
has required separate molds for making modules with plastic tension
members and metal tension member modules. The new invention would
allow both plastic and metal tension members to be produced from
the same mold saving valuable time and money in the production
process as well as giving the manufacturer increased flexibility to
satisfy code agencies and client personal preference. It would also
be desirable to have a way to help retain the reinforcing steel
positioned within the stacked metal tension member module before
and during the pouring of the wet cement so that the waffle wall is
properly reinforced according to the designed specifications. Such
a retaining mechanism similar to the one incorporated in the
embodied invention has not been forthcoming for the metal tension
members used in the waffle wall assemblies. Prior to the present
invention, the modules incorporating metal tension members would
tie the horizontal reinforcing to the vertical reinforcing steel.
In situations that required displacement from center positions of
the reinforcing steel for structural reasons, placement of these
vertical and horizontal bars was difficult or impossible to
maintain through the placing of the concrete.
[0023] Prior embodiment art found the tongue and groove arrangement
for attaching one module to the other most desirable. Unfortunately
due to several factors, these tongue and groove arrangements were
subject to frequent failure, either due to shipping damage
inadequacy in the structural integrity during concrete placement,
or handling damage while stacking the wall. Because of the new
design of the proposed invention, it was necessary to change the
typical design of the tongue and groove for structural integrity
consideration adjoining two modules. This had the synergistic
effect of solving prior conventional structural concerns about the
tongue and groove.
[0024] Accordingly, there has been a long-felt need for improving
the foamed plastic modules used in the construction of insulated
waffle wall assemblies. Improvements in the form modules for
constructing insulated waffle walls is thus necessary.
SUMMARY OF INVENTION
[0025] According to the invention, a new design is provided for the
foamed plastic modules used in the construction of an insulated
waffle wall. Each module comprises a rigid form block generally
rectangular configuration having a hollow interior of a particular
predetermined configuration formed between spaced apart confronting
sidewalls. Certain of the modules are preferably of right-and -left
hand "L" shaped configurations to provide for making corners
between perpendicular sections of insulated waffle wall.
[0026] The sidewalls of the module are secured one to the other by
a plurality of spaced tension members. Each tension member a
central web portion with the opposed edges thereof terminating in
end flanges arranged perpendicular to the wall faces of the
confronting wall members and parallel respective to the inner and
outer wall surfaces of the module. The opposed flanges of each
tension member are embedded within the polystyrene plastic and
terminate near the wall surface thereof.
[0027] According to one aspect of the invention, the module is
designed to be made with either metal or plastic tension members.
This allows the same basic molding equipment for making the module
to be used for manufacturing modules with metal or plastic tension
members, meeting the local building code requirements, or the
customers design preferences.
[0028] According to another aspect of the invention, the tension
members are positioned at evenly spaced centers, including across
adjoining modules, whereby afterwards the flanges can always be
quickly and easily located by vertical raised lines, or recessed
divets centered on the outside surface of the foam form module and
centered over the recessed metal or plastic tension member. Most
preferably, the tension members are positioned to have the flanges
located on convenient one-foot centers, although any convenient
spacing can be used. Using this design, the tension members are
appropriately placed from the ends of a module about one-half the
distance of the desired spacing of the remaining tension members,
whereby two tension members are not positioned more closely
adjacent to one-another than the desired spacing when the forms are
positioned end to end and stacked vertically. This also solves the
problem of voids forming between closely adjacent tension members.
Unfortunately positioning the tension members away from the ends of
the module tends to weaken the ends of the module for holding the
hydrostatic pressure of poured wet concrete. Redesign of the waffle
wall module itself allows for proper tension member positioning and
hydrostatic integrity.
[0029] Accordingly to yet another aspect of the invention, the
interlocking tongue and groove features of a convention module have
been modified to increase the nominal base width of the tongue and
groove to be at least equal to the nominal height or depth of the
tongue and groove, respectively, without increasing the lever arm
of the tongue. All else being equal, making the nominal base width
of the tongue and groove be at least equal to the height or depth
of the tongue and groove, respectively, decreases the propensity of
breaking the tongue off the module. As used herein, the same
"nominal" dimensions is understood to mean that the tongue and
groove have substantially, but not exactly, the same dimensions,
whereby the tongue can be easily guided to fit snugly within the
groove. Furthermore, this aspect of the invention with the changed
spacing of the tension members is particularly advantageous and
provides a synergistic result with increasing the relative with of
the tongue and groove.
[0030] These and other aspects and advantages of the invention will
become apparent to persons skilled in the art from the following
drawings and detailed description of a presently most preferred
embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0031] The accompanying drawings are incorporated into and form a
part of the specification to provide illustrative examples of the
present invention and to explain the principles of the invention.
The drawings are only for purposes of illustrating preferred and
alternate embodiments of how the invention can be made and used. It
is to be understood, of course, that the drawings are not to
engineering scale, but are merely intended to represent and
illustrate the concepts of the invention. The drawings are not to
be construed as limiting the invention to only the illustrated and
described examples. Various advantages and features of the present
invention will be apparent from a consideration of the accompanying
drawings in which:
[0032] FIG. 1 is a fragmentary, broken, pictorial representation of
a conventional insitu insulated concrete wall structure;
[0033] FIG. 2 is a fragmentary, broken, perspective view of a
completed insitu insulated concrete wall structure of FIG. 1;
[0034] FIG. 3 is a side view of one conventional module shown in
FIG. 1;
[0035] FIG. 4 is a top view of one conventional module shown in
FIG. 1;
[0036] FIG. 5 is a longitudinal cross-sectional view of FIG. 4
taken along lines 10-10;
[0037] FIG. 6 is a cross-sectional view of FIG. 4 taken along lines
11-11;
[0038] FIG. 7 is a side elevation view of a first face of an
example of a metal tension member that can be used in the new
modules according to the present invention;
[0039] FIG. 8 is a side elevation view of a second face that is
opposite the first side elevation on view of the tension member
shown in FIG. 7;
[0040] FIG. 9 is a top (or bottom) elevation view that is
perpendicular to the side elevation views of the tension member
shown in FIG. 7;
[0041] the tension member shown in FIG. 7;
[0042] FIG. 10 is an end elevation view that is perpendicular to
both the side elevation views and a perpendicular to the top (or
bottom) elevation views of the tension member shown FIG. 7;
[0043] FIG. 10 is an end elevation view that is perpendicular to
both the side elevation views and also perpendicular to the top (or
bottom) elevation views of the tension member shown in FIG. 7;
[0044] FIG. 11 is a side elevation view of a face of a plastic
tension member that can be used in the new modules according to the
present invention;
[0045] FIG. 12 is a top (or bottom) elevation view that is
perpendicular to the side elevation view of the tension member
shown in FIG. 11;
[0046] FIG. 13 is a top plan view of a foamed plastic module
according to the invention;
[0047] FIG. 14 is a side elevation view of the foamed plastic
module shown is FIG. 13;
[0048] FIG. 15 is a bottom plan view of the foamed plastic module
shown in FIG. 13;
[0049] FIG. 16 is an end elevation view of the foamed plastic
module shown in FIG. 13;
[0050] FIG. 17 is another end elevation view of the foamed plastic
module shown in FIG. 13;
[0051] FIG. 18 is a top plan view of a foamed plastic module for
making a "right" corner according to the invention (which is a
mirror image of a foamed plastic module for making a "left"
corner);
[0052] FIG. 19 is a side elevation view of the foamed plastic
module shown in FIG. 18;
[0053] FIG. 20 is a bottom plan view of the foamed plastic module
shown in FIG. 18; and
[0054] FIG. 21 is an end elevation view of the foamed plastic
module shown in FIG. 18.
[0055] FIG. 22 is an exploded three view of the invention corner
module with exposed metal cross members.
[0056] FIG. 23 is an exploded three view of the invention with
metal cross members.
[0057] This concludes all presented figures.
DETAILED DESCRIPTION OF A PRESENTLY MOST PREFERRED EMBODIMENT AND
BEST MODE OF PRACTICING THE INVENTION
Prior Art Context of the Invention
[0058] In FIG. 1, the reference numeral 10 indicates a wall
structure undergoing construction supported by a footing 11, by
using a modular construction block or module 12. As shown in FIG.
2, the module 12 can be attached to a plurality of similar blocks
of modules 12 of like or similar dimensions to provide a structural
form or mold within which recently-mixed cementitious material can
be poured, thereby forming a monolithic, composite, concrete wall
of great structural integrity. Accordingly, the filled modular
hollow blocks cooperate with one another to provide an insitu
insulated composite concrete and steel wall structure.
[0059] The term "composite" is intended to mean that the hollow
plastic modular construction blocks have reinforcing means, such as
steel bars and metal tension members, incorporated therewith so
that when freshly mixed, or wet, concrete is poured therewithin,
the resultant is a monolithic, insulated, composite, reinforced,
concrete wall structure. The term "insitu" is intended to mean that
the fresh concrete is poured directly into the assembled plastic
modular construction blocks, all of which jointly cooperate
together to form a new monolithic "poured-in-place" structure that
exhibits great structural strength.
[0060] The term "waffle wall" is intended to mean a poured in place
series of modules which who's concrete filled wall structure forms
a series of vertical posts, horizontal beams, and adjoining webs
which together comprise a monolithic concrete wall of great
structural integrity.
[0061] Preferably, the modular block is marketed as a unitary
module, less the concrete and rebar to enable one to assemble the
modules 12 into a structural hollow form, or mold, within which
rebar is incorporated thereinto, and then recently-mixed
cementitious material, or wet concrete, subsequently is poured
thereinto, thereby forming a monolithic concrete wall of great
structural integrity, and having many advantages, including cost
effectiveness as well as reduced heat loss, and rapid, low-cost
construction, but most important is the simple method of
construction that is within the comprehension of most handymen.
[0062] Moreover, decorative sheets of selected paneling material,
sheetrock, stucco and brick can be attached to the sidewalls 13 and
14 of the modules 12 and of the resultant monolithic structure 10
to provide a conventional appearing interior wall surface of
pleasing design and high quality.
[0063] In FIGS. 1-6, there is disclosed a modular construction
block 12, by which the aforesaid wall structure 10 shown in FIGS. 1
and 2 can be fabricated. The structural form provided by the blocks
12 is ready to be filled with concrete, as shown in FIGS. 1 and 2,
wherein spaced apart sidewalls 13 and 14 are formed from the foam
plastic walls of the module and provides a cavity 15
therebetween.
[0064] FIGS. 1 and 5 and 6 best illustrate that the peripheral edge
of the top 16 of each module 12 has an upwardly directed tongue 16a
formed thereon while bottom 17 has a co-acting tongue receiving
groove 17a formed thereon. The tongues and grooves located on the
opposed top 16 and bottom 17 of the module 12 enable adjacent rows
of blocks to be releaseably engaged with one another in the
illustrated manner of FIG. 2.
[0065] In FIG. 4, it is shown that ends 20 and 21 of each module 12
are provided with co-acting tongues 20a and grooves 21a to enable
one end of the block to be releaseably engaged with respect to the
adjacent end of another block, as indicated in FIG. 2.
[0066] As known in the art, a tension member 18, made of sheet
metal, is provided to connect the sidewalls 13 and 14 of the module
12.
[0067] Lengths of rebar 22 and 24 are suitably tied in supported
relationship within the cavity 15 to impart further strength into
the monolithic concrete structure.
[0068] In FIG. 2, the before-mentioned cavity 15 (also see FIG. 1 )
forms the illustrated vertical load bearing columns 19 and 28 and
when concrete is poured into the cavity between the confronting,
spaced, sidewalls 13 and 14. Note the intervening web 26 of
concrete attached integrally between the aforesaid vertical columns
19, and the horizontal beam 30, all units acting in consort to form
a monolithic "waffle wall" structure.
Presently Most Preferred Embodiment of A Metal Tension Member
100a--FIGS. 7-10
[0069] The presently most-preferred embodiment of a metal tension
member has increased strength and reduces the manufacturing costs
of a modular construction block of the type generally described
above. A metal tension member, generally referred to by the
reference numeral 100a, is illustrated in FIGS. 7-10 of the
drawing. The metal tension member 100a can be substituted for the
type of prior art tension member 18 shown in FIG. 1, resulting in a
new modular construction block or module.
[0070] The tension member 100a is preferably made of a sheet of
thin metal, which is cut perforated, creased, and bent to obtain
the illustrated structure according to metal working methods well
known to those skilled in such arts. As will be appreciated by
those skilled in such arts, the small circular apertures 101 shown
in FIGS. 7 and 8 are initially formed in the sheet metal for
alignment purposes during the manufacture of the tension member
100a.
[0071] As shown in FIGS. 7 and 8, the tension member 100a can be
described as having opposed faces 102 and 104 of the tension member
100a. As shown in the drawing, the faces of the tension member 100a
also can be helpfully described with reference to a center line
X.
[0072] FIGS. 7 and 8 illustrate the presently most preferred design
of the new shape for the opposed faces 102 and 104 of the tension
member 100a. As shown in the drawing, the faces of the tension
member 100a preferably present a generally octagonal shape, having
edges 111-118.
[0073] It is to be understood that the set of edges 112-114 and/or
the set of edges 116-118 of the faces can be modified to present a
single substantially curved edge rather than several substantially
straight edges. As will hereinafter be described in more detail,
the feature of having edges 112-114 present a substantially
triangular or curved cutout portion of the tension member of a
feature known in the art to provide a cantilever action between the
weight of any rebar that is placed on and partially supported by
the edge 113 of the tension member 100a and the uppermost portion
or tip 119 of the tension member 100a, when shown in the
orientation of FIGS. 7 and 8.
[0074] According to one aspect of the invention, the new tension
member 100a is provided with a symmetrical design when rotated 180
degrees about an imaginary center line X. Thus, the new tension
member 100a can be oriented in a module as shown in FIGS. 1 and 2,
with edges 112-114 facing upward, or, equally, the new tension
member 100a can be rotated about center line X and oriented with
edges 116-118 facing upward. As will hereinafter be described in
more detail, this additional degree or orientation freedom for the
new tension member 100a simplifies manufacturing considerations for
the new modules made using tension members 100a.
[0075] As shown in FIGS. 8-10, a plurality of anchoring tabs 120
are formed on the tension member 100a by cutting and bending or by
punching the anchoring tabs 120 out of the sheet metal forming the
tension member. These anchoring tabs 120 are bent substantially
perpendicular to the plane of the faces 102 and 104 of the tension
member 100a. (Of course, it is not critical that the tabs 120 be
bent exactly perpendicular to the faces 102 and 104.) The anchoring
tabs 120 are located on the tension member 100a at the end portions
107 and 109 and near the side edges 111 and 115. The end portions
107 and 109 are to be placed in a mold and embedded in the foam
plastic that forms the sidewalls 13 and 14 of an otherwise
conventional module 12.
[0076] The anchoring tabs 120 are preferably arranged in at least
two rows. As best shown in FIG. 8, the inner and outer rows of tabs
are preferably oppositely bent relative to one another, but
extending from the same face 104 of the tension member 100a.
Further, the cutouts 120a in the sheet metal of the tension member
100a that forms the anchoring tabs 120 provide apertures through
which the plastic can freely flow, and thereby help provide
anchoring and attachment at locations between the mass of plastic
material found adjacent either face 102 and 104 after the tension
member 100a is positioned to be molded and embedded in the plastic
material of the module. The placement of the anchoring tabs can be
further optimized by staggering at least one of the rows of the
anchoring tabs 120, for example as shown in FIGS, 7-10. The
staggered arrangement of the anchoring tabs 120 in the opposed
plastic walls 13 and 14 associated with the tension member 100a
helps anchor the tension member in the plastic and increases its
rigidity to avoid deformation when subjected to the hydrostatic
head of the wet concrete.
[0077] As best shown in FIG. 9, it will be noted that a flange 130
extends outward from the face 102 at each end portion 107 and 109
of the tension member 100a Each flange 130 more preferably receives
a single bend at 132 to form a single stiffening lip 134. Thus, the
flanges 130 and the anchoring tabs 120 preferably extend in
opposite directions from the faces of the tension member 100a. The
entire flange 130 along with the anchoring tabs 120 are embedded
within the polystyrene body of the module, with the polystyrene
encapsulating the tabs 120 and the flanges 130, thereby helping to
make the entire module 12 more rigid and forming the
before-mentioned cavity 15 for containment of the wet concrete.
[0078] The end most surface 136 of the flange 130, which surface
136 extends substantially perpendicular to the web portion 105 of
the tension member 100a, and preferably spaced about 3/8 inch below
the outermost surface of the polystyrene, lowering thermal
bridging, and reducing, the need for application of additional
polystyrene during synthetic stucco applications. After the
concrete has set up, the location of the flanges 130 is apparent
from observing the module exterior wall surface FIG. 13 raised
center of tension member "identification lines" 114 and even if
covered or removed, can still be quickly and easily located based
on the even spacing, preferably on one-foot centers. A self tapping
screw can be screwed into the flange face using an electric
screwdriver to directly attach the paneling to the wall surface of
either side of the structure.
[0079] A pair of alignment apertures 141a, 142a are located on the
central web portion of the tension member 100a for achieving exact
alignment between the several tension members 100a and with respect
to the mold cavity during the manufacture of the modules 12. The
apertures 141a and 142a formed by the punching of alignment tabs
141,142 and the apertures are used to allow the accurate alignment
of the tension members 100a in the modules 12 so that the
subsequent attachment of panel members can be made onto the wall
surface of a sidewall 13 or 14 of the completed structure by
attachment to the flanges 130. The alignment apertures 140a, 142a
are indexed with detents or small apertures that are formed during
the manufacture of the metal molds (not shown) so that the
polystyrene beads are molded or compressed about the tension member
100a in a manner that precisely positions the plurality of tension
members respective to one another and to the resultant sidewalls 13
and 14 of the module 12.
[0080] According to the new symmetrical design of the new tension
member 100a, a second pair of alignment apertures 143a, 144a are
symmetrically positioned "below" the center line X. The apertures
143a and 144a formed by the punching of the alignment tabs 143 and
144 to allow the accurate alignment of the tension members 100a in
the modules 12 so that the subsequent attachment of panel members
can be made onto the wall surface of a sidewall 13 or 14 of the
completed structure by attachment to the flanges 130. Thus, the new
tension member 100a can be oriented in a module as shown in FIGS. 1
and 2, with edges 112-114 facing upward, or equally, the new
tension member 100a can be rotated about the center line X and
oriented with edges 116-118 facing upward. This additional degree
of orientational freedom for the new tension member 100a simplifies
manufacturing considerations for the new modular construction block
made using tension members 100a.
[0081] The large cutout defined by edges 112-114 provides a rebar
support structure at a location between the end portion of the
tension members that are to be embedded in the plastic foamed
sidewalls 13 and 14 if a module 12. In the orientation represented
in FIGS. 7 and 8 of the drawing, the edges 112-114 extend "upwards"
toward the "upper" edge portion 119 adjacent the "upper" end of the
flanges 130. Hence, the large cutout can be in the form of a
truncated inverted triangle, which feature provides a cantilever
action between the weight of the rebar that is to be supported at
the "upper" edge 113 of the new tension member 100a. At least one
rebar seat 151 is formed on the edge 113 of the tension member
100a. More preferably, three rebar seats 151-153 are formed on the
edge 113. The rebar seats 151-153 are preferably crescent-shaped as
shown in FIGS. 7-8. The rebar seats 151-153 act to help position
and support a length of rebar on the tension member 100a.
[0082] According to the new symmetrical design of the tension
member 100a, the edges 116-118 are symmetrically designed about
center line X relative to edges 112-114. At least one rebar seat
154 is also formed on the edge 117 of the tension member 100a. More
preferably three rebar seats 154-156 are formed on the edge 117.
This, the new tension member 100a can be oriented in a module as
shown in FIGS. 1 and 2, with edges 112-114 facing upward, or,
equally, the new tension member 100a can be rotated about the
center line X and oriented with edges 116-118 facing upward, in
which case the rebar seats 154-156 act to help position and support
a length of rebar on the tension member 100a. This additional
degree of orientational freedom for the new tension member 100a
simplifies manufacturing considerations for the new modular
construction block make using tension members 100a.
[0083] One hole 160 is preferably formed in the central web portion
of the tension member 100a. The hole 160 is sufficiently large
enough to allow cementitious material to freely flow between the
spaces formed in the interior of a module 12.
[0084] According to another aspect of the invention, the new
tension member 100a has at least one, and preferably two,
stiffening structures in the central web portion 105. The
stiffening structure is most preferably in the form of an elongated
rib 170 pressed or otherwise formed in the central web portions 107
and 109. According to the presently most preferred embodiment of
the invention, the elongated ribs 170 are pressed from the side of
face 102 to create the elongated rib extending outward from face
104 of the tension member. The stiffening structure provides
additional strength to the tension member 100a, which helps
maintain the rigid form of the modules made with the tension member
100a against the hydrostatic head of the wet cememt.
[0085] The confronting polystyrene sidewalls 13 and 14 of a module
12 can be secured one to the other by a plurality of the spaced
tension members 100a disclosed in FIGS. 7-10.
[0086] A module can be fabricated having, for example, the
following dimensions: width 9.25 inches; length 4 feet; height 16
inches; tension member width 8.25 inches; height 12.5 inches; and
the flange width 1.5 inches; height 12.5 inches; upper cutout
dimensions at rebar seat 3 inches; anchoring tab size 1
inch.times.0.75 inch; alignment tab size 0.25.times.0.25 inch; and
8 tabs on each side arranged in two rows of four per row to provide
a total of 8 tabs aligned in two rows, or 16 anchor tabs in four
rows; and additionally the two alignment tabs at each of the
opposed ends of each tension member.
[0087] It is to be understood, or course, that while this is the
presently most preferred embodiment of a metal tension member for
used in the present invention, numerous variations and
modifications to the tension member can be made without departing
from the scope and spirit of the present invention.
Presently Most Preferred Embodiment of A Plastic Tension Member
100f--FIGS. 11-12
[0088] As an alternative to using a metal tension member, it is
sometimes desirable to use a plastic tension member. A tension
member formed of plastic can have many of the same design features
as described with respect to the various designs for a metal
tension member. A representative example of a plastic tension
member, generally referred to by the reference numeral 100f is
illustrated in FIGS. 11 and 12. The plastic tension member can have
similar functions and dimensions as the metal tension member 100a
described above. Because the tension member 100f is formed of
plastic, rather than bent metal, it can have a symmetrical I-beam
design, illustrated in the top plan view FIG. 12. The plastic
tension member 100f can be substituted for the type of prior art
tension member 18 shown in FIG. 1, resulting in a new modular
construction block or module.
[0089] The tension member 100f is preferably made of a plastic
molded into the desired shape according to plastic working methods
well known to those skilled in such arts.
[0090] As shown in FIGS. 11 and 12, the tension member 100f can be
described as having opposed faces 102 and 104, a central web
portion 105, and end portions 107 and 109. The tension member 100f
also can be helpfully described with reference to a center line
X.
[0091] FIGS. 11 and 12 illustrate the presently most preferred
design of the new shape for the opposed faces 102 and 104 of the
tension member 100f. As shown in the drawing, the faces of the
tension member 100f preferably present a generally octagonal shape,
having edges 111-118.
[0092] It is to be understood that the set of edges 112-114 and/or
the set of edges 116-118 of the faces can be modified to present a
single substantially curved edge rather than several substantially
straight edges. As will hereinafter be described in more detail,
the feature of having edges 112-114 present a substantially
triangular or curved cutout portion of the tension member is a
feature known in the art to provide a cantilever action between the
weight of any rebar that is placed on and partially supported by
the edge 113 of the tension member 100f and the uppermost portion
or tip 119 of the tension member 100f, when shown in the
orientation of FIGS. 11 and 12.
[0093] According to one aspect of the invention, the new tension
member 100f is provided with a symmetrical design when rotated 180
degrees about an imaginary X. Thus, the new tension member 100f can
be oriented in a module as shown in FIGS. 1 and 2, with edges
112-114 facing upward, or, equally, the new tension member 100f can
be rotated about center line X and oriented with edges 116-118
facing upward. As will hereinafter be described in more detail,
this additional degree of orientational freedom for the new tension
member 100f simplifies manufacturing considerations for the new
modules made using tension member 100f.
[0094] Although not shown in FIGS. 11 and 12, if desired, a
plurality of anchoring tabs, similar to the anchoring tabs 120
shown in FIGS. 7-10, can be formed on the tension member 100f
within the foam plastic that forms sidewalls 13 and 14 of an
otherwise conventional module 12. The anchoring tabs can be
preferably arranged in at least two rows, similar to the anchoring
tabs 120 shown in FIGS. 7-10. However, because of the different
nature of the molding process, such tabs on a polypropylene plastic
tension member for example, may have-but would not require,
apertures adjacent thereto, which in the metal embodiment are
formed by cutting and bending the sheet metal. Like for the metal
tension member described above, however, if formed in the tension
member, the apertures would allow the plastic to freely flow and
thereby help provide anchoring and attachment at locations between
the mass of plastic material found adjacent either face 102 and 104
after the tension member 100f is positioned to be molded and
embedded in the plastic material of the module.
[0095] As best shown in FIG. 12, it will be noted that a flange 130
extends outward from both the faces 102 and 104 at each end portion
107 and 109 of the tension member 100f. Because of the nature of
plastic compared to metal, stiffening features similar to those
described above for a metal tension member could be advantageously
employed with plastic. The entire flange 130 is embedded within the
polystyrene body of the module, with the polystyrene encapsulating
the flange 130, thereby helping to make the entire module 12 more
rigid and forming the before-mentioned cavity 15 for containment of
the wet concrete.
[0096] The end most surface 136 of each flange 130, which surface
136 extends substantially perpendicular to the web portion 105 of
the tension member 100f, is preferably spaced about 3/8 inch below
the outermost surface of the polystyrene so that sheets of
paneling, or the like, can more easily be screwed directly into the
flange 130. After the concrete has set up, the location of the
flanges is apparent from observing the module exterior wall
surface, but not, of course, after being covered with any wall
finishing material. A self-tapping screw can be screwed into the
flange face using an electric screwdriver to directly attach the
paneling to the wall surface on either side of the structure.
[0097] The large cutout defined by the edges 112-114 provides a
rebar support structure at a location between the end portions of
the tension member that are to be embedded in the plastic foamed
sidewalls 13 and 14 of a module 12. In the orientation represented
in FIGS. 7 and 8 of the drawing, the edges 112-114 extend "upwards"
toward the "upper" portion 119 adjacent the "upper" end of the
flanges 130. Hence, the large cutout can in the form of a truncated
inverted triangle, which feature provides a cantilever action
between the weight of the rebar that is to be supported at the
"upper" edge 113 of the new tension member 100f.
[0098] At least one rebar seat 151 is formed on the edge 113 of the
tension member 100f. More preferably, three rebar seats 151-153 are
formed on the edge 113. The rebar seats 151-153 are preferably
crescent-shaped as shown in FIGS. 11-12. The rebar seats 151-153
act to help position and support a length of rebar on the tension
member 100f.
[0099] According to the new symmetrical design of the new tension
member 100f, the edges 116-118 are symmetrically designed about
center line X relative to edges 112-114. At least one rebar seat
154 is also formed on the edge 117 on the tension member 100. More
preferably, three rebar seats 154-156 are formed on the edge 117.
Thus, the new tension member 100f can be oriented in a module as
shown in FIGS. 1 and 2, with edges 112-114 facing upward, or,
equally, the new tension member 100f can be rotated about the
center line X and oriented with edges 116-118 facing upward, in
which case the rebar seats 154-156 act to help position and support
a length of rebar on the tension member 100f. This additional
degree of orientational freedom for the new tension member 100f
simplifies manufacturing considerations for the new modular
construction block made using tension members 100f.
[0100] According to an aspect of the invention, the rear seats
151-156 are preferably adapted for supporting and actually engaging
reinforcing rear for the cement waffle wall. More particularly, the
rear seats are preferably sized and adapted such that the nature of
the plastic material allows the rear to be "snapped" into a rear
seat of the plastic tension member.
[0101] At least one hole 160 is preferably formed in the central
web portion of the tension member 100f.
[0102] The hole is sufficiently large to allow cementious material
to freely flow between the spaces formed in the interior of a
module 12.
[0103] Although not shown in FIGS. 11-12, like for the metal
tension member 100a previously described, the plastic tension
member 100f can have one or more stiffening structures in the
central web portion 105.
[0104] It is to be understood, that while this is a representative
example of a suitable plastic tension member for use in the present
invention, numerous variations and modifications to the tension
member can be made without departing from the scope and spirit of
the present invitation.
Regular Foamed Plastic Module with Metal or Plastic Tension
Members--FIGS. 13-18
[0105] Referring now to FIGS. 13-18 Engineering detailed drawings
illustrate a regular, generally rectangular-shaped, foamed plastic
module according to the presently most preferred embodiment of the
invention and best mode for practicing the invention. Such a module
is used for forming a new insulated concrete waffle wall according
to the invention.
[0106] As will be appreciated by those skilled in the art, these
engineering drawings fully disclose the shape and structure of the
foamed plastic module. The mold for making the disclosed module can
be easily engineered based on these drawings for the module.
[0107] It should be noted, however, that FIGS. 13, 15 and 18 of
these drawings illustrate a module having either a metal tension
member 100a or a plastic tension member 100f, substantially as
previously described in detail herein. Although both are
illustrated in the drawing, it is to be understood that one or the
other could actually be used, or the tension members could be
alternated within a module. An insert (not shown) is used to help
position one or the other of the tension members in the mold for
making the foamed plastic module.
[0108] Please note FIG. 4. This is a typical embodiment of a
conventional tension member positioned within the module. In FIG. 4
note the end tension member 9 and 9a and their position to the ends
of the module. Also note in FIG. 4 the closed face of the module
ends 22 and 22a along with 23 and 23a compared to the ends of the
module in FIG. 13 103 and 103a. In FIG. 4 there are four cores per
module as indicated by 28, 25, 26, 27.
[0109] In some prior art embodiment, attempts to leave the end
tension member 9 and 9a absent resulted in the tension members
being moved to core center 16 of positions 28, 26,25, and 27 FIG.
4. Tension member placement at position 16 was at maximum concrete
pressure, but minimum foam bridging, and resulted in module
failure.
[0110] In the new invention embodiment FIG. 13 the number of
complete cores 109, 109a, and 109b, have been reduced to three per
module with half cores 103 and 103a located on the ends of the
module. In FIG. 13 the half core creates a complete core of similar
size and dimension to the previous core when the next module is
placed in running bond with the tongue 110 and 110a and the groove
111 and 111a of the adjacent module. In FIG. 13 the extra strength
necessary to withstand the concrete pouring pressure, while
increasing building integrity was achieved by increasing the size,
dimension and design of the tongue 110 and 110a and the groove 111
and 111a, decreasing the core width 112 and increasing the nominal
core length 113 relative to its width 112. Making these changes
allowed more concrete to be placed into the wall increasing the
overall strength of the wall system, while maintaining the strength
of the module. When the modules are stacked in running bonds FIG. 2
with the corner modules in FIG. 18, all cores 103, 103a, 109, 109a,
and 109b in FIG. 13 and 18 will align with any and all subsequent
modules stacked in the wall. In FIG. 13 external alignment lines
114, align with all other simialr lines of 114 throughout the
module, ie. FIG. 18 alignment lines 114. All of these
identification lines will be of equal spacing horizontally with the
modules having the proper stagger. No two tension members will be
in close proximity to one another creating possible voids in the
wall structure.
L-shaped Foamed Plastic Module with Metal or Plastic Tension
Members--FIGS. 18-23
[0111] Referring to FIGS. 18-21 of the drawings, engineering detail
drawings illustrate a regular, generally rectangular-shaped, formed
plastic module according to the presently most preferred embodiment
of the invention and best mode for practicing the invention. Such a
module is used for forming a corner portion for a new insulated
concrete waffle wall according to the invention.
[0112] As will be appreciated by those skilled in the art, these
engineering drawings fully disclose the shape and structure of the
L-shaped foamed plastic module. The mold for making the disclosed
module can be easily engineered based on these drawings for the
module.
[0113] Again, it should be noted, however, that FIGS. 18 and 20 of
these drawings illustrate a module have either a metal tension
member 100a or a plastic tension member 100f, substantially as
previously described in detail herein Although both are illustrated
in the illustrated, it is to be understand that one or the other
would actually be used. An insert (not shown) is used to help
position one or the other of the tension members in the mold for
making the foamed plastic module.
[0114] In addition, the L-shaped member is preferably provided with
a corner bracket 200, which can be used to help attached finishing
materials to the corner of the finished insulated waffle wall.
Manufacture and Use of New Module Construction Blocks
[0115] The individual modules are fabricated by placing the
plurality of tension members having one or more of the inventive
features of the above-described tension members (e.g., 100a or
100f) within the mold cavities. As will be appreciated by those in
the molding art, small mold inserts are used, not shown in the
drawing, to position either metal or plastic tension members 100f
in the mold.
[0116] At least in the case of the metal members 100a using the
small apertures 140a formed by the cutout of making the alignment
tabs 140 as alignment means by which the individual tension members
100a are precisely aligned with one another within the mold cavity,
and also more perfectly aligned respective to the subsequently
formed polystyrene side walls 13 and 14. The alignment tabs 140 are
preferably adapted to be received within a detent formed in one of
the polystyrene mold halves. The detent, or locating aperture 140a
formed by the cutout of the alignment tabs, places the flanges 130
of the tension members precisely spaced 3/8 inch below the
outermost polystyrene wall surfaces of the completed product where
they are accessible for subsequent attachment of paneling and the
like thereof.
[0117] Referring again to FIGS. 1 and 2, in use, a first row of
modules 12 is placed on the concrete footing 11 and arranged in the
desired row, with adjacent ends being fastened together by the
before-mentioned tongue-and-groove arrangement. The lower end of
the first module can be either pressed into wet concrete footer, or
glued to the footer 11 so it will be held in place resisting
lateral movement of the forms during the place ment of the
concrete.
Best Mode--Appendix
[0118] Additional information regarding the best mode of practicing
the present invention, which is being marketed under the brand name
"Granite Block" TM, is described in detail in the "Granite Block TM
Forming System Structural Procedures Manual " dated January 2000, a
complete copy of which is attached hereto and incorporate by
reference herein in its entirety.
Scope of Invention Not Limited to Preferred Embodiments
[0119] The invention is described with respect to presently
preferred embodiments, but is not intended to be limited to the
described embodiments. It will be apparent to one skilled in the
art, that numerous such modifications may be made to the invention
without departing from the spirit and scope of the invention.
* * * * *