U.S. patent application number 12/138344 was filed with the patent office on 2009-03-12 for insulated concrete wall section form.
This patent application is currently assigned to MIGHTY WALL INDUSTRIES CORPORATION. Invention is credited to Sammy Ciling, Robert Montoya.
Application Number | 20090064617 12/138344 |
Document ID | / |
Family ID | 40130224 |
Filed Date | 2009-03-12 |
United States Patent
Application |
20090064617 |
Kind Code |
A1 |
Montoya; Robert ; et
al. |
March 12, 2009 |
Insulated Concrete Wall Section Form
Abstract
A system, method, and apparatus for forming insulated concrete
structures, using a foam panel and lightweight cementious type of
material as forms. The assembled forms are then preferably placed
into position to form a wall and/or roof type of structure which
then has concrete or another cementious type of material filled
into at least some of the voids formed in the forms.
Inventors: |
Montoya; Robert;
(Albuquerque, NM) ; Ciling; Sammy; (Temecula,
CA) |
Correspondence
Address: |
PEACOCK MYERS, P.C.
201 THIRD STREET, N.W., SUITE 1340
ALBUQUERQUE
NM
87102
US
|
Assignee: |
MIGHTY WALL INDUSTRIES
CORPORATION
Albuquerque
NM
|
Family ID: |
40130224 |
Appl. No.: |
12/138344 |
Filed: |
June 12, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60943450 |
Jun 12, 2007 |
|
|
|
Current U.S.
Class: |
52/309.12 ;
52/425; 52/742.14 |
Current CPC
Class: |
E04B 2/8623 20130101;
E04B 2002/867 20130101; E04B 5/043 20130101; E04B 5/36 20130101;
E04B 1/161 20130101 |
Class at
Publication: |
52/309.12 ;
52/425; 52/742.14 |
International
Class: |
E04B 2/86 20060101
E04B002/86; E04B 2/02 20060101 E04B002/02; E04C 2/288 20060101
E04C002/288; E04C 1/41 20060101 E04C001/41 |
Claims
1. A form comprising: a spacer panel attached to a support panel
with an adhesive; and said spacer panel comprising one or more
voids therebetween prior to a form-setting material being deposited
into said one or more voids.
2. The form of claim 1 wherein said spacer panel comprises an
expanded foam material.
3. The form of claim 1 wherein said support panel comprises
gypsum.
4. The form of claim 1 wherein said spacer panel comprises a
plurality of spacers and grooves.
5. The form of claim 1 wherein said spacer panel comprises a chase
disposed therein.
6. The form of claim 1 wherein said form comprises one or more
alignment structures.
7. A form comprising: a spacer panel attached to a support panel by
a portion of said spacer panel being embedded within said support
panel; and one or more voids therebetween prior to a form-setting
material being deposited into said one or more voids.
8. The form of claim 7 wherein said spacer panel comprises an
expanded foam material.
9. The form of claim 7 wherein said support panel comprises
gypsum.
10. The form of claim 7 wherein said spacer panel comprises a
plurality of spacers and grooves.
11. The form of claim 7 wherein said spacer panel comprises a chase
disposed therein.
12. The form of claim 7 wherein said form comprises one or more
alignment structures.
13. A form comprising: a spacer panel comprising one or more
spacers and one or more grooves; a support panel attached to said
spacer panel; one or more voids provided between said spacer panel
and said support panel, said voids formed from said grooves; and
said spacer panel and said support panel constructed from different
materials.
14. The form of claim 13 wherein said spacer panel comprises an
expanded foam material.
15. The form of claim 14 wherein said expanded foam material
comprises expanded polystyrene foam.
16. The form of claim 13 wherein said spacer panel is attached to
said support panel with an adhesive.
17. The form of claim 13 wherein said spacer panel is attached to
said support panel by the support panel being formed around an end
portion of at least one of said spacers.
18. The form of claim 13 further comprising an alignment structure
selected from a joint consisting of a lap joint, a tongue and
groove joint, a mortise and tenon joint, a biscuit joint, a finger
joint, a box joint, a dove tail joint, and combinations
thereof.
19. A method for creating a structural building component
comprising: providing a form having a support panel attached to a
spacer panel, the spacer panel comprising one or more spacers
extending from a surface thereof, the spacers made from
substantially the same material as the spacer panel; erecting the
form at a jobsite; filling the form with a form-setting material;
and allowing the form-setting material to harden.
20. The method of claim 19 wherein the form is left in place after
the form-setting material has hardened, thus forming a portion of
the structure being constructed.
21. The method of claim 19 further comprising disposing one or more
reinforcing members within the form.
22. The method of claim 19 further comprising providing a chase
within the form.
23. The method of claim 19 wherein erecting the form at a job site
comprises aligning at least two forms with one another via an
alignment structure.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of the
filing of U.S. Provisional Patent Application Ser. No. 60/943,450,
entitled "Insulated Concrete Wall Section Form", filed on Jun. 12,
2007, and the specification thereof is incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention (Technical Field)
[0003] The present invention relates to a form system which enables
a user to rapidly and efficiently produce a concrete or other
form-setting reinforced structural member having an insulated
exterior portion.
[0004] 2. Description of Related Art
[0005] Concrete forms, including those made from an insulative
material, such as expanded polystyrene foam, have been known for
some time. The problem with known forms, however, is that they are
often difficult and/or time consuming to stack together or
otherwise assemble. Further, known concrete forms for use in the
construction of buildings and the like do not incorporate and thus
provide an interior surface which can be quickly, easily, and
inexpensively finished. U.S. Pat. No. 5,172,533 to Gibbar, Jr. for
example, teaches a panel which requires a user to cut grooves into
a slab of expanded polystyrene foam, lay reinforcing members into
the grooves, close off the ends of the grooves, fill the grooves
with a concrete, allow the concrete to harden, then glue an outer
panel onto it, before it can be transported to the jobsite and
erected. Of course this entire procedure is very time consuming and
even when the panel is finally produced, the procedure forces a
user to transport and then attempt to position into place the very
heavy panel.
[0006] There is thus a need for a concrete form, particularly for
the construction of buildings and the like, which not only provides
an insulating effect, but which also enables a user to quickly,
easily, and inexpensively finish interior portions of buildings and
the like so constructed while simultaneously providing a user with
the ability to fill the form while it rests in its intended
position.
BRIEF SUMMARY OF THE INVENTION
[0007] An embodiment of the present invention comprises a form
having a spacer panel attached to a support panel with an adhesive
and comprising one or more voids therebetween prior to a
form-setting material being deposited into the one or more voids.
The spacer panel can be made from an expanded foam material,
including but not limited to an extruded polystyrene foam. The
support panel can be made of various materials, including but not
limited to gypsum. The spacer panel preferably has a plurality of
spacers and grooves on at least one of its surfaces and one or more
wire chases disposed therein. The form can also have one or more
alignment structures, including but not limited to a lap joint, a
tongue and groove joint, a mortise and tenon joint, a biscuit
joint, a finger joint, a box joint, a dove tail joint, and
combinations thereof.
[0008] An embodiment of the present invention also comprises a form
having a spacer panel attached to a support panel and forming one
or more voids therebetween prior to form-setting material being
deposited into the one or more voids. The spacer panel may be
attached to the support panel by a portion of the spacer panel
being embedded within the support panel.
[0009] Another embodiment of the present invention comprises a form
having a spacer panel with one or more spacers and one or more
grooves, a support panel attached to the spacer panel, one or more
voids provided between the spacer panel and the support panel, the
voids formed from the grooves; and the spacer panel and the support
panel constructed from different materials. The spacer panel can be
attached to the support panel by the support panel being formed
around an end portion of at least one of the spacers.
[0010] An embodiment of the present invention also comprises a
method for creating a structural building component which includes
providing a form having a support panel attached to a spacer panel,
the spacer panel having one or more spacers extending from a
surface thereof, the spacers made from substantially the same
material as the spacer panel; erecting the form at a jobsite;
filling the form with a form-setting material; and allowing the
form-setting material to harden.
[0011] In the method, the form can be left in place after the
form-setting material has hardened, thus forming a portion of the
structure being constructed. The method can also include disposing
one or more reinforcing members within the form; and/or providing a
wire chase within the form. Two or more forms can be erected at job
site and aligned with one another via an alignment structure.
[0012] Objects, advantages and novel features, and further scope of
applicability of the present invention will be set forth in part in
the detailed description to follow, taken in conjunction with the
accompanying drawings, and in part will become apparent to those
skilled in the art upon examination of the following, or may be
learned by practice of the invention. The objects and advantages of
the invention may be realized and attained by means of the
instrumentalities and combinations particularly pointed out in the
appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated into and
form a part of the specification, illustrate one or more
embodiments of the present invention and, together with the
description, serve to explain the principles of the invention. The
drawings are only for the purpose of illustrating one or more
preferred embodiments of the invention and are not to be construed
as limiting the invention. In the drawings:
[0014] FIGS. 1-3 are perspective view drawings illustrating
embodiments of the present invention;
[0015] FIG. 4 is a perspective view drawing illustrating a spacer
panel according to an embodiment of the present invention;
[0016] FIGS. 5 and 6 are end view drawings illustrating an
embodiment of a form of the present invention;
[0017] FIGS. 7 and 8 are perspective, end-view drawings
illustrating a squared corner section and a rounded corner section
according to embodiments of the present invention;
[0018] FIG. 9 is a perspective view drawing illustrating a squared
corner section disposed in accordance with the teachings of the
present invention;
[0019] FIGS. 10 and 11 are end view drawings of an embodiment of
the present invention illustrating most preferred dimensions for
some aspects of that embodiment;
[0020] FIG. 12 is a side-view, perspective drawing illustrating an
embodiment of the present invention;
[0021] FIG. 13 illustrates an embodiment of the present invention
wherein hardened material-filled forms, according to an embodiment
of the present invention, are supporting a roof structure;
[0022] FIG. 14 illustrates an embodiment of the present invention
wherein hardened material-filled forms, according to an embodiment
of the present invention, are supporting a roof structure and
wherein side panels have a mesh pre-applied thereto;
[0023] FIG. 15 is a drawing illustrating a side-view of a panel
having a spacer panel is glued to a support panel;
[0024] FIG. 16 is a drawing illustrating a side-view of a panel
having openings for a wire chase disposed within the spacer
panel;
[0025] FIG. 17 is a drawing illustrating a top-view of a panel
having an opening for a wire chase disposed within the spacer
panel; and
[0026] FIG. 18 is a drawing illustrating a front view of a panel
wherein wire chases are disposed within the panel.
DETAILED DESCRIPTION OF THE INVENTION
[0027] An embodiment of the present invention is directed to a
concrete form structure, particularly a lightweight concrete form
structure which enables a user to rapidly create insulated
concrete-reinforced structural members.
[0028] The terms "concrete", "cement" and "cementious material" are
used interchangeably throughout this application and are intended
to include any type of structural material which can be disposed
within a form while in at least a substantially liquid form and
which can then either harden or be hardened into an at least
substantially solid material. Accordingly, the terms "concrete",
"cement" and "cementious material" include but are not limited to
all known types and formulations of concretes and plasters. The
term "form-setting materials" is also intended to include and used
interchangeably with "concrete", "cement" and "cementious
materials", and additionally includes plastics, resins, and any
other materials which can flow and harden into a solid
material.
[0029] Referring now to the Figures, according to an embodiment of
the present invention, form 10 preferably comprises spacer panel 12
attached to support panel 14. Spacer panel 12 preferably comprises
spacers 16 and grooves 18. In one embodiment, spacer panel 12 is
most preferably formed from a material known to exhibit thermal
insulating properties. In a most preferred embodiment, spacer panel
12 is preferably formed from an expanded or extruded polystyrene or
foam-rubber material. Although spacer panel 12 can be constructed
to comprise virtually any length, width, and height, in a most
preferred embodiment, spacer panel 12 comprises a length and width
suitable for use in wall panels. For example, in one embodiment,
spacer panel 12 comprises a length of from about 7.5 feet to about
14 feet tall, and a width of from about 3 to about 4 feet. Upon
studying this application, those skilled in the art will readily
appreciate that spacer panel 12 can comprise almost any height as
determined by any given application. In a preferred embodiment,
spacer panel 12 most preferably comprises a height of about 1 inch
to about 24 inches, and spacer panel 12 most preferably comprises a
height of from about 4 inches to about 12 inches.
[0030] Support panel 14 is most preferably made from a light-weight
form-setting material. Although in one embodiment support panel 14
is most preferably made from a light-weight form-setting material
which has a very short set time. Support panel 14 can be formed
from any material known to those skilled in the art to be useful in
the construction of a form and can include any form-setting
material, e.g. cement, concrete, plastics, resins, etc. Although
support panel 14 can also be constructed to virtually any length
and width, support panel 14 preferably comprises a length and width
substantially similar to that of a corresponding spacer panel 12
which attaches thereto. In addition, although the thickness of
support panel 14 can be selected to provide the most desirable
results for a given application, the thickness of support panel 14
is preferably from about one half of an inch to about 4 inches, and
most preferably from about 1 inch to about 2 inches. Because an
embodiment of the present invention wherein a portion of one or
more spacers 16 are embedded into support panel 14 comprises a
support panel 14 which is most preferably made from a light-weight
form-setting material, the mass of resulting form 10 is preferably
substantial enough to permit form 10 to be placed in an upright
position and remain in that position, with little or no bracing,
until filled with a form-setting material.
[0031] In one embodiment, as best illustrated in FIG. 6, form 10 is
most preferably provided by inserting, at least partially, the tips
of one or more spacers 16 of spacer panel 12 into support panel 14
before the material from which support panel 14 is made has set
into its solid form. In this embodiment, one or more protrusions 20
are preferably disposed at or near terminal ends of spacers 16. One
or more protrusions 20 preferably enable the wet form-setting
material of support panel 14 to flow around them, thus causing
protrusions 20 to become embedded into the wet form-setting
material and when the wet form-setting material has hardened, thus
fixedly attaching spacer panel 12 to support panel 14.
[0032] In a most preferred embodiment, support panel 14 preferably
comprises a flat clean exterior surface, which most preferably
forms an interior surface of a structure and which readily enables
a user to apply texture or coating thereto, or alternatively, to
simply paint, stain or coat support panel 14, thus eliminating the
need for installation of drywall or another material and thus
facilitating the rapid finishing of buildings constructed from the
forms of the present invention.
[0033] In one embodiment, one or more corner sections 22 are
preferably provided. Although corner sections 22 can comprise a
rounded, square, or flattened shape, virtually any shape can be
provided. As best illustrated in FIGS. 7 and 8, corner sections 22
most preferably comprise a rounded or square shape. In this
embodiment, when a plurality of form-setting material forms 10 are
arranged to create a corner, one or more corner sections 22 are
preferably abutted thereto as illustrated in FIG. 9. Upon studying
this application, those skilled in the art will recognize multiple
ways in which corner section 22 can be held against form-setting
material forms 10, including tie wire, buttressing braces, scab
braces, other braces, and the like. As further illustrated in FIG.
9, rebar 24 is preferably disposed within forms 10 prior to being
filled with concrete or another form-setting material 26.
[0034] Because a preferred embodiment of the present invention
results in the concrete (or other form-setting material) portion
residing in an interior side of the insulative spacer panel 12, for
a building constructed from forms 10, the thermal mass of the
material thus resides within the insulative shell of the building
and therefore provides a more stable temperature controlled
environment which is less susceptible to temperature cycles
associated with a warmer daytime temperature and a cooler nighttime
temperature.
[0035] In one embodiment, the grid pattern formed by the voids
between spacer panel 12 and support panel 14 fully complies with
and/or exceeds the requirements of the "SCREEN-GRID ICF" as defined
in the International Residential Code. In this embodiment, at least
one length of 3/8'' rebar is preferably disposed within each row
and column of voids created by spacer panel 12 and support panel
14. And in this embodiment, the spacing of each void preferably
meets and/or exceeds construction standards. Further, FIGS. 10 and
11 illustrate dimensions commensurate with a most preferred
embodiment of the present invention. As illustrated therein, a most
preferred width and/or height of each row and column formed between
spacer panel 12 and support panel 14 is most preferably about 6
inches. Further, the most preferred thickness of an outer portion
of spacer panel 12 is preferably about 23/4'' but can, of course,
be adjusted to provide higher or lower insulation values for a
particular application.
[0036] In an alternative embodiment of the present invention,
spacer panel 12 of form 10 can comprises an additional flat panel,
which is also preferably formed from a quick-setting, lightweight
form-setting material, disposed on a front face thereof. As with
support panel 14, the additional support panel can optionally be
fixedly attached to spacer panel 12 via one or more protruding
members around which the additional support panel hardens, or it
can be attached with an adhesive. Alternatively, or in addition
thereto, one or more pitted or otherwise hollow recesses can
optionally be formed into a front face of spacer panel 12, thus
enabling portions of the additional support panel, if applied in at
least substantially liquid form, to flow therein prior to
hardening. By providing the additional support panel on a front
face of spacer panel 12, a user can quickly and easily finish an
exterior surface of a structure formed therefrom.
[0037] Because of the waffle-shaped, rebar-reinforced, concrete (or
other material) portion which is provided by filling the forms of
the present invention with rebar and material, the resulting wall
portions, having an insulative outer surface and most preferably a
readily finishable interior surface, are thus capable of supporting
substantial loads. The wall sections of the building can themselves
thus provide load-bearing structure, capable of supporting upper
floors and/or a roof, as illustrated in FIG. 13. In this
embodiment, roof panels 40 most preferably comprise spacer panel
42, which is most preferably formed from a material known to
exhibit thermal insulating properties. In a most preferred
embodiment, spacer panel 42 is preferably formed from an expanded
or extruded polystyrene or foam-rubber material and panels 40 most
preferably comprise dimensions which are suitable for forming roof
panels 40. Panels 40 can comprise dimensions similar to those of
wall panels 10. Spacer panel 42 preferably comprise one or more
channels 44. In a preferred embodiment, a plurality of reinforcing
members, such a rebar or concrete wire are preferably arranged on
spacer panel 42 before lightweight cementious or other material 46
is poured and/or formed onto at least a portion of spacer panel 42,
thus providing a structural rigidity to roof panel 40. After roof
panels 40 are placed on the top of a structure, forms are
preferably placed against one or more spacer panels 40 before a
material is disposed within recessed areas 48 formed by spacer
panels 42 and material 46.
[0038] In one embodiment, illustrated in FIG. 14, panel 10
optionally comprises exterior mesh 30 for example a fiberglass
mesh, and a base coat across a substantial surface area of at least
one side of panel 10, thus eliminating the additional steps needed
for application of exterior lathe and base coat and greatly reduces
the amount of labor required to complete construction. In this
embodiment, mesh 30 is most preferably applied along an entire
length of panel 10, but does not extend all the way to each side
thereof. Accordingly, after placing panels 10, a user need only
apply strips of mesh where two panels meet 32, thus locking the
panels together and greatly reducing installation labor. In one
embodiment, form-setting material placed within the voids hardens
and the panel is thus installed, the insulated form-setting
material form's exterior face is preferably coated with a
fiberglass mesh applied with an adhesive ground coat followed by a
stucco color coat or other finish. An acrylic stucco color coat,
acrylic paint or other paint, stain or coating can be used to coat
the exterior of the finished structure created with panels 10.
Stone and masonry products can be attached to the exterior face of
the product. Wooden furring strips are preferably attached to the
wall by embedding screws into the form-setting material cavity
prior to pouring form-setting material therein, or another type of
form-setting material attachment product is preferably provided to
connect furring strips to the form-setting material core. The
siding can be attached to the furring strips by conventional
methods.
[0039] As best illustrated in FIG. 15, in an alternative embodiment
of the present invention, spacer panel 12 is preferably attached
directly to support panel 14 with an adhesive. In this embodiment,
support panel 14 is preferably a pre-formed panel having dimensions
as previously discussed. While support panel 14 can comprise a
form-setting type of material, in this embodiment, support panel 14
is most preferably a panel formed from a gypsum type of material,
such as a sheet of drywall.
[0040] FIGS. 16-18 illustrate an embodiment of the present
invention wherein spacer panel 12 comprises one or more wire chases
50 disposed therein. While the number, size, shape, and location of
wire chases 50 can be adjusted to fit any particular application,
as one non-limiting example, spacer panel 12 preferably comprises
horizontal wire chases at a height for electrical wall-sockets, and
for light switches which are respectively provided at a height of
from about six inches from a bottom edge of an erected panel
section to a height of about 1 foot and from a height of about
three and one-half feet from a bottom of an erected panel to a
height of about four and one-half feet. Spacer panel 12 also
optionally comprises vertically arranged wire chases positioned
from an upper portion of an erected panel to an intersecting
horizontal wire chase and most preferably are spaced about every
two to about every four linear feet of a wall formed from panels
10. In one embodiment, wire chases 50 are cut into spacer panel 12
with a hot-knife having a ring-type of blade, and the resulting
cut-away portion, having a substantially circular
cross-section--formed from the ring-type blade, is then preferably
pulled from panel 12 as a an elongated rod-type member. Of course
other methods can be used to create a void in panel 12 for use as
wire chase 50 as those skilled in the art will readily appreciate
upon studying this application. Wire chase 50 permits a user to run
wires through panel 10 without the use of a conduit prior to, or
after concrete or other form-setting material has been disposed
within panel 10.
[0041] As is also best illustrated in FIGS. 16 and 17, spacer
panels 12 also optionally comprise one or more alignment structures
52 disposed on one or more sides of spacer panel 12. Although
alignment structures 52 are illustrated as being a protrusions
and/or rounded recesses, the particular shape of structures 52 are
not essential, but are preferably shaped such that adjacently
disposed panels 10 can mate with one another, thus enabling a user
to quickly align the adjacently disposed panels with one another.
Other types of alignment structures that can also optionally be
used and will produce desirable results for various applications
include but are not limited to: a lap joint, a tongue and groove
joint, a mortise and tenon joint, a biscuit joint, a finger joint,
a box joint, a dove tail joint, and combinations thereof.
[0042] Because preferred embodiments of the present invention
comprise spacer panel 12 already attached to support panel 14,
forms according to embodiments of the present invention can be
filled while standing in a vertical or substantially vertical
position such that the form-setting material can be poured into
form 12 where a wall is desired, thus avoiding the need to
transport and/or erect a heavy panel which already has been filled
with concrete or another form-setting material.
[0043] In one embodiment, form 10 comprises only spacer panel 12
attached to support panel 14 and does not comprise additional
panels or sheets. According to one embodiment of the present
invention, form 10 is designed and/or intended to be left in place
after hardening of the concrete or other form-setting material,
thus forming a portion of the completed wall or roof structure. One
embodiment of the present invention does not rely on the use of
metal and/or plastic components for attaching support panel 14 to
spacer panel 12. Although spacer panel 12 is most preferably made
from an expanded polystyrene foam material, other materials,
including plastics and expanded foams can also be used and will
provide desirable results.
[0044] Although consistently referred to as "flat panel 14", this
is done merely for simplicity and to refer to a most preferred
embodiment. Accordingly, the physical shape of flat panel 14 is not
intended to be limited only to flat and substantially flat shapes,
but rather can comprise any shape capable of attaching to spacer
panel 12. Thus, this panel is also referred to herein as a "support
panel."
[0045] Although the invention has been described in detail with
particular reference to these preferred embodiments, other
embodiments can achieve the same results. Variations and
modifications of the present invention will be obvious to those
skilled in the art and it is intended to cover in the appended
claims all such modifications and equivalents. The entire
disclosures of all references, applications, patents, and
publications cited above are hereby incorporated by reference.
* * * * *