U.S. patent application number 10/778225 was filed with the patent office on 2004-08-19 for insulated concrete form system and method for use.
Invention is credited to Schmidt, Donald L..
Application Number | 20040159061 10/778225 |
Document ID | / |
Family ID | 32854329 |
Filed Date | 2004-08-19 |
United States Patent
Application |
20040159061 |
Kind Code |
A1 |
Schmidt, Donald L. |
August 19, 2004 |
Insulated concrete form system and method for use
Abstract
An insulated concrete form system for receiving poured concrete
to form a unitary, insulated concrete wall. A novel tie bracket,
spaced on one foot centers, space the two sides of he forms apart
from one another. The tie brackets extend fully from top to bottom
of the forms, thereby providing increased structural strength to
the formed wall and providing "studs" at regular intervals for the
fastening of structural elements, such as paneling or sheetrock. A
rebar attachment piece may be attached to the a rebar receptacle
formed in the tie bracket such that rebar may be offset to either
side of the poured wall, as necessary. The forms are in straight,
corner and Tee configurations to aid in the quick laying of the
forms and to provide increased strength to the formed wall. A
combination of tongue and groove joints and interlocking
protrusions and notches add further strength and integrity to the
formed wall.
Inventors: |
Schmidt, Donald L.;
(Oronoco, MN) |
Correspondence
Address: |
Randy Shay
PO Box 2607
Fairfax
VA
22031
US
|
Family ID: |
32854329 |
Appl. No.: |
10/778225 |
Filed: |
February 17, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10778225 |
Feb 17, 2004 |
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09932096 |
Aug 20, 2001 |
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10778225 |
Feb 17, 2004 |
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09932095 |
Aug 20, 2001 |
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6691481 |
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10778225 |
Feb 17, 2004 |
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09932081 |
Aug 20, 2001 |
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Current U.S.
Class: |
52/415 |
Current CPC
Class: |
E04B 2002/8676 20130101;
E04B 2/8617 20130101; E04B 2002/867 20130101 |
Class at
Publication: |
052/415 |
International
Class: |
E04C 001/00 |
Claims
What is claimed is:
1. A wall form for receiving poured concrete, said wall form
comprising a first insulating panel formed from expanded foam, a
second opposed insulating panel formed from expanded foam, and a
tie bracket spanning and connecting said first insulating panel and
said second insulating panel, wherein said tie bracket includes a
web having a securing plate at a first end embedded within said
first insulating panel, and a securing plate at a second end
embedded within said second insulating panel, said first and second
insulating panels having a height, and said first and second
securing plates extending the full height of the first and second
insulating panels; said first insulating panel and said second
insulating panel each have an upper edge, a lower edge, two side
edges, an exterior surface and an interior surface, with said
interior surface of each insulating panel facing the interior
surface of the other insulating panel; one of said side edges of
each insulating panel having a tongue, and the other of said side
edges of each insulating panel having a groove sized for receiving
said tongue, whereby adjacent panels in a wall can be interlocked
by inserting the tongue of one side edge of a first panel into the
groove of a side edge of an adjacent panel; said upper edge of each
insulating panel having a longitudinally extending tongue and at
least one projection of a given size extending laterally from said
longitudinally extending tongue; said lower edge of each insulating
panel having a longitudinally extending groove and at least one
notch of a given size extending laterally from said longitudinally
extending tongue, said longitudinally extending groove sized for
receiving said longitudinally extending tongue, and said at least
one notch sized for receiving said at least one projection, whereby
vertically stacked panels can be interlocked by cooperation between
the longitudinally extending tongue and at least one projection of
the upper edge of the lower panel being received within the
longitudinally extending tongue and at least one notch of the lower
edge of the upper panel.
2. The wall form of claim 1, wherein said at least one projection
and said at least one notch comprise a plurality of projections and
a plurality of notches, said projections and notches being located
symmetrically at regular intervals along the length of each
insulating panel.
3. The wall form of claim 2, wherein said plurality of projections
and said plurality of notches are located at 12 inch intervals,
starting 12 inches from one side edge of each insulating panel, the
interval being measured from the centerline of one projection or
notch to the centerline of an adjacent projection or notch.
4. The wall form of claim 3, wherein said plurality of projections
and said plurality of notches are vertically aligned with respect
to one another.
5. The wall form of claim 3, further comprising a half projection
extending laterally from each end of said longitudinally extending
tongue of each of said insulating panels and a half notch extending
laterally from each end of said longitudinally extending groove of
each of said insulating panels, the half projections and half
notches being located such that their ends closest to the
respective side edge of each insulating panel is 12 inches from the
centerline of the closest respective projection or notch, whereby
when two wall forms are interlocked in side-by-side relationship,
two of said half projections from adjacent wall forms can be
received within a full-sized notch of another wall form, and two of
said half notches can receive a full-sized projection from another
wall form.
6. The wall form of claim 5, further comprising additional
projections extending laterally from said longitudinally extending
tongue and situated respectively at the midpoint between each half
projection and the projection closest thereto, the size of said
additional projections being the same as one another, but of a
different size from said projections and said half projections.
7. The wall form of claim 6, further comprising additional notches
extending laterally from said longitudinally extending groove and
situated respectively at the midpoint between each half projection
and the projection closest thereto, and between each pair of
adjacent projections on the lower edge of each insulating panel,
the size of said additional notches corresponding to the size of
said additional projections.
8. The wall form of claim 1, further comprising bulkhead retainers
at both ends of each panel, said bulkhead retainers designed to
retained a bulkhead at each end of the wall form to stop concrete
flow out of said wall form at a desired void in the wall, such as a
door or window.
9. The wall form of claim 1, further comprising a plurality of said
tie brackets, wherein a first tie bracket is located such that the
vertical centerline of its securing plates are located at 6 inches
from a side edge of each insulating panel, and the remaining tie
brackets are positioned at 12 inch intervals along the length of
the form, the interval being measured from the vertical centerline
of one securing plate to the vertical centerline of an adjacent
securing plate, thereby providing securing plates which are
positioned at regular and predictable locations along the length
of, and extend the full height of, a wall created by any number of
said wall forms interlocked together, said securing plates acting
as studs and being suitable for receiving fasteners therein to
secure sheathing or other items to a finished wall.
10. The wall form of claim 1, wherein said interior surface of each
insulating panel has a principally flat surface comprising a series
of male extensions protruding therefrom collectively to thereby
form a void between said interior surfaces of said insulating
panels such that a plurality of spaced apart posts, a plurality of
spaced apart beams disposed to intersect said posts, and a
plurality of webs spanning and joining adjacent said posts and
adjacent said beams are formed when said void is filled with poured
concrete and the concrete cures.
11. The wall form of claim 10, wherein the series of protrusions of
said first and second interior surfaces are substantially
rectilinear and face one another in an opposing manner such that
said posts and said beams are parallelepiped.joined where said
posts and said beams intersect one another; and wherein said posts
have exterior surfaces disposed perpendicular to said first
insulating panel and said second insulating panel, and said beams
have exterior surfaces disposed parallel to said first insulating
panel and said second insulating panel.
12. The wall form of claim 1, wherein said first insulating panel
and said second insulating panel both are straight, whereby said
insulating concrete form is a straight insulating concrete
form.
13. The wall form of claim 12, wherein said first insulating panel
and said second insulating panels have a length of 48 inches.
14. The wall form of claim 1, wherein said first insulating panel
and said second insulating panel each include a long leg and a
short leg, each said short leg disposed at an angle to each said
long leg, and together forming a unitary panel, whereby said
insulating concrete form is a corner insulating concrete form.
15. The wall form of claim 14, wherein one of said legs has a
length of 30 inches, and the other of said legs has a length of 18
inches.
16. The wall form of claim 1, wherein said first insulating panel
is straight, and said second insulating panel is formed in two
parts that are a mirror image of one another, each part of the
second insulating panel having a first leg which is substantially
parallel to said first insulating panel and extends from a point
opposite one of said side edges of said first panel parallel to a
second point partway along the length of said first insulating
panel, and a second leg which is perpendicular to said first leg
and said first panel, said second leg extending from said second
point to an end point remote from said first leg and opposite the
end point of the second leg of the other part of the second
insulating panel, whereby together the first panel and the first
and second parts of the second panel form a void whose overall
shaped when viewed from above is in the shape of a "T".
17. The wall form of claim 16, wherein the length of the first
panel, and hence the length of the top bar of the "T" shape, is 48
inches long, and the length of the vertical leg of the "T" shape,
as measured from the first insulating panel to the end point remote
from said first leg, is 18 inches long.
18. The wall form of claim 16, wherein the length of the first
panel, and hence the length of the top bar of the "T" shape, is 24
inches long, and the length of the vertical leg of the "T" shape,
as measured from the first insulating panel to the end point remote
from said first leg, is 30 inches long.
19. The wall form of claim 1, wherein the web of said tie bracket
includes an upwardly open receptacle formed by two
upwardly-pointing legs; further comprising a rebar attachment piece
comprising a "U" shaped receptacle and an attachment means for
removably mounting the rebar attachment piece to one of the two
upwardly-pointing legs to enable rebar to be supported by the "U"0
shaped receptacle.
20. The wall form of claim 19, wherein the attachment means of said
rebar attachment piece comprises an opening designed to receive
therein one of the upwardly-pointing legs of said upwardly open
receptacle of said tie bracket.
21. The wall form of claim 19, wherein the rebar attachment piece
comprises a plurality of said "U" shaped receptacles.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part of applications
Ser. No. 09/932,096, FORM BRACING TIE BRACKET FOR MODULAR
INSULATING CONCRETE FORM SYSTEM AND FORM USING THE SAME; Ser. No.
09/932,095, CORNER FORM FOR MODULAR INSULATING CONCRETE FORM
SYSTEM, now U.S. Pat. No.______; and Ser. No. 09/932,081, MODIFIED
FLAT WALL MODULAR INSULATED CONCRETE FORM SYSTEM; all filed on Aug.
20, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to modular insulating concrete
forms of the type which receive poured concrete and are left in
place after pouring, thereby becoming an integral part of a static
structure being built. The invention is particularly applicable to
residential and light commercial construction. The novel forms are
usable by homeowners, contractors, municipal, industrial, and
institutional personnel in building and improving existing
structures wherever insulated load bearing walls are to be built
from poured concrete.
[0004] 2. Description of the Prior Art
[0005] Left-in-place insulting concrete forms for building
foundations and load bearing walls from poured concrete are known.
In commercial practice, courses of forms are stacked until the
final desired height of a wall is attained. Concrete is poured into
the erected forms and allowed to cure. The resultant wall must
provide both strength and also insulative protection against the
elements. A variety of different insulating concrete forms have
been proposed to answer these needs. In order to maximize both
strength and insulation values within a given volume dedicated to a
left-in-place form wall, the concrete elements must be carefully
designed to utilize a minimum amount of concrete, so that the
balance of the available volume may be filled with the insulating
form.
[0006] There are three distinct types of insulated concrete form
systems in the prior art which produce three distinct types of
walls.
[0007] Flat wall systems, as their name implies, consist of a flat
sheet of foam on both sides, which produce a flat concrete wall
therebetween. Assuming 11/2" thick foam on each side, an 11" thick
form would produce an 8" thick concrete wall.
[0008] Waffle grid systems have a series of rounded posts and beams
formed in the foam such that when a poured concrete posts and beams
are formed with a web of thinner concrete therebetween. Since the
strength of a waffle grid wall is based on the square that can be
described within the rounded columns, the same 11" thick form with
8" round columns only has the strength of a 6" straight wall.
[0009] In screen grid systems the forms are generally formed of
foam with the two sides of the form joined by foam which, after the
concrete pour leaves holes in the concrete which are filled with
foam. An 11" screen grid wall with an 8" concrete pour doe not have
the strength of an 11" flat wall because the concrete wall is
broken at the foam connectors, thereby reducing the fire rating of
the wall and its effectiveness as a sound barrier.
[0010] The present invention presents a cross between the flat wall
system and the waffle grid system in which a flat wall with square
posts and beams, providing greater strength than the rounded waffle
grid system.
[0011] Each of the above referenced form systems must, ideally,
address several needs.
[0012] First is the necessity for each form be properly aligned
with respect to adjacent forms, both vertically and horizontally,
to assure that finished wall surfaces are flat and flush. Also,
opposing exterior panels of each form section must be held in place
without distortion of overall configuration of the finished
wall.
[0013] Secondly, it is desirable for the tie brackets within the
forms to be aligned vertically, preferably form a continuous
vertical structure (a stud), at regular intervals which conforms to
standard dimensions of building products (typically, multiples of
one foot). It is especially desirable that this uniform placement
of tie brackets be consistent in both inside and outside
measurements in corner forms. If a form section has tie brackets
and associated plates or flanges serving as a structural members
which can receive driven and threaded fasteners, and these plates
or flanges are located at each end of the form section, then
abutment of two form sections results in abutting plates or
flanges. This arrangement will likely interfere with even spacing
apart of tie brackets at even distance intervals of a whole number
of feet since the two abutting end brackets will be spaced on
either side of the center line. Thus, if a fastener is driven at
the point of abutment, there will be no solid structural member to
receive the fastener.
[0014] Flat wall systems are taught by Severino (U.S. Pat. No.
6,308,484), Moore, Jr. (U.S. Pat. No. 6,170,220), Cymbala, et (U.S.
Pat. No. 5,896,714), Boeshart (U.S. Pat. No. 5,658,483), Mensen
(U.S. Pat. No. 5,657,600), and Young (U.S. Pat. No. 4 730,422),
while waffle grid systems are taught by Vaughan, et al. (U.S. Pat.
No. 5,845,449), Vaughan, et al. (U.S. Pat. No. 5,709,060), Mensen
(U.S. Pat. No. 5,657,600), and Sparkman (U.S. Pat. No. 5,459,971).
None of the above references cite a combinations of the flat wall
and waffle grid system, as does the present invention, the unique
tie bracket of the present invention, which further serves as
"studs" spaced at regular intervals, or the combination of spacing
and joint reinforcing elements of the present invention.
SUMMARY OF THE INVENTION
[0015] The present invention provides insulating concrete forms
which provide the best features of both the "flat wall" and the
"waffle grid" type forms which satisfy two practical needs. One
need is that of forms which can be erected in interlocked stacks
which oppose sliding and disengagement of one form with respect to
both its vertical and horizontal neighbors. Another need is to
provide forms which favor current U.S. building practices with
regard to dimensions. It is frequently the case that buildings are
designed in increments of one foot and even in increments of four
feet. The novel forms satisfy both needs.
[0016] Interlocking is achieved by forming male interlocking
members in the top surface of each form, and corresponding female
interlocking members in the bottom surface of each form. The male
and female interlocks are a combination of tongue and groove edges
on respective upper and lower surfaces of each form, and vertically
aligned projections and notches extending laterally from the
respective tongue and groove so that a stack of forms will enable
each form to interlock with a form placed directly thereon and also
with the form located directly below, thereby preventing horizontal
shifting between vertically stacked forms and ensuring alignment of
the tie brackets.
[0017] The forms are configured such that pouring concrete into the
void formed between the opposing panels of insulating material
generates a modified flat wall configuration having a substantially
flat surface with vertical posts and horizontal beams at regular
intervals.
[0018] Preferably, the posts and beams are configured as
parallelepipeds so that all constituent material thereof
contributes to compressive strength in at least one direction of an
orthogonal or Cartesian system. No concrete is thus ineffectually
used. Overall building costs and weight are minimized, while still
affording maximal strength. Also, volume within the form devoted to
insulating material is maximized, thereby maximizing temperature
insulating value of the form.
[0019] Forms may be either straight or angled, the latter being
known either as corner forms or as Tee forms, because angled forms
are usually used to form the corner of intersecting walls. Straight
forms, corner forms and Tee forms are all dimensioned with regard
to modular building. That is, the length of a straight form is
preferably four feet, and a Tee form has a length of either two
feet or four feet. A corner form has a combined length of both legs
of four feet. These dimensions favor building designs laid out in
increments of one, two, and four feet. This characteristic
minimizes the number of forms which must be cut in length to
achieve a desired wall length, thereby saving labor and tending to
promote straightness and integrity of the finished poured wall,
although forms can be cut to allow for walls of other than even
foot lengths.
[0020] Similarly, tie brackets connecting inner and outer walls of
each form section are located at one foot intervals along the
length of the form, the first being one half foot from the end of
the form. This location prevents tie brackets of adjacent abutting
forms in one course from interfering with regular spacing of the
tie brackets along the entire length of the wall. Rather, tie
bracket spacing remains constant. As a consequence, location of
concealed flanges or plates of each tie bracket, which is employed
to receive and support driven fasteners for fixing plywood and dry
wall sections to the wall, is predictable. Effort and expense of
mounting either interior or exterior finishing materials on the
finished concrete wall is minimized.
[0021] Interlocking members of the form are spaced apart and
dimensioned so that clogging with concrete is not a problem when
the top of the forms are exposed during concrete placement. If the
notches, or female interlocking members, were too small, it would
be difficult to dislodge concrete overflow and other materials
therefrom. They are spaced apart so that an inordinate number of
notches, which would otherwise require cleaning, is avoided.
[0022] Accordingly, it is one object of the invention to provide
insulating concrete forms which readily interlock when vertically
stacked.
[0023] It is another object of the invention that the novel forms
facilitate construction of building designs laid out in increments
of one, two, and four feet, as measured from the outside corner of
the form system.
[0024] It is a further object of the invention to minimize labor
required to erect the forms.
[0025] Still another object of the invention is to enable ready
location of concealed tie bracket flanges or plates when driving
fasteners into the wall built by the novel forms.
[0026] An additional object of the invention is to maximize
strength of the wall for the amount of concrete consumed.
[0027] It is again an object of the invention to maximize
insulation value of the wall.
[0028] It is an object of the invention to provide improved
elements and arrangements thereof in an apparatus for the purposes
described which is inexpensive, dependable and fully effective in
accomplishing its intended purposes.
[0029] These and other objects of the present invention will become
readily apparent upon further review of the following specification
and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Various other objects, features, and attendant advantages of
the present invention will become more fully appreciated as the
same becomes better understood when considered in conjunction with
the accompanying drawings, in which like reference characters
designate the same or similar parts throughout the several views,
and wherein:
[0031] FIG. 1 is a perspective view of the tie bracket of the
present invention.
[0032] FIG. 2 is a cross sectional detail view of the tie bracket
of the present invention at line 2-2 of FIG. 1.
[0033] FIG. 3 is a perspective view of the rebar attachment piece
of the present invention.
[0034] FIG. 4 is a side elevational view of the rebar attachment
piece of the present invention in place on the rebar receptacle of
the tie bracket of FIG. 1.
[0035] FIG. 5 is a top perspective view of the straight form of the
present invention incorporating the tie brackets of FIG. 1.
[0036] FIG. 6 is a bottom perspective view of the straight form of
FIG. 5.
[0037] FIG. 7 is a plan view of the straight form showing spacing
of various elements.
[0038] FIG. 8 is a diagramatic view of several of the straight
forms stacked as a wall segment.
[0039] FIG. 9 is a top perspective view of the corner form of the
present invention incorporating the tie bracket of FIG. 1.
[0040] FIG. 10 is a bottom perspective view of the corner form of
FIG. 9.
[0041] FIG. 11 is a partial, perspective view of the corner bracket
of the corner form.
[0042] FIG. 12 is a plan view of a corner form of the present
invention showing spacing of various elements.
[0043] FIG. 13 is a diagramatic view of two of the corner forms and
a straight form stacked as a wall segment.
[0044] FIG. 14 is a plan view of a first embodiment of the Tee form
of the present invention.
[0045] FIG. 15 is a plan view of a second embodiment of the Tee
form of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] FIG. 1 of the drawings shows a wall tie bracket 10 according
to the present invention. Tie bracket 10 comprises a first elongate
plate 12, a second elongate plate 14 spaced apart from plate 12,
and a web 16 securing plates 12, 14 in spaced apart relation. Web
16 includes a plurality of vertically spaced apart spanning members
18, 20, 22, 24 which extend horizontally, in the depiction of FIG.
1, from plate 12 to plate 14, to join plates 12 and 14
structurally. Spanning members 18, 20, 22, 24 are connected to one
another by braces 26, 28. Spanning members 18, 20, 22, 24 and
braces 26, 28 are preferably formed by intersecting ridges
selectively orthogonally oriented to one another, as shown in FIG.
2. That is to say, that each of the spanning members 18, 20, 22, 24
and braces 26, 28 are formed of a plurality of orthogonal ridges
extending along substantially the full length of the spanning
member or brace, such that each spanning member or brace has
cross-sectional shape of a "T"(as shown at FIG. 2) or a "+". First
elongate plate 12 and second elongate plate 14 can also each be
seen in FIG. 1 to have an orthogonal ridge extending substantially
along the full length of each. This cross sectional configuration
maximizes strength of the respective member while minimizing the
amount of constituent material thereof. Circumferentially closed
openings 30, 32, 34, 35, 36 are thus formed in web 16.
[0047] At least two horizontal rows of circumferentially closed
openings are formed when plates 12, 14 are oriented vertically, as
shown in FIG. 1, there being at least two adjacent openings in each
horizontal row. The arrangement of openings between horizontal and
vertical members results in a very useful array of openings. First,
it will be seen that outer openings 30, 36 and inner or central
openings 32, 34, 35 all formed between spanning members 20, 22, are
oriented such that their lengths extend horizontally. Additionally,
it can be seen in FIG. 1 that the orthogonal ridge which extends
down one side of each plate 12, 14 has a break therein which
coincides with the outer openings 30, 36. As a consequence, with
the center lines of outer openings 30, 36 and central openings 32,
34, 35 arranged in line, and the break in the orthogonal ridge of
plates 12, 14, it is easy for a mechanic to saw through tie bracket
10 horizontally without diminishing structural integrity of either
remaining section of the tie bracket and of the entire form module.
This must occasionally be done to create a form half the height of
the uncut form to limit form height to the desired height of a
finished wall. Furthermore, location of end openings 30, 36 where
they terminate respectively at plates 12, 14 creates convenient
electrical cable and conduit chases. To protect cables, openings
30, 36 are bounded by horizontally oriented ridges. It will be seen
that outer openings 30, 36 each has a height greater than that of
central openings 32, 34, 35. The extra height of openings 30, 36
accommodates plural cables and conduits, whereas central openings
32, 34, 35 require only nominal height for accommodating a saw
blade. Openings 45, 47 are each dimensioned and configured to
receive an electrical work box (not shown) which may be installed
by sawing away an appropriate portion of plate 12 or 14.
[0048] Uppermost spanning member 18 has an upwardly open receptacle
38 for receiving reinforcing bars (rebar)(not shown). The height of
receptacle 38 is greater than the width, so that two sections of
rebar can be laid in receptacle 38 and supported in overlying,
overlapping relationship to facilitate splicing. Uppermost spanning
member 18 also has a small circumferentially closed openings 40,
42, 43 located above spanning member 18. Openings 40, 42, 43
accommodate tie wires and tethers for scaffolding (not shown),
bracing (not shown), and general purpose securement to tie bracket
10 and larger elements such as plumbing and HVAC conduits.
Lowermost spanning member 24 similarly has two openings 44, 46
formed therein.
[0049] It is often desirable that the rebar within a poured
concrete wall be offset from the center of the wall toward one
surface of the wall. For this purpose, a rebar attachment piece 50,
shown at FIG. 3 and 4 may be used. Formed of the same material as
the tie bracket 10 consists of at least one, preferably two, "U"
shaped receptacle 52, with an attachment receptacle 54 adapted to
fit over one arm of receptacle 38, as at FIG. 4. It would, however,
be evident to one skilled in the art that rebar attachment piece 50
could have any number of "U" shaped receptacles 52, each variation
in number being adaptable to different applications. The base 56 of
the rebar attachment piece 50 is formed to snugly fit the contour
of the exterior of receptacle 38. It would be evident to one
skilled in the art that other methods of attaching the rebar
attachment piece to the tie bracket 10 without departing from the
spirit of the present invention.
[0050] Use of a rebar attachment piece 50 allows for economy in
production of form in that the tie bar 10 need only have provision
for a central rebar, with provision being made for offset only in
the locations when and where it is needed.
[0051] It would be evident to one of ordinary skill in the art that
while the rebar attachment piece 50 is designed for use with the
insulated concrete form system of the present invention, it could
easily be adapted for similar systems currently known in the art or
to be developed.
[0052] Referring now to FIG. 5 through 7, the principal function of
tie bracket 10 is to connect opposing insulating panels 110, 112 of
insulating concrete forms 100 for the purpose of holding panels
110, 112. Panel 110 is an insulating panel preferably formed from
expanded foam. Panel 112 is a second insulating panel formed from
expanded foam, and is located on the opposed side of the final form
100, which comprises panels 110 and 112 and a plurality of tie
brackets 10. Tie brackets 10 span and connect panels 110 and 112.
Panels 110 and 112 are dimensioned and configured such that the
height of each plate 12 or 14 (see FIG. 1) of the various tie
brackets 10 are equal to the height of each panel 110 or 112. This
characteristic improves vertical load bearing strength of the form,
and further, forms a "stud" which may be used to attach structural
elements, such as paneling or sheetrock, to a finished wall.
[0053] Form 100 is dimensioned and configured so that as adjacent
forms are located beside one another, they interlock with one
another and as succeeding courses of forms 100 are formed by
stacking forms 100 on one another, they interlock with one another.
This characteristic is enabled by a tongue 114 at one vertically
extending edge of each of panel 110, 112 and a mating groove 116 at
the other vertically extending edge, as well as a top tongue 118
with cooperating projections 120, 122, 124 and bottom groove 132
with cooperating notches 126, 128, 130. As previously state, the
upper surface of panel 110 has a plurality of inward projections
120, 122, 124 formed therein, extending laterally inwardly of form
100 from tongue 118. Panel 112 is essentially a mirror image of
panel 110, so that description set forth regarding panel 110 will
be understood to apply equally to panel 112. The lower surface of
panel 110 bears a bottom groove 132 with notches 126, 128, 130
corresponding to projections 120, 122, 124, extending inwardly of
form 100 from groove 132. Each notch 126, 128, 130 is dimensioned
and configured to receive one projection 120, 122 or 124 of another
form 100 in close cooperation therewith such that a form 100 placed
above can interlock with a form 100 located below when pressed into
mutual engagement. To this end, notches 126, 128, 130 are located
directly below respective projections 120, 122, 124, thereby
ensuring proper offset in increments of one foot of forms 100 when
stacked. Additionally, at each end of the upper surface of panel
110 is a half projection 134, 136, such than when two forms 100 are
placed end to end, the two half projections 134, 136 form the
equivalent of a full projection. Likewise, a half notch 138, 140 is
located at each end of the lower surface of panel 110, such that
when two forms 100 are place end to end, the two half notches 134,
136 form the equivalent of a full notch. Thus, when two forms 100
are stacked, the two half projections 134, 136 will mate with one
of the full notches 126, 128, 130 and the two half notches 138, 140
will receive one of the full projections 120, 122, 124. In a four
foot form 100, the projections 120, 122, 124 are space apart on one
foot centers beginning from the end of the half projections 134,
136 adjacent the ends of the straight form 100 (FIG. 7), with the
notches 126, 128, 130, situated directly below projections 120,
122, 124 having the same spacing. Based on the spacing of the
protrusions and grooves, the straight form 100 need not be limited
to the four foot length disclosed, but rather, could be produced in
any length which is a multiple of one foot, so long as the form is
manageable.
[0054] In addition to the projections 120, 122, 124 (FIG. 5) on the
upper surface of panels 110, additional projections 142, 144 are
situated at the mid point between projections 120, 124 and the half
projection 134, 136 adjacent each, respectively. Likewise,
additional notches 146, 148, 150, 152 are formed in the lower edge
of panel 110 at the midpoint between each of the notches 126, 128,
130 and half notches 138, 140. The additional projections 142, 144
and additional notches 146, 148, 150, 152 (FIG. 6) are of a length
different from that of projections 120, 122, 124 and half
projections 134, 136 and notches 126, 128, 130 and half notches
128, 140 to assure proper vertical alignment of forms 100, and thus
the vertical alignment of tie brackets 10 and the "stud" of the
elongate plates 12, 14 within the wall. The intent of additional
projections 142, 144 and additional notches 146, 148, 150, 152 is
to form a more solid connection between a straight form 100 and
vertically adjacent corner forms 200 as they are stacked vertically
in the wall assembly, as will be explained in greater detail,
hereinafter. It is important to note that there are more additional
notches than additional projections, as the additional projections
are designed to reinforce the joints between forms and may line up
with notches along the length of the form 100, not just at the
ends, especially in the joint between straight forms 100 and corner
forms 300.
[0055] It would be evident to one skilled in the art that other
additional projections and notches would be equally effective, so
long as the recurring, symmetrical pattern of twelve inches, on
center, is maintained.
[0056] The present invention is susceptible to variations and
modifications which may be introduced thereto without departing
from the inventive concept. Illustratively, there is no necessity
that the projections and notches be inwardly directed. They could
be outwardly, upwardly, or otherwise directed if desired as long as
they accommodate interlocking as described herein.
[0057] FIGS. 9 and 10 of the drawings shows the essential nature of
a corner form 200, which forms a corner in the form system. Corner
form 200 includes an interior insulating panel 210 formed from
expanded foam, having a first leg 212 and a second leg 214. Legs
212, 214 are each straight and positioned to form an angle with
respect to one another. Typically this angle is substantially 90
degrees, though any angle suited to a particular use of the form
system would fall within the scope of the invention. An exterior
insulating panel 220 formed from expanded foam has a first leg 222
and a second leg 224 which are preferably straight and positioned
parallel to legs 212, 214 of panel 210, respectively, with legs 222
and 224 positioned to form a similar angle as that formed by legs
212 and 214. Panels 210, 220 are connected and held in spaced
apart, parallel orientation by tie brackets 10 which include
members embedded within panels 210, 220. Only cross members of tie
brackets 10 spanning panels 210, 220 are visible.
[0058] It will be seen that legs 212 and 214 of interior panel 210
are different in length. Similarly, legs 222, 224 of panel 220 are
different in length. In most cases, to conform to general building
practices, oblique angle 216 is a right angle. Legs 214, 224 of
panels 210, 220 terminate in a plane normal to legs 214, 224. The
effective length of legs 214, 224 is indicated by arrow 230 (FIG.
12). A groove 226 is formed in the length of the free vertical edge
of leg 214 and a groove 228 in the length of the free vertical edge
of leg 224. Grooves 226, 228 cooperate with the tongues 114 of an
adjacent straight form 100 to ensure a tight fit between corner
form 200 and an adjacent straight form 100.
[0059] In similar vein, second legs 212, 222 of respective panels
210, 220 terminate in a second plane which is normal to first leg
212 of panel 210. Effective length of legs 212, 222 of panels 210,
220, respectively is indicated by arrow 232 (FIG. 12). A tongue 234
is formed in the length of the free vertical edge of leg 212 and a
groove 236 in the length of free vertical edge of leg 222. The
tongues 234, 236 cooperate with the grooves 116 of a straight form
100 to ensure a tight fit between corner form 200 and an adjacent
straight form 100. The combined effective lengths of legs 222 and
224 is four feet. The length indicated by arrow 232 is preferably
thirty inches, while the length indicated by arrow 230 is
preferably eighteen inches.
[0060] Panels 210, 220 each have a respective upper surface and a
lower surface. A tongue 238, 240 is formed in the upper surface of
each of panels 212, 220, respectively and a cooperating groove 242,
244 is formed in the lower surfaces of each of panels 212, 220,
respectively. A projection 246 is formed in the upper surface of
leg 224, and two projections 248, 250 are formed in the upper
surface of leg 222. A projection 252 is formed in the upper surface
of leg 212. Correspondingly, a notch 254 is formed in the lower
surface of leg 224 and notches 256, 258 are formed in the lower
surface of leg 222, while a notch 260 is formed in the lower
surface of leg 212. Notch 254 is located directly below projection
246, notches 256, 258 are located directly below corresponding
projections 248, 250, and notch 260 is located directly below
corresponding projection 252. A half projection 262, having one
half the length of projections 246, 248, 250 and 252, is located on
each of the four upper ends of panels 212, 214, 222 and 224. Each
half projection 262 is configured to occupy one half of a notch,
with a half projection 165 of a straight form 100 occupying the
other half of the same notch.
[0061] An additional projection 264 is situated on the upper
surface of leg 222 at a point equidistant between projection 250
and half projection 262 and projection 252 and half projection 262,
respectively. Additional projections 264 have a length different
from both projections 246, 248, 250, 252 and half projections 262.
Additional projections 264 and notches 266, which are vertically
aligned with and sized to cooperate with one another, provide
additional strength to the junction between vertically stacked
corner forms 200 and adjacent straight forms 100. This added
strength at the corners is important, as greater outward pressures
are exerted at the corners than along the straight length of a wall
as the wet concrete is poured.
[0062] Plural corner forms 200 can be stacked in the manner shown
in FIG. 13 and interlocked by interfitting projections of one
corner form 200 into notches of the corner form 200 above.
[0063] Projections 248, 250 and notches 256, 258 are spaced apart
from one another by a distance interval 268 which is twice the
magnitude of distance interval 270 existing between additional
projections 264 and each of its neighboring projections, the half
projections 262 and the projections 252 of panel 200.
[0064] FIG. 12 shows spacing of tie brackets 10. Measuring from the
outside corner of exterior panel 200, center line 282 of a first
tie bracket 10A is located at a distance interval 284 of one foot
from the corner 275 at the juncture of leg 222 with leg 224. Center
line 286 of tie bracket 10B is located at a distance interval 288
of one foot from center line 282, and at a distance interval 290 of
six inches from the free end of leg 222. In a similar manner,
center line 292 of tie bracket 10C is separated by a distance
interval 294 of one foot from the corner 275, and by a distance
interval 296 of six inches from the free end of leg 224.
[0065] It is important that center lines 282, 286, 292 pass through
the centers of the plates 12, 14 of the tie brackets 10. It will be
appreciated that tie brackets 10 have end plates 12, 14 which are
embedded within insulating panels 212, 220 to anchor the tie
brackets 10 within insulating panels 212, 220. These plates 12, 14
provide broad, flat surfaces typically parallel to the outer
surfaces of legs 222, 224 of exterior panel 220 to which fasteners
(not shown) may be engaged by threading and friction. It is
strongly desirable that these plates be located on one foot
centers, measuring from corner of the juncture of legs 222, 224 for
the purpose of enabling craftsmen to affix construction elements
such as paneling and gypsum wall board sheets (neither shown) to a
wall built utilizing form 200. This is readily accomplished by
placing a construction element against the form and nailing or
otherwise fastening the construction element at one foot intervals
to the form.
[0066] In summary, it will be seen that the center line of each tie
bracket 10A or 10C which is adjacent to corner 275 is spaced apart
from the corner 275 by a distance interval which is a whole number
multiple of one foot. Each tie bracket 10 of any one leg is spaced
apart from every adjacent tie bracket 10 by a distance interval
which is a whole number multiple of measurements of one foot. The
foregoing holds true regardless of the actual number of tie
brackets provided and of the overall length of each leg of the
corner form. This also holds true along the length of a wall, as in
relation to connecting and interlocking with adjacent straight
forms. Like the straight form 100, while disclosed as having a
combined length of four fee, the corner form 200 could be formed in
any multiple of one foot, so long as the form remains
manageable.
[0067] Looking now at the left of FIG. 12, it will be seen that
corner 275 is formed at the intersection of legs 222, 224. A
vertical bracket 300 (FIG. 11) is optionally embedded within
exterior panel 220 in a vertical opening 298 (see FIG. 12) formed
around bracket 300 at corner 275. Referring also to FIG. 11,
bracket 300 includes a first plate 302 disposed parallel to leg 222
and a second plate 304 disposed parallel to leg 224 of panel 220.
Plates 302, 304 both reinforce the corner of form 200 and also
provide fastener receiving surfaces similar in function to the
plates 12, 14 of tie brackets 10 (see FIG. 13). Bracket 300
preferably includes webs bracing 306, 308 and reinforcing plates
310, 312 to stiffen and strengthen bracket 300.
[0068] Corner form 200 also includes bulkhead retainers 314, 316
(FIGS. 9 and 10) formed on the ends of each leg of panels 210, 220.
Retainers 314, 316 may comprise any structure which would surround
or otherwise entrap a flat panel placed just within the ends of the
form to close the otherwise open ends. The precise nature of
retainers 314. 316 is not critical to their function.
[0069] Corner form 200 is intended to be formed in both right hand
(R) and left hand (L) versions, to accomplish staggered joints, as
at FIG. 13, each being a mirror image of the other, with the
exception that tongue 234 and groove 246 would be reversed in
position.
[0070] While the corner form 200 provides for two walls to meet in
an "L", concrete walls are often poured in a "T" configuration, as
well, with a wall extending outwardly from the middle of a
continuing wall. Straight forms 100 could be adapted, on site to
create a "T", but the Tee form 300 provides a ready made form for
this purpose.
[0071] Referring now to FIG. 14 through 17, the Tee forms 400 and
400A are formed substantially like the straight form 100, with a
first panel 410 having a tongue 414 at one end and a groove 416 at
the other. An upper tongue 432 extends along the length of the
upper surface of panel 410 and a lower groove along the lower
surface, which is not visible, but is the same as the groove shown
in lower edges of the other embodiments of wall forms. Projections
420 are situated at regular intervals of one foot on center, as in
the straight form 100, with a half projections 434 at each end. The
opposing panel 412 is a mirror image of panel 410 with the
exception that a void is formed between the center most two of tie
brackets 10 which join the panels 410 and 412. Tie brackets 10 are
situated at regular intervals of one foot on center, commencing one
half foot from the end of panel 410. As in the straight form,
additional projections 146 are formed 6' from the end of each
panel, at the first tie bracket 10, additional projections 146
being of a different length than both projections 420 and half
projections 434. Panels 410, 412 form what would be the top cross
member of the letter "T", and would typically be formed in 24" (Tee
form 400A)(FIG 15) and 48" (Tee form 400)(FIG. 14) length versions.
Corresponding notches 426 and half notches 440 are formed in the
lower surface of panels 410, 412.
[0072] Extending outwardly from the void in panel 412 is what would
be the vertical leg of the letter "T", again consisting of a
portion of a typical straight form 100. As in the cross segment,
tie brackets 10 are spaced on one foot centers, commencing one half
foot from the end, a half projection 434 is situated at the end of
each panel. In Tee form 400 the vertical leg is typically
6.sup.3/4" long (18" from the outer surface of panel 410), and
therefore there is no projection along this leg. In Tee form 400A,
however, the vertical leg is typically 18.sup.3/4" long (30" from
the outer surface of panel 410) and a projection 420 is used.
Corresponding notches and half notches are formed in the lower
surfaces, which are the same as the notches and half notches shown
in the other embodiments of the form. In both the Tee form 400 and
400A, a tie bracket 10 is situated such that the "stud" formed by
the elongate plates 12, 14 abut in both panels joining to form the
wall corners.
[0073] As previously stated, the Tee form is formed in a
48".times.18" (Tee form 400) and 24".times.30" (Tee form 400A),
thereby allowing staggering of the joints between the Tee forms
400, 400A and adjacent straight forms 100. As with the straight
form 100, however, the Tee form 400/400A could be of any length in
a multiple of one foot, so long as the size of the form remains
manageable.
[0074] It is to be understood that the present invention is not
limited to the embodiments described above, but encompasses any and
all embodiments within the scope of the following claims:
* * * * *