U.S. patent application number 13/926418 was filed with the patent office on 2013-11-28 for insulated concrete form.
The applicant listed for this patent is SYNTHEON, INC.. Invention is credited to Ginawati Au, Tricia G. Guevara, Blain Hileman, Shawn P. Jarvie, Justin D. Rubb, Michael T. Williams.
Application Number | 20130312349 13/926418 |
Document ID | / |
Family ID | 39184447 |
Filed Date | 2013-11-28 |
United States Patent
Application |
20130312349 |
Kind Code |
A1 |
Hileman; Blain ; et
al. |
November 28, 2013 |
Insulated Concrete Form
Abstract
A concrete wall forming system including interconnected mold
units that include a top surface containing a first portion bond
beam form, a first top ledge, a first top lip seal portion, a
second top ledge, and a second top lip seal portion; a bottom
surface containing a second portion bond beam form, a first bottom
ledge, a first bottom lip seal portion, a second bottom ledge, and
a second bottom lip seal portion; and two or more column forms
extending from the top depression to the bottom depression. The
first top lip seal portion and first bottom lip seal portion and
second top lip seal portion and second bottom lip seal portion are
adapted to form a seal between two mold units such that the bond
beam form portions are combined to form a bond beam form. The
system can be used to form an insulated concrete wall.
Inventors: |
Hileman; Blain; (New Castle,
PA) ; Williams; Michael T.; (Beaver Falls, PA)
; Rubb; Justin D.; (Coraopolis, PA) ; Guevara;
Tricia G.; (Jasper, GA) ; Jarvie; Shawn P.;
(Monaca, PA) ; Au; Ginawati; (Aliquippa,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SYNTHEON, INC. |
Leetsdale |
PA |
US |
|
|
Family ID: |
39184447 |
Appl. No.: |
13/926418 |
Filed: |
June 25, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11521179 |
Sep 14, 2006 |
|
|
|
13926418 |
|
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Current U.S.
Class: |
52/421 ;
52/742.14 |
Current CPC
Class: |
E04B 2/8629 20130101;
E04B 2/8647 20130101; E04B 2002/867 20130101; E04G 21/02
20130101 |
Class at
Publication: |
52/421 ;
52/742.14 |
International
Class: |
E04B 2/86 20060101
E04B002/86; E04G 21/02 20060101 E04G021/02 |
Claims
1-21. (canceled)
22. A wall comprising: a wall form comprising foamed plastic and
defining a plurality of vertical column forms and a plurality of
horizontal beam forms; and a concrete web comprising a plurality of
vertical columns and a plurality of horizontal beams disposed
within the wall form.
23. The wall according to claim 22, wherein the wall form comprises
a plurality of mold units each comprising a foamed plastic body,
wherein the mold units are aligned to form the plurality of
vertical column forms and the plurality of horizontal beam
forms.
24. The wall according to claim 23, wherein each mold unit
comprises a top lip seal portion and a top ledge portion and a
bottom lip seal portion and bottom ledge portion and adjacent first
and second mold units are connected to one another by an
interlocking engagement of the bottom lip seal portion and the
bottom ledge of the first mold unit with the top lip seal portion
and the top ledge of the second mold unit.
25. The wall according to claim 24, wherein the bottom ledge
portion includes bumps that align with indents in the top ledge
portion to assist in aligning the mold units such that they form
the plurality of vertical column forms and the plurality of
horizontal beam forms.
26. The wall according to claim 24, wherein a continuous seal is
formed between adjacent first and second mold units by the
interlocking engagement of the bottom lip seal portion and the
bottom ledge of the first mold unit with the top lip seal portion
and the top ledge of the second mold unit and the weight of the
concrete web.
27. The wall according to claim 23, wherein each mold unit
comprises at least one partial horizontal beam form such that
alignment of adjacent mold units form a complete horizontal beam
form.
28. The wall according to claim 22, wherein the vertical concrete
columns and the horizontal concrete beams are perpendicular to one
another and the vertical column forms and the horizontal beam forms
are perpendicular to one another.
29. The wall according to claim 22, wherein the plurality of
vertical concrete columns and the plurality of concrete beams
intersect to form a grid.
30. The wall according to claim 22, wherein the vertical concrete
columns, the vertical concrete beams, or both, further comprise a
reinforcing structure.
31. The wall according to claim 30, wherein the reinforcing
structure is at least one of rebar, fiber reinforced polymer,
carbon fibers, aramid fibers, glass fibers, metal, and fibers.
32. The wall according to claim 22, wherein the plurality of
vertical concrete columns are evenly spaced across a width of the
wall and the plurality of horizontal concrete beams are evenly
spaced across a height of the wall.
33. The wall according to claim 32, wherein the vertical concrete
columns and horizontal concrete beams intersect and areas between
the intersecting vertical concrete columns and horizontal concrete
beams comprise the foamed plastic of the wall form.
34. The wall according to claim 22, wherein the vertical column
forms and the horizontal beam forms are completely filled with the
concrete web.
35. The wall according to claim 22, wherein the foamed plastic is
an expanded polymer matrix.
36. A method of making a wall comprising: providing a wall form
comprising foamed plastic and defining a plurality of vertical
column forms and a plurality of horizontal beam forms; filling the
vertical column forms and the horizontal beam forms with concrete;
and curing the concrete to form a concrete web comprising a
plurality of concrete columns and a plurality of concrete
beams.
37. The method of claim 36, wherein the wall form comprises a
plurality of mold units each comprising a foamed plastic body and
the method further comprises aligning the mold units to define the
plurality of vertical column forms and the plurality of horizontal
beam forms.
38. The method of claim 37, wherein each mold unit comprises a top
lip seal portion and a bottom lip seal portion and the method
further comprises connecting adjacent first and second mold units
by interlocking the bottom lip seal portion of the first mold unit
and the top lip seal portion of the second mold unit.
39. The method of claim 36 further comprising placing rebar into
the vertical column forms, the horizontal beam forms, or both,
prior to filling the vertical column forms and the horizontal beam
forms with concrete.
40. A wall comprising a foamed plastic structure surrounding a
concrete web, wherein the concrete web comprises vertical concrete
columns and horizontal concrete beams.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to a concrete wall forming
system and insulated concrete walls formed using the wall forming
system.
[0003] 2. Description of the Prior Art
[0004] Concrete walls in building construction are most often
produced by first setting up two parallel form walls and pouring
concrete into the space between the forms. After the concrete
hardens, the builder then removes the forms, leaving the cured
concrete wall.
[0005] This prior art technique has drawbacks. Formation of the
concrete walls is inefficient because of the time required to erect
the forms, wait until the concrete cures, and take down the forms.
This prior art technique, therefore, is an expensive,
labor-intensive process.
[0006] Accordingly, techniques have developed for forming modular
concrete walls, which use a foam insulating material. The modular
form walls are set up parallel to each other and connecting
components hold the two form walls in place relative to each other
while concrete is poured there between. The form walls, however,
remain in place after the concrete cures. That is, the form walls,
which are constructed of foam insulating material, are a permanent
part of the building after the concrete cures. The concrete walls
made using this technique can be stacked on top of each other many
stories high to form all of a building's walls. In addition to the
efficiency gained by retaining the form walls as part of the
permanent structure, the materials of the form walls often provide
adequate insulation for the building.
[0007] Although the prior art includes many proposed variations to
achieve improvements with this technique, drawbacks still exist for
each design. The connecting components used in the prior art to
hold the walls are constructed of (1) plastic foam, (2) high
density plastic, or (3) a metal bridge, which is a non-structural
support, i.e., once the concrete cures, the connecting components
serve no function. Even so, these members provide thermal and sound
insulation functions and have long been accepted by the building
industry.
[0008] Thus, current insulated concrete form technology requires
the use of small molded foam blocks normally 12 to 24 inches in
height with a standard length of four feet. The large amount of
horizontal and vertical joints that require bracing to correctly
position the blocks during a concrete pour, restricts their use to
shorter wall lengths and lower wall heights. Wall penetrations such
as windows and doors require skillfully prepared and engineered
forming to withstand the pressures exerted upon them during
concrete placement.
[0009] The characteristics present in current block forming systems
require skilled labor, long lay-out times, engineered blocking and
shoring and non-traditional finishing skills. This results in a
more expensive wall that is not suitable for larger wall
construction applications. The highly skilled labor force that is
required to place, block, shore and apply finishes in a block
system seriously restricts the use of such systems when compared to
traditional concrete construction techniques.
[0010] One approach to solving the problem of straight and true
walls on larger layouts has been to design larger blocks. Current
existing manufacturing technology has limited this increase to 24
inches in height and eight feet in length. Other systems create hot
wire cut opposing foamed plastic panels mechanically linked
together in a secondary operation utilizing metal or plastic
connectors. These panels are normally 48 inches in width and 8 feet
in height and do not contain continuous furring strips.
[0011] However, none of the approaches described above adequately
address the problems of form blowout at higher wall heights due to
pressure exerted by the poured concrete, fast and easy construction
with an unskilled labor force, and low cost.
[0012] Thus there is a need in the art for composite pre-formed
insulated concrete forms that are relatively inexpensive, easy to
assemble and install and that are not prone to blowout.
SUMMARY OF THE INVENTION
[0013] The present invention provides a concrete wall forming
system that includes a plurality of interconnected mold units for
forming a wall by receiving concrete therein. The mold units
include a generally rectangular foamed plastic body having a first
side, a second side oppositely opposed to the first side, a first
end, a second end oppositely opposed to the first end, a top
surface, a bottom surface oppositely opposed to the top surface,
and at least two column forms.
[0014] The top surface includes a first portion bond beam form, a
first top ledge, a first top lip seal portion, a second top ledge,
and a second top lip seal portion.
[0015] The first portion bond beam form extends into the body
lengthwise and is defined by a top depression extending
transversely to the length of the body, the first end, and the
second end.
[0016] The first top ledge extends lengthwise along the body from
the top depression to the first top lip seal portion, which in turn
extends from the first top ledge to the first side. The second top
ledge extends lengthwise along the body from the top depression to
the second top lip seal portion, which in turn extends from the
second top ledge to the second side.
[0017] The bottom surface includes a second portion bond beam form,
a first bottom ledge, a first bottom lip seal portion, a second
bottom ledge, and a second bottom lip seal portion.
[0018] The second portion bond beam form extends into the body
lengthwise and is defined by a bottom depression extending
transversely to the length of the body, the first end, and the
second end.
[0019] The first bottom ledge extends lengthwise along the body
from the first side to the first top lip seal portion, which in
turn extends from the first bottom ledge to the bottom depression.
The second bottom ledge extends lengthwise along the body from the
second side to the second bottom lip seal portion, which in turn
extends from the second bottom ledge to the bottom depression. The
column forms extend from the top depression to the bottom
depression.
[0020] The first top lip seal portion and first bottom lip seal
portion are adapted to form a first seal between two mold units and
the second top lip seal portion and second bottom lip seal portion
are adapted to form a second seal between two mold units such that
the first portion bond beam form and second portion bond beam form
are combined to form a bond beam form.
[0021] The present invention also provides a wall that includes one
or more rows (or courses) of the above-described concrete wall
forming system, where concrete is poured into and set in the bond
beam forms, partial bond beam forms and column forms in the mold
units.
DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a mold unit according to the
present invention;
[0023] FIG. 2 is a top plan view of a mold unit according to the
invention;
[0024] FIG. 3 is a bottom plan view of a mold unit according to the
invention;
[0025] FIG. 4 is a side elevation view of a mold unit according to
the invention;
[0026] FIG. 5 is a top plan view of a corner mold unit according to
the invention;
[0027] FIG. 6 is a bottom plan view of a corner mold unit according
to the invention;
[0028] FIG. 7 is a top perspective view of a corner mold unit
according to the invention;
[0029] FIG. 8 is a wall end elevation view of a corner mold unit
according to the invention;
[0030] FIG. 9 is a corner side elevation view of a corner mold unit
according to the invention;
[0031] FIG. 10 is a mold end elevation view of a corner mold unit
according to the invention;
[0032] FIG. 11 is a top plan view of linked linear and corner mold
units according to the invention;
[0033] FIG. 12 is a bottom plan view of linked linear and corner
mold units according to the invention;
[0034] FIG. 13 is a top perspective view of linked linear and
corner mold units according to the invention;
[0035] FIG. 14 is a top plan view of a continuous wall system
according to the invention;
[0036] FIG. 15 is an end elevation view of a three-course wall
forming system according to the invention;
[0037] FIG. 16 is a perspective view of a three-course wall forming
system according to the invention;
[0038] FIG. 17 is a perspective view of a concrete web formed in
the three-course wall forming system of FIGS. 15 and 16 according
to the invention; and
[0039] FIG. 18 is a cut away perspective view of an insulated
reinforced concrete wall according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] For the purpose of the description hereinafter, the terms
"upper," "lower," "inner", "outer", "right," "left," "vertical,"
"horizontal," "top," "bottom," and derivatives thereof, shall
relate to the invention as oriented in the drawing Figures.
However, it is to be understood that the invention may assume
alternate variations and step sequences except where expressly
specified to the contrary. It is also to be understood that the
specific devices and processes, illustrated in the attached
drawings and described in the following specification, is an
exemplary embodiment of the present invention. Hence, specific
dimensions and other physical characteristics related to the
embodiment disclosed herein are not to be considered as limiting
the invention. In describing the embodiments of the present
invention, reference will be made herein to the drawings in which
like numerals refer to like features of the invention.
[0041] Other than where otherwise indicated, all numbers or
expressions referring to quantities, distances, or measurements,
etc. used in the specification and claims are to be understood as
modified in all instances by the term "about." Accordingly, unless
indicated to the contrary, the numerical parameters set forth in
the following specification and attached claims are approximations
that can vary depending upon the desired properties, which the
present invention desires to obtain. At the very least, and not as
an attempt to limit the application of the doctrine of equivalents
to the scope of the claims, each numerical parameter should at
least be construed in light of the number of reported significant
digits and by applying ordinary rounding techniques.
[0042] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the invention are approximations,
the numerical values set forth in the specific examples are
reported as precisely as possible. Any numerical values, however,
inherently contain certain errors necessarily resulting from the
standard deviation found in their respective measurement
methods.
[0043] Also, it should be understood that any numerical range
recited herein is intended to include all sub-ranges subsumed
therein. For example, a range of "1 to 10" is intended to include
all sub-ranges between and including the recited minimum value of 1
and the recited maximum value of 10; that is, having a minimum
value equal to or greater than 1 and a maximum value of equal to or
less than 10. Because the disclosed numerical ranges are
continuous, they include every value between the minimum and
maximum values. Unless expressly indicated otherwise, the various
numerical ranges specified in this application are
approximations.
[0044] As used herein, the term "expandable polymer matrix" refers
to a polymeric material in particulate or bead form that is
impregnated with a blowing agent such that when the particulates
and/or beads are placed in a mold and heat is applied thereto,
evaporation of the blowing agent (as described below) effects the
formation of a cellular structure and/or an expanding cellular
structure in the particulates and/or beads and the outer surfaces
of the particulates and/or beads fuse together to form a continuous
mass of polymeric material conforming to the shape of the mold.
[0045] As used herein, the term "polymer" is meant to encompass,
without limitation, homopolymers, copolymers and graft
copolymers.
[0046] As used herein, the terms "(meth) acrylic" and
"(meth)acrylate" are meant to include both acrylic and methacrylic
acid derivatives, such as the corresponding alkyl esters often
referred to as acrylates and (meth)acrylates, which the term
"(meth)acrylate" is meant to encompass.
[0047] The present invention provides a concrete wall forming
system that includes a plurality of interconnected mold units for
forming a wall by receiving concrete therein.
[0048] The mold units are made of a foamed plastic that can be
produced by expanding an expandable polymer matrix. The expanded
polymer matrix is typically molded from expandable thermoplastic
particles. These expandable thermoplastic particles are made from
any suitable thermoplastic homopolymer or copolymer. Particularly
suitable for use are homopolymers derived from vinyl aromatic
monomers including styrene, isopropylstyrene, alpha-methylstyrene,
nuclear methylstyrenes, chlorostyrene, tert-butylstyrene, and the
like, as well as copolymers prepared by the copolymerization of at
least one vinyl aromatic monomer as described above with one or
more other monomers, non-limiting examples being divinylbenzene,
conjugated dienes (non-limiting examples being butadiene, isoprene,
1,3- and 2,4-hexadiene), alkyl methacrylates, alkyl acrylates,
acrylonitrile, and maleic anhydride, wherein the vinyl aromatic
monomer is present in at least 50% by weight of the copolymer. In
an embodiment of the invention, styrenic polymers are used,
particularly polystyrene. However, other suitable polymers can be
used, such as polyolefins (e.g. polyethylene, polypropylene),
polycarbonates, polyphenylene oxides, and mixtures thereof.
[0049] In a particular embodiment of the invention, the expandable
thermoplastic particles are expandable polystyrene (EPS) particles.
These particles can be in the form of beads, granules, or other
particles convenient for the expansion and molding operations.
Particles polymerized in an aqueous suspension process are
essentially spherical and are useful for molding the mold units
and/or forms described herein below. These particles can be
screened so that their size ranges from about 0.008 inches (0.2 mm)
to about 0.16 inches (4 mm).
[0050] In an embodiment of the invention, resin beads (unexpanded)
containing any of the polymers or polymer compositions described
herein have a particle size of at least 0.2 mm, in some situations
at least 0.33 mm, in some cases at least 0.35 mm, in other cases at
least 0.4 mm, in some instances at least 0.45 mm and in other
instances at least 0.5 mm. Also, the resin beads can have a
particle size of up to about 4 mm, in some situations up to about
3.5 mm, in other situations up to about 3 mm, in some instances up
to 2 mm, in other instances up to 2.5 mm, in some cases up to 2.25
mm, in other cases up to 2 mm, in some situations up to 1.5 mm and
in other situations up to 1 mm. The resin beads used in this
embodiment can be any value or can range between any of the values
recited above.
[0051] The average particle size and size distribution of the
expandable resin beads or pre-expanded resin beads can be
determined using low angle light scattering, which can provide a
weight average value. As a non-limiting example, a Model LA-910
Laser Diffraction Particle Size Analyzer available from Horiba
Ltd., Kyoto, Japan can be used As used herein, the terms
"expandable thermoplastic particles" or "expandable resin beads"
refers to a polymeric material in particulate or bead form that is
impregnated with a blowing agent such that when the particulates
and/or beads are placed in a mold or expansion device and heat is
applied thereto, evaporation of the blowing agent (as described
below) effects the formation of a cellular structure and/or an
expanding cellular structure in the particulates and/or beads. When
expanded in a mold, the outer surfaces of the particulates and/or
beads fuse together to form a continuous mass of polymeric material
conforming to the shape of the mold.
[0052] As used herein, the terms "pre-expanded thermoplastic
particles," "pre-expanded resin beads," or "prepuff" refers to
expandable resin beads that have been expanded, but not to their
maximum expansion factor and whose outer surfaces have not fused.
As used herein, the term "expansion factor" refers to the volume a
given weight of resin bead occupies, typically expressed as cc/g.
Pre-expanded resin beads can be further expanded in a mold where
the outer surfaces of the pre-expanded resin beads fuse together to
form a continuous mass of polymeric material conforming to the
shape of the mold.
[0053] The expandable thermoplastic particles can be impregnated
using any conventional method with a suitable blowing agent. As a
non-limiting example, the impregnation can be achieved by adding
the blowing agent to the aqueous suspension during the
polymerization of the polymer, or alternatively by re-suspending
the polymer particles in an aqueous medium and then incorporating
the blowing agent as taught in U.S. Pat. No. 2,983,692. Any gaseous
material or material which will produce gases on heating can be
used as the blowing agent. Conventional blowing agents include
aliphatic hydrocarbons containing 4 to 6 carbon atoms in the
molecule, such as butanes, pentanes, hexanes, and the halogenated
hydrocarbons, e.g. CFC's and HCFC'S, which boil at a temperature
below the softening point of the polymer chosen. Mixtures of these
aliphatic hydrocarbon blowing agents can also be used.
[0054] Alternatively, water can be blended with these aliphatic
hydrocarbons blowing agents or water can be used as the sole
blowing agent as taught in U.S. Pat. Nos. 6,127,439; 6,160,027; and
6,242,540 in these patents, water-retaining agents are used. The
weight percentage of water for use as the blowing agent can range
from 1 to 20%. The texts of U.S. Pat. Nos. 6,127,439, 6,160,027 and
6,242,540 are incorporated herein by reference.
[0055] The impregnated thermoplastic particles are generally
pre-expanded to a density of at least 0.5 lb/ft.sup.3, in some
cases at least 0.75 lb/ft.sup.3, in other cases at least 1.0
lb/ft.sup.3, in some situations at least 1.25 lb/ft.sup.3, in other
situations at least 1.5 lb/ft.sup.3, and in some instances at least
about 1.75 lb/ft.sup.3. Also, the density of the impregnated
pre-expanded particles can be up to 12 lb/ft.sup.3, in some cases
up to 10 lb/ft.sup.3, and in other cases up to 5 lb/ft.sup.3. The
density of the impregnated pre-expanded particles can be any value
or range between any of the values recited above. The pre-expansion
step is conventionally carried out by heating the impregnated beads
via any conventional heating medium, such as steam, hot air, hot
water, or radiant heat. One generally accepted method for
accomplishing the pre-expansion of impregnated thermoplastic
particles is taught in U.S. Pat. No. 3,023,175.
[0056] The impregnated thermoplastic particles can be foamed
cellular polymer particles as taught in U.S. patent application
Ser. No. 10/021,716, the teachings of which are incorporated herein
by reference. The foamed cellular particles can be polystyrene that
are pre-expanded and contain a volatile blowing agent at a level of
less than 14 wt %, in some situations less than 8 wt %, in some
cases ranging from about 2 wt % to about 7 wt %, and in other cases
ranging from about 2.5 wt % to about 6.5 wt % based on the weight
of the polymer.
[0057] The thermoplastic particles according to the invention can
include an interpolymer of a polyolefin and in situ polymerized
vinyl aromatic monomers. Non-limiting examples of such
interpolymers are disclosed in U.S. Pat. Nos. 4,303,756 and
4,303,757 and U.S. Application Publication 2004/0152795, the
relevant portions of which are herein incorporated by reference. A
non-limiting example of interpolymers that can be used in the
present invention include those available under the trade name
ARCEL.RTM., available from NOVA Chemicals Inc., Pittsburgh, Pa. and
PIOCELAN.RTM., available from Sekisui Plastics Co., Ltd., Tokyo,
Japan.
[0058] The expanded polymer matrix can include customary
ingredients and additives, such as pigments, dyes, colorants,
plasticizers, mold release agents, stabilizers, ultraviolet light
absorbers, mold prevention agents, antioxidants, and so on. Typical
pigments include, without limitation, inorganic pigments such as
carbon black, graphite, expandable graphite, zinc oxide, titanium
dioxide, and iron oxide, as well as organic pigments such as
quinacridone reds and violets and copper phthalocyanine blues and
greens.
[0059] In a particular embodiment of the invention the pigment is
carbon black, a non-limiting example of such a material being EPS
SILVER.RTM., available from NOVA Chemicals Inc.
[0060] In another particular embodiment of the invention the
pigment is graphite, a non-limiting example of such a material
being NEOPOR.RTM., available from BASF Aktiengesellschaft Corp.,
Ludwigshafen am Rhein, Germany.
[0061] The pre-expanded particles or "pre-puff" are usually heated
in a closed mold to form the present mold units.
[0062] In another embodiment of the invention, the mold units can
have a male "tongue" edge and a female "groove" edge that
facilitates a "tongue and groove" union of two matching mold units.
In other embodiments of the invention, the mold units can have
overlapping lip ends adapted to join matching mold units
together.
[0063] In embodiments of the invention shown in FIGS. 1-4, mold
units 10 can be used to form a wall by receiving concrete therein.
Mold units 10 include a generally rectangular foamed plastic body
12 having a first side 14, a second side 16 oppositely opposed to
the first side 14, a first end 18, a second end 20 oppositely
opposed to the first end 18, a top surface 22, a bottom surface 24
oppositely opposed to the top surface, and at least two column
forms 26.
[0064] Top surface 22 of mold unit 10 includes a first portion bond
beam form 28 extending into body 12 lengthwise and defined by a top
depression 30 extending transversely to the length of body 12,
first end 18, and second end 20. First top ledge 32 extends
lengthwise along the body from first side 14 to top depression 30
and includes a first top lip seal portion 34. Second top ledge 36
extends lengthwise along body 14 from second side 16 to top
depression 30 and includes second top lip seal portion 38.
[0065] Bottom surface 24 includes second portion bond beam form 38
extending into body 12 lengthwise and defined by a bottom
depression 40 extending transversely to the length of body 12,
first end 18, and second end 20. First bottom ledge 42 extends
lengthwise along body 12 from first side 14 to first bottom lip
seal portion 44, which in turn extends to bottom depression 40.
Second bottom ledge 46 extends lengthwise along body 12 from second
side 16 to second bottom lip seal portion 48, which extends to
bottom depression 40.
[0066] Column forms 26 extend from top depression 30 to bottom
depression 40.
[0067] First top lip seal portion 34 and first bottom lip seal
portion 44 are adapted to form a first seal with first top ledge 32
and first bottom ledge 32 respectively. Second top lip seal portion
38 and second bottom lip seal portion 48 are adapted to form a
second seal with second top ledge 36 and second bottom ledge 46
respectively. Thus the mold units are adapted to form at least two
seals between two mold units such that the first portion bond beam
form and second portion bond beam form are combined to form a bond
beam form.
[0068] In an embodiment of the invention, first end 18 includes a
first extended portion 47 and a first recessed portion 49 and
second end 20 includes a second extended portion 45 adapted to be
received by first recessed portion 49 and a second recessed portion
43 adapted to receive first extended portion 47 to facilitates a
union between corresponding mold units 12.
[0069] As indicated above, body 12 can contain an expanded polymer
matrix. As such, body 12 can have a density of at least about 0.5
lb/ft.sup.3, in some cases at least about 0.75 lb/ft.sup.3, in
other cases at least about 1.0 lb/ft.sup.3, in some situations at
least about 1.25 lb/ft.sup.3, and in other situations at least
about 1.5 lb/ft.sup.3. Also, the density of the impregnated
pre-expanded particles can be up to about 12 lb/ft.sup.3, in some
cases up to about 10 lb/ft.sup.3, in other cases up to about 5
lb/ft.sup.3, in some instances up to up to about 3 lb/ft.sup.3, and
in other instances at up to about 1.75 lb/ft.sup.3. The density of
the impregnated pre-expanded particles can be any value or range
between any of the values recited above.
[0070] Top depression 30 and bottom depression 40 can be combined
to provide any suitable cross-sectional shape that will provide a
concrete web having desired properties, such as strength, weight
and concrete usage. As such, top depression 30 and bottom
depression 40 each have a cross sectional shape that provides a
matching portion of a desired concrete beam cross-sectional
shape.
[0071] Non-limiting examples of desired cross-sectional beam shapes
include circular, oval, elliptical, triangular, square,
rectangular, hexagonal, and octagonal. In an embodiment of the
invention, each of top depression 30 and bottom depression 40 have
a concave cross-sectional shape that provides a concrete beam
having a circular, oval, or elliptical cross-sectional shape.
[0072] In embodiments of the invention, top depression 30 and
bottom depression 40 have a generally curved shape and have a
minimum dimension 41, defined herein as the distance between top
depression 30 and bottom depression 40 at their closest point or
proximity to each other (see FIG. 1). In some embodiments of the
invention, the minimum dimension can be optimized to minimize the
amount of concrete used with mold 10 and therefore maximize the
volume of foamed plastic, while staying below deformation
thresholds and strain--fracture points. As such, minimum dimension
41 can be at least about 5 inches (13 cm), in some cases at least
about 6 inches (15 cm) and in other cases at least about 7 inches
(18 cm) and can be up to about 15 inches (38 cm), in some cases up
to about 12 inches (30.5 cm) and in other cases up to about 9
inches (23 cm) depending on the overall dimensions of mold unit 10
and the desired characteristics of the insulated concrete wall to
be formed. Minimum dimension 41 can be any value or range between
any of the values recited above.
[0073] In an embodiment of the invention, top depression 30 and
bottom depression 40 each have a concave shape.
[0074] In embodiments of the invention, the present concrete wall
forming system includes a plurality of linear mold units 10 as
described above and one or more corner units as shown in FIGS.
5-10. The corner units can be right facing or left facing, which is
a mirror image of a right facing corner unit. Referring to FIGS.
5-10, corner unit 50 include a generally rectangular foamed plastic
body 52 having a first corner side 54, a second corner side 56
oppositely opposed to first corner side 54, a first corner end 58,
a second corner end 60 oppositely opposed to first corner end 58, a
top corner surface 62, a bottom corner surface 64 oppositely
opposed to top corner surface 62, and at least two corner column
forms 66.
[0075] Top corner surface 62 includes a first portion top corner
bond beam form 68 and a second portion top corner bond beam 74.
First portion top corner bond beam form 68 extends into the body
lengthwise and defined by a lengthwise top depression 70 extending
transversely to the length of body 52, first end 58, and wall 72 at
second end 60, which includes a top wall ledge 64 and a top wall
lip seal portion 66. Second portion top corner bond beam form 74
extends into body 52 crosswise and defined by a crosswise top
depression 76 extending from lengthwise top depression 70, wall 72
at second end 60 and a terminal portion 78 of first top ledge
80.
[0076] First top ledge 80 extends lengthwise along body 52 from
second side 56 to lengthwise top depression 70 and from crosswise
top depression 76 to first end 58 and includes first top lip seal
portion 82.
[0077] Second top ledge 84 extends lengthwise along body 52 from
first side 54 to lengthwise top depression 70 and includes a second
top lip seal portion 86.
[0078] Bottom corner surface 64 includes a first portion bottom
corner bond beam form 88 extending into body 52 lengthwise and
defined by a lengthwise bottom depression 90 extending transversely
to the length of body 52, first end 58, and wall 72 at second end
60, which includes first bottom wall lip seal portion 92. Second
portion bottom corner bond beam form 94 extends into body 52
crosswise and is defined by crosswise bottom depression 96
extending from lengthwise bottom depression 90, wall 72 at second
end 60, first side 54 and a terminal portion 98 of a first bottom
ledge 100.
[0079] First bottom ledge 100 extends lengthwise along body 52 from
second side 56 to lengthwise bottom depression 90 and from wall 72
to first end 58 and a first bottom lip seal 102 extends along first
bottom ledge 100.
[0080] Second bottom ledge 104 extends lengthwise along body 52
from first side 54 to bottom depression 90 and from first end 58 to
crosswise bottom depression 96 includes a second bottom lip seal
portion 106.
[0081] Column forms 66 extend from top depression 70 bottom
depression 90.
[0082] First top lip seal portion 82 and first bottom lip seal
portion 102 are adapted to form a first seal between two mold units
and the second top lip seal portion 86 and second bottom lip seal
portion 106 are adapted to form a second seal between two mold
units such that the first portion top corner bond beam 68 and first
portion bottom bond beam form 88 and second portion top corner bond
beam form 74 and second portion bottom bond beam form 94 combine to
form a corner bond beam form.
[0083] In an embodiment of the invention, as shown in FIGS. 11-13,
linear mold units 10 and corner mold units 50 are adapted to fit
together and form continuous corner wall unit 120. First corner end
58 includes a first corner extended portion 91 and a first recessed
corner portion 89 and a connection portion 99 where crosswise top
depression 76 meets first corner side 54 includes second corner
extended portion 95 adapted to be received by first recessed
portion 49 of mold unit 10 and a second corner recessed portion 97
adapted to receive first extended portion 47 of mold unit 10 to
facilitates a union between a corner mold unit 50 and a mold unit
10. When mold units are arrayed as shown in FIGS. 11-13, top
depression 30, lengthwise top depression 70, and crosswise top
depression 76 are aligned to form a continuous bottom beam form.
Similarly, bottom depression 40, lengthwise bottom depression 90,
and crosswise bottom depression 96 are aligned to form a continuous
top beam form.
[0084] As shown in FIG. 14, mold units 10 and corner units 50 can
be arranged sequentially from a first unit 172 to a last unit 174
such that the first end 176 of first unit 172 is in contact with
the second end 178 of last unit 174 to form continuous wall mold
system 170. As shown, wall mold system 170 includes a plurality of
evenly spaced column forms 26 and 66.
[0085] Mold units 10 and corner units 50 can have any suitable
length that allows for ease of manufacture and transportation. As
such, mold units 10 and corner units 50 can independently have a
length measured from first end 18 to second end 20 or first corner
end 58 to second corner end 60 respectively of from at least about
2 feet (0.6 m), in some cases at least about 2.5 feet (0.76 m) and
in other cases at least about 3 feet (0.91 m) and can be up to
about 10 feet (3 m), in some cases up to about 8 feet (2.4 m) and
in other cases up to about 6 feet (1.8 m). The length of mold units
10 and corner units 50 can independently by any of the values or
range between any of the values recited above.
[0086] Mold units 10 and corner units 50 can have any suitable
width based on the design properties of the desired insulated
concrete wall to be erected. As such, mold units 10 and corner
units 50 can independently have a width measured from first side 14
to second side 16 or first corner side 54 to second corner side 56
respectively of from at least about 4 in. (10.2 cm), in some cases
at least about 6 in. (15.2 in) and in other cases at least about 7
inches (18 cm) and can be up to about 24 inches (61 cm), in some
cases up to about 20 inches (51 cm) and in other cases up to about
16 inches (41 cm). The width of mold units 10 and corner units 50
can independently by any of the values or range between any of the
values recited above.
[0087] Mold units 10 and corner units 50 can have a vertical height
of at least about 4 in. (10.2 cm), in some cases at least about 6
in. (15.2 in) and in other cases at least about 8 inches (20.4 cm)
and can be up to about 24 in. (61 cm), in some cases up to about 20
in. (51 cm) and in other cases up to about 16 in. (41 cm). The
vertical height of mold units 10 and corner units 50 is determined
by the intended number of courses of mold units 10 and corner units
50 to be used in an overall insulated concrete wall design. The
Vertical height of mold units 10 and corner units 50 can be any
value or range between any of the values recited above.
[0088] The bond beam formed by combining first portion bond beam
form 28 and second portion bond beam form 38; first portion top
corner bond beam form 68 and second portion top corner bond beam
74; and/or second portion top corner bond beam form 74 and second
portion bottom corner bond beam form 94 can have any suitable
cross-sectional shape so long as the resulting concrete beam can
provide desired strength characteristics. As such, the
cross-sectional shape can be selected from U-shaped, trapezoidal,
circular, oval, elliptical, triangular, square, rectangular,
hexagonal, and octagonal.
[0089] The cross-sectional area of the bond beam formed by
combining first portion bond beam form 28 and second portion bond
beam form 38; first portion top corner bond beam form 68 and second
portion top corner bond beam 74; and second portion top corner bond
beam form 74 and/or second portion bottom corner bond beam form 94
column forms 34 is determined based on the load bearing design of
the resulting insulated concrete wall. The cross-sectional area of
the bond beam forms can be at least about 8 in.sup.2 (52 cm.sup.2),
in some cases at least about 12 in.sup.2 (77 cm.sup.2) and in other
cases at least about 16 in.sup.2 (103 cm.sup.2) and can be up to
about 80 in.sup.2 (516 cm.sup.2), in some cases up to about 60
in.sup.2 (387 cm.sup.2), and in other cases up to about 40 in.sup.2
(258 cm.sup.2). The cross-sectional area of the bond beam can be
any value or range between any of the values recited above.
[0090] In embodiments of the invention, the cross-sectional shape
of the bond beam is circular having a diameter of at least about 2
inches (5 cm) and in some cases at least about 3 inches (7.5 cm)
and can be up to 7.5 inches about (19 cm), in some cases up to
about 7 inches (18 cm) and in other cases up to about 6 inches (15
cm) based on the load bearing design of the resulting insulated
concrete wall. The diameter of the circular cross-sectional shape
of the bond beam can be any value or range between any of the
values recited above.
[0091] In embodiments of the invention, the cross-sectional shape
of the bond beam is that of an ellipse. As used herein, an ellipse
is an oval shape defined by a major axis and a minor axis,
perpendicular to the major axis and passing through the center of
the ellipse, both terminating at the edge of the ellipse. The major
axis is the longest segment that passes through the ellipse. The
ellipse can be characterized by the ratio of the major axis to the
minor axis (aspect ratio). For a circle, the aspect ratio is 1.
[0092] The major axis can have a length of at least about 2 inches
(5 cm) and in some cases at least about 3 inches (7.5 cm) and can
be up to 7.5 inches about (19 cm), in some cases up to about 7
inches (18 cm) and in other cases up to about 6 inches (15 cm)
based on the load bearing design of the resulting insulated
concrete wall. The length of the major axis of the ellipse-shaped
bond beam form can be any value or range between any of the values
recited above.
[0093] The aspect ratio of the ellipse-shaped bond beam form can be
at least about 1.1, in some cases at least about 1.2, and in other
cases at least about 1.3 and the aspect ratio can be up to about 3,
in some cases up to about 2 and in other cases up to about 1.75.
The aspect ratio of the ellipse-shaped bond beam form can be any
value or range between any of the values recited above.
[0094] Each of column forms 26 and 66 can independently have any
suitable cross-sectional shape so long as the resulting concrete
column can provide desired strength characteristics. As such, the
cross-sectional shape can be selected from trapezoidal, circular,
oval, elliptical, triangular, square, rectangular, hexagonal, and
octagonal.
[0095] The cross-sectional area of column forms 26 and 66 is
determined based on the load bearing design of the resulting
insulated concrete wall. The cross-sectional area of column forms
26 and 66 can be at least about 8 in.sup.2 (52 cm.sup.2), in some
cases at least about 12 in.sup.2 (77 cm.sup.2) and in other cases
at least about 16 in.sup.2 (103 cm.sup.2) and can be up to about 80
in.sup.2 (516 cm.sup.2), in some cases up to about 60 in.sup.2 (387
cm.sup.2), and in other cases up to about 40 in.sup.2 (258
cm.sup.2). The cross-sectional area of column forms 26 and 66 can
be any value or range between any of the values recited above.
[0096] In embodiments of the invention, the cross-sectional shape
of column forms 26 and 66 is circular having a diameter of at least
about 2 inches (5 cm) and in some cases at least about 3 inches
(7.5 cm) and can be up to 7.5 inches about (19 cm), in some cases
up to about 7 inches (18 cm) and in other cases up to about 6
inches (15 cm) based on the load bearing design of the resulting
insulated concrete wall. The diameter of the circular column forms
26 and 66 can be any value or range between any of the values
recited above.
[0097] In embodiments of the invention, molds 10 and 50 are
designed so column forms 26 and 66 are evenly spaced as defined by
the distance between the centers of each adjacent column forms. As
such the column forms can be at least about 4.5 inches (11.5 cm)
and in some cases at least about 6.5 inches (16.5 cm) and can be up
to about 16 inches (41 cm), in some cases up to about 15 inches (38
cm) and in other cases up to about 13 inches (33 cm) on center
based on the load bearing-design of the resulting insulated
concrete wall.
[0098] In embodiments of the invention, one or more courses of mold
units 10 and corner units 50 can be used to provide a concrete wall
forming system. As a non-limiting example shown in FIGS. 15 and 16,
multi-course wall form system 201 includes three courses of wall
units 10, bottom course 200, second course 202 and top course
204.
[0099] Proper alignment of mold units 10 provide for the formation
of three course column forms 214 and a series of bond beam forms,
bottom partial bond beam form 206, first bond beam form 208, second
bond beam form 210, and top partial bond beam form 212.
[0100] As noted above, first top lip seal portion 34 and first
bottom lip seal portion 44 are adapted to form a first seal with
first bottom ledge 42 and first top ledge 32 respectively. Second
top lip seal portion 38 and second bottom lip seal portion 48 are
adapted to form a second seal with second bottom ledge 46 and
second top ledge 36 respectively. The continuous seal that is
formed is held in place by the weight of the concrete poured within
mold unit forms and provides improved concrete leakage prevention
when compared with prior art systems. In embodiments of the
invention, if the surface that multi-course wall form system 201
rests on is uneven resulting in less than a flush interface between
first top lip seal portion 34 and first bottom ledge 42, first
bottom lip seal portion 44 and first top ledge 32, second top lip
seal portion 38 and second bottom ledge 46, and/or second bottom
lip seal portion 48 and second top ledge 36, spray foam, as is
known in the art, can be used to fill any gaps.
[0101] As was mentioned above, proper alignment of mold units 10
provides for three course column forms 214. Proper alignment of
mold units 10 is provided by the design of lip seal portions 34,
38, 44 and 48 and ledges 32, 36, 42 and 46. Referring to FIGS. 2
and 3, first bottom ledge 42 and second bottom ledge 46 include
bumps 220 that align with indents 222 in first top ledge 32 and
second top ledge 36 respectively allowing a first mold units 10 to
only sit flush on a second mold unit when bumps 220 and indents 222
are in alignment, which also orients and aligns column forms
26.
[0102] Similarly, corner units 50 can be aligned using bumps 224
and indents 226.
[0103] As shown in FIG. 17, when concrete is poured into
multi-course wall form system 201 and allowed to set, concrete web
230 is formed. Concrete web 230 includes concrete columns 240
formed within three course column forms 214, bottom partial
concrete beam 232 formed within bottom partial bond beam form 206,
first concrete beam 234 formed within first bond beam form 208,
second concrete beam 236 formed within second bond beam form 210,
and top partial concrete beam formed within top partial bond beam
form 212.
[0104] As those skilled in the art will appreciate, various numbers
of courses can be used to provide a plurality of concrete beams and
columns according to the invention. Also, various insulated
concrete wall system layouts can be designed with one or more
courses of mold units. As a non-limiting example, the three course
wall system of FIGS. 15-17 can be implemented in the continuous
insulated concrete wall system layout shown in FIG. 14.
[0105] As such, the present invention provides a wall that includes
one or more rows of the concrete wall forming systems as described
above where concrete is poured into and set in the bond beam forms,
partial bond beam forms and column forms in the mold units.
[0106] Embodiments of the invention provide a continuous wall that
includes the above-described concrete wall forming system, where
concrete is poured into and set in the partial bond beam forms and
column forms in the mold units.
[0107] Often, in order to add strength to an insulated concrete
wall system, concrete reinforcing products are placed within the
bond beam forms, partial bond beam forms and/or column forms
described above.
[0108] In embodiments of the invention, the concrete reinforcing
product can be selected from rebar, fiber reinforced polymer,
carbon fibers, aramid fibers, glass fibers, metal fibers and
combinations thereof.
[0109] As used herein, the term "fiber reinforced polymer" refers
to plastics that include, but are not limited to reinforced
thermoplastics and reinforced thermoset resins. Thermoplastics
include polymers and polymers made up of materials that can be
repeatedly softened by heating and hardened again on cooling.
Suitable thermoplastic polymers include, but are not limited to
homopolymers and copolymers of styrene, homopolymers and copolymers
of C.sub.2 to C.sub.20 olefins, C.sub.4 to C.sub.20 dienes,
polyesters, polyamides, homopolymers and copolymers of C.sub.2 to
C.sub.20 (meth)acrylate esters, polyetherimides, polycarbonates,
polyphenylethers, polyvinylchlorides, polyurethanes, and
combinations thereof.
[0110] Suitable thermoset resins are resins that when heated to
their cure point, undergo a chemical cross-linking reaction causing
them to solidify and hold their shape rigidly, even at elevated
temperatures. Suitable thermoset resins include, but are not
limited to alkyd resins, epoxy resins, diallyl phthalate resins,
melamine resins, phenolic resins, polyester resins, urethane
resins, and urea, which can be crosslinked by reaction, as
non-limiting examples, with diols, triols, polyols, and/or
formaldehyde.
[0111] Fiber reinforcing materials that can be incorporated into
the thermoplastics and/or thermoset resins include, but are not
limited to carbon fibers, aramid fibers, glass fibers, metal
fibers, woven fabric or structures of the mentioned fibers, and/or
fiberglass, and can optionally include one or more fillers,
non-limiting examples including carbon black, graphite, clays,
calcium carbonate, titanium dioxide, and combinations thereof.
[0112] In an embodiment of the invention shown in FIG. 18, rebar
can be added to the concrete wall and wall forming system shown in
FIGS. 15-17. As such, reinforced insulated concrete wall 260
includes horizontal rebar 250, which can be placed in first bond
beam form 208 and second bond beam form 210 and vertical rebar 252,
which can be placed in three course column forms 214. At
intersection 254, where horizontal rebar 250 and vertical rebar 252
intersect, the rebar can be secured into position using appropriate
ties, rope, wire, etc. as is known in the art. In many embodiments
of the invention, horizontal rebar 250 is placed at approximately
the center of the cross-section of first bond beam form 208 and
second bond beam form 210 and vertical rebar 252 is placed at
approximately the center of the cross-section of three course
column forms 214.
[0113] In certain embodiments of the invention, mold units 10 and
50 are designed to minimize stress concentrations in order to
reduce the risk of deformation and fracture when concrete is placed
in the mold units. In these embodiments, the internal column form
surfaces are designed as cylinders so that the lateral pressure
from the concrete is as evenly distributed within the mold unit as
possible. This is an improvement over prior art all-foam ICFs,
where the internal surfaces have squared edges, which can lead to
stress concentrations at the corners. By eliminating the stress
concentrations in the present wall forming system, the pressure at
which deformation and/or failure occurs is increased, reducing the
likelihood of deformation and/or failure of the wall forming
system. Ultimately, this allows the ICF to be made from lower
density foam (for the same performance as a higher density with
another design) and subsequently at a lower cost.
[0114] In particular embodiments of the invention, mold units 10
and 50 are designed to optimally meet International Residential
Code standards for screen grid ICFs. As such the column forms of
mold units 10 and 50 are cylinders having a diameter of from about
5 inches (12.7 cm) to about 6 inches (15.2 cm), in some cases about
5.5 inches (14 cm) spaced apart by about 7 inches (18 cm) to about
9 inches (23 cm), in some cases about 8 inches (20.3 cm) on center.
The dimensions of mold units 10 and 50 in this embodiment are
length of from about 40 inches (102 cm) to about 56 inches (142
cm), in some cases about 48 inches (122 cm); width of from about 7
inches (18 cm) to about 9 inches (23 cm), in some cases about 8
inches (20.3 cm); and height of from about 10 inches (25.4 cm) to
about 14 inches (35.5 cm), in some cases about 12 inches (30.5 cm).
The bond beam cross sectional shape is an ellipse having a major
axis of from about 5 inches (12.7 cm) to about 6 inches (15.2 cm),
in some cases about 5.5 inches (14 cm) and an aspect ratio of from
about 1.25 to about 1.5, in some cases about 1.375. In this
embodiment, minimum dimension 41 is about 7 inches (18 cm) to about
9 inches (23 cm), in some cases about 8 inches (20.3 cm).
[0115] Any suitable type of concrete can be used to make the
concrete walls and concrete wall systems described herein. The
specific type of concrete will depend on the desired and designed
properties of the concrete walls and concrete wall systems. In
embodiments of the invention, the concrete includes one or more
hydraulic cement compositions selected from Portland cements,
pozzolana cements, gypsum cements, aluminous cements, magnesia
cements, silica cements, and slag cements.
[0116] In an embodiment of the invention, the cement includes a
hydraulic cement composition. The hydraulic cement composition can
be present at a level of at least 3, in certain situations at least
5, in some cases at least 7.5, and in other cases at least 9 volume
percent and can be present at levels up to 40, in some cases up to
35, in other cases up to 32.5, and in some instances up to 30
volume percent of the cement mixture. The cement mixture can
include the hydraulic cement composition at any of the above-stated
levels or at levels ranging between any of levels stated above.
[0117] In an embodiment of the invention, the concrete mixture can
optionally include other aggregates and adjuvants known in the art
including but not limited to sand, additional aggregate,
plasticizers and/or fibers. Suitable fibers include, but are not
limited to glass fibers, silicon carbide, aramid fibers, polyester,
carbon fibers, composite fibers, fiberglass, metal and combinations
thereof as well as fabric containing the above-mentioned fibers,
and fabric containing combinations of the above-mentioned
fibers.
[0118] Non-limiting examples of fibers that can be used in the
invention include MeC-GRID.RTM. and C-GRID.RTM. available from
TechFab, LLC, Anderson, S.C., KEVLAR.RTM. available from E.I. du
Pont de Nemours and Company, Wilmington Del., TWARON.RTM. available
from Teijin Twaron B. V., Arnheim, the Netherlands, SPECTRA.RTM.
available from Honeywell International Inc., Morristown, N.J.,
DACRON.RTM. available from Invista North America S.A.R.L. Corp.
Wilmington, Del., and VECTRAN.RTM. available from Hoechst Celanese
Corp., New York, N.Y. The fibers can be used in a mesh structure,
intertwined, interwoven, and oriented in any desirable
direction.
[0119] In a particular embodiment of the invention fibers can make
up at least 0.1, in some cases at least 0.5, in other cases at
least 1, and in some instances at least 2 volume percent of the
concrete composition. Further, fibers can provide up to 10, in some
cases up to 8, in other cases up to 7, and in some instances up to
5 volume percent of the concrete composition. The amount of fibers
is adjusted to provide desired properties to the concrete
composition. The amount of fibers can be any value or range between
any of the values recited above. Further to this embodiment, the
additional aggregate can include, but is not limited to, one or
more materials selected from common aggregates such as sand, stone,
and gravel. Common lightweight aggregates can include ground
granulated blast furnace slag, fly ash, glass, silica, expanded
slate and clay; insulating aggregates such as pumice, perlite,
vermiculite, scoria, and diatomite; light-weight aggregate such as
expanded shale, expanded slate, expanded clay, expanded slag, fumed
silica, pelletized aggregate, extruded fly ash, tuff, and
macrolite; and masonry aggregate such as expanded shale, clay,
slate, expanded blast furnace slag, sintered fly ash, coal cinders,
pumice, scoria, and pelletized aggregate.
[0120] When included, the other aggregates and adjuvants are
present in the concrete mixture at a level of at least 0.5, in some
cases at least 1, in other cases at least 2.5, in some instances at
least 5 and in other instances at least 10 volume percent of the
concrete mixture. Also, the other aggregates and adjuvants can be
present at a level of up to 95, in some cases up to 90, in other
cases up to 85, in some instances up to 65 and in other instances
up to 60 volume percent of the concrete mixture. The other
aggregates and adjuvants can be present in the concrete mixture at
any of the levels indicated above or can range between any of the
levels indicated above.
[0121] In embodiments of the invention, the concrete compositions
can contain one or more additives, non-limiting examples of such
being anti-foam agents, water-proofing agents, dispersing agents,
set-accelerators, set-retarders, plasticizing agents,
superplasticizing agents, freezing point decreasing agents,
adhesiveness-improving agents, and colorants. The additives are
typically present at less than one percent by weight with respect
to total weight of the composition, but can be present at from 0.1
to 3 weight percent.
[0122] Suitable dispersing agents or plasticizers that can be used
in the invention include, but are not limited to hexametaphosphate,
tripolyphosphate, polynaphthalene sulphonate, sulphonated polyamine
and combinations thereof.
[0123] Suitable plasticizing agents that can be used in the
invention include, but are not limited to polyhydroxycarboxylic
acids or salts thereof, polycarboxylates or salts thereof;
lignosulfonates, polyethylene glycols, and combinations
thereof.
[0124] Suitable superplasticizing agents that can be used in the
invention include, but are not limited to alkaline or earth
alkaline metal salts of lignin sulfonates; lignosulfonates,
alkaline or earth alkaline metal salts of highly condensed
naphthalene sulfonic acid/formaldehyde condensates; polynaphthalene
sulfonates, alkaline or earth alkaline metal salts of one or more
polycarboxylates (such as poly(meth)acrylates and the
polycarboxylate comb copolymers described in U.S. Pat. No.
6,800,129, the relevant portions of which are herein incorporated
by reference); alkaline or earth alkaline metal salts of
melamine/formaldehyde/sulfite condensates; sulfonic acid esters;
carbohydrate esters; and combinations thereof.
[0125] Suitable set-accelerators that can be used in the invention
include, but are not limited to soluble chloride salts (such as
calcium chloride), triethanolamine, paraformaldehyde, soluble
formate salts (such as calcium formate), sodium hydroxide,
potassium hydroxide, sodium carbonate, sodium sulfate,
12CaO.7Al.sub.2O.sub.3, sodium sulfate, aluminum sulfate, iron
sulfate, the alkali metal nitrate/sulfonated aromatic hydrocarbon
aliphatic aldehyde condensates disclosed in U.S. Pat. No.
4,026,723, the water soluble surfactant accelerators disclosed in
U.S. Pat. No. 4,298,394, the methylol derivatives of amino acids
accelerators disclosed in U.S. Pat. No. 5,211,751, and the mixtures
of thiocyanic acid salts, alkanolamines, and nitric acid salts
disclosed in U.S. Pat. No. Re. 35,194, the relevant portions of
which are herein incorporated by reference, and combinations
thereof.
[0126] Suitable set-retarders that can be used in the invention
include, but are not limited to lignosulfonates, hydroxycarboxylic
acids (such as gluconic acid, citric acid, tartaric acid, malic
acid, salicylic acid, glucoheptonic acid, arabonic acid, acid, and
inorganic or organic salts thereof such as sodium, potassium,
calcium, magnesium, ammonium and triethanolamine salt), cardonic
acid, sugars, modified sugars, phosphates, borates,
silico-fluorides, calcium bromate, calcium sulfate, sodium sulfate,
monosaccharides such as glucose, fructose, galactose, saccharose,
xylose, apiose, ribose and invert sugar, oligosaccharides such as
disaccharides and trisaccharides, such oligosaccharides as dextrin,
polysaccharides such as dextran, and other saccharides such as
molasses containing these; sugar alcohols such as sorbitol;
magnesium silicofluoride; phosphoric acid and salts thereof, or
borate esters; aminocarboxylic acids and salts thereof;
alkali-soluble proteins; humic acid; tannic acid; phenols;
polyhydric alcohols such as glycerol; phosphonic acids and
derivatives thereof, such as aminotri(methylenephosphonic acid),
1-hydroxyethylidene-1,1-diphosphonic acid,
ethylenediaminetetra(methylenephosphonic acid),
diethylenetriaminepenta(methylenephosphonic acid), and alkali metal
or alkaline earth metal salts thereof, and combinations of the
set-retarders indicated above.
[0127] Suitable defoaming agents that can be used in the invention
include, but are not limited to silicone-based defoaming agents
(such as dimethylpolysiloxane, diemthylsilicone oil, silicone
paste, silicone emulsions, organic group-modified polysiloxanes
(polyorganosiloxanes such as dimethylpolysiloxane), fluorosilicone
oils, etc.), alkyl phosphates (such as tributyl phosphate, sodium
octylphosphate, etc.), mineral oil-based defoaming agents (such as
kerosene, liquid paraffin, etc.), fat- or oil-based defoaming
agents (such as animal or vegetable oils, sesame oil, castor oil,
alkylene oxide adducts derived there from, etc.), fatty acid-based
defoaming agents (such as oleic acid, stearic acid, and alkylene
oxide adducts derived there from, etc.), fatty acid ester-based
defoaming agents (such as glycerol monoricinolate, alkenylsuccinic
acid derivatives, sorbitol monolaurate, sorbitol trioleate, natural
waxes, etc.), oxyalkylene type defoaming agents, alcohol-based
defoaming agents: octyl alcohol, hexadecyl alcohol, acetylene
alcohols, glycols, etc.), amide-based defoaming agents (such as
acrylate polyamines, etc.), metal salt-based defoaming agents (such
as aluminum stearate, calcium oleate, etc.) and combinations of the
above-described defoaming agents.
[0128] Suitable freezing point decreasing agents that can be used
in the invention include, but are not limited to ethyl alcohol,
calcium chloride, potassium chloride, and combinations thereof.
[0129] Suitable adhesiveness-improving agents that can be used in
the invention include, but are not limited to polyvinyl acetate,
styrene-butadiene, homopolymers and copolymers of (meth)acrylate
esters, and combinations thereof.
[0130] Suitable water-repellent or water-proofing agents that can
be used in the invention include, but are not limited to fatty
acids (such as stearic acid or oleic acid), lower alkyl fatty acid
esters (such as butyl stearate), fatty acid salts (such as calcium
or aluminum stearate), silicones, wax emulsions, hydrocarbon
resins, bitumen, fats and oils, silicones, paraffins, asphalt,
waxes, and combinations thereof. Although not used in many
embodiments of the invention, when used suitable air-entraining
agents include, but are not limited to vinsol resins, sodium
abietate, fatty acids and salts thereof, tensides,
alkyl-aryl-sulfonates, phenol ethoxylates, lignosulfonates, and
mixtures thereof.
[0131] In some embodiments of the invention, the concrete is
light-weight concrete. As used herein, the term "light weight
concrete" refers to concrete where light-weight aggregate is
included in a cementitous mixture. Exemplary light weight concrete
compositions that can be used in the present invention are
disclosed in U.S. Pat. Nos. 3,021,291, 3,214,393, 3,257,338,
3,272,765, 5,622,556, 5,725,652, 5,580,378, and 6,851,235, JP 9 071
449, WO 98 02 397, WO 00/61519, and WO 01/66485 the relevant
portions of which are incorporated herein by reference.
[0132] In particular embodiments of the present invention, the
lightweight concrete (LWC) composition includes a concrete mixture
and polymer particles. In many instances the size, composition,
structure, and physical properties of expanded polymer particles,
and in some instances their resin bead precursors, can greatly
affect the physical properties of LWC used in the invention. Of
particular note is the relationship between bead size and expanded
polymer particle density on the physical properties of the
resulting LWC wall.
[0133] The polymer particles, which can optionally be expanded
polymer particles, are present in the LWC composition at a level of
at least 10, in some instances at least 15, in other instances at
least 20, in particular situations up to 25, in some cases at least
30, and in other cases at least 35 volume percent and up to 90, in
some cases up to 85, in other cases up to 78, in some instances up
to 75, in other instance up to 65, in particular instances up to
60, in some cases up to 50, and in other cases up to 40 volume
percent based on the total volume of the LWC composition. The
amount of polymer particles will vary depending on the particular
physical properties desired in a finished LWC wall. The amount of
polymer particles in the LWC composition can be any value or can
range between any of the values recited above.
[0134] The polymer particles can include any particles derived from
any suitable expandable thermoplastic material. The actual polymer
particles are selected based on the particular physical properties
desired in a finished LWC wall. As a non-limiting example, the
polymer particles, which can optionally be expanded polymer
particles, can include one or more polymers selected from
homopolymers of vinyl aromatic monomers; copolymers of at least one
vinyl aromatic monomer with one or more of divinylbenzene,
conjugated dienes, alkyl methacrylates, alkyl acrylates,
acrylonitrile, and/or maleic anhydride; polyolefins;
polycarbonates; polyesters; polyamides; natural rubbers; synthetic
rubbers; and combinations thereof.
[0135] In an embodiment of the invention, the polymer particles
include thermoplastic homopolymers or copolymers selected from
homopolymers derived from vinyl aromatic monomers including
styrene, isopropylstyrene, alpha-methylstyrene, nuclear
methylstyrenes, chlorostyrene, tert-butylstyrene, and the like, as
well as copolymers prepared by the copolymerization of at least one
vinyl aromatic monomer as described above with one or more other
monomers, non-limiting examples being divinylbenzene, conjugated
dienes (non-limiting examples being butadiene, isoprene, 1,3- and
2,4-hexadiene), alkyl methacrylates, alkyl acrylates,
acrylonitrile, and maleic anhydride, wherein the vinyl aromatic
monomer is present in at least 50% by weight of the copolymer. In
an embodiment of the invention, styrenic polymers are used,
particularly polystyrene. However, other suitable polymers can be
used, such as polyolefins (e.g. polyethylene, polypropylene),
polycarbonates, polyphenylene oxides, and mixtures thereof.
[0136] In a particular embodiment of the invention, the polymer
particles are expandable polystyrene (EPS) particles. These
particles can be in the form of beads, granules, or other
particles.
[0137] In the present invention, particles polymerized in a
suspension process, which are essentially spherical resin beads,
are useful as polymer particles or for making expanded polymer
particles. However, polymers derived from solution and bulk
polymerization techniques that are extruded and cut into particle
sized resin bead sections can also be used.
[0138] In an embodiment of the invention; resin beads (unexpanded)
containing any of the polymers or polymer compositions described
herein have a particle size of at least 0.2 mm, in some situations
at least 0.33 mm, in some cases at least 0.35 mm, in other cases at
least 0.4 mm, in some instances at least 0.45 mm and in other
instances at least 0.5 mm. Also, the resin beads can have a
particle size of up to 3 mm, in some instances up to 2 mm, in other
instances up to 2.5 mm, in some cases up to 2.25 mm, in other cases
up to 2 mm, in some situations up to 1.5 mm and in other situations
up to 1 mm. In this embodiment, the physical properties of LWC
walls made according to the invention have inconsistent or
undesirable physical properties when resin beads having particle
sizes outside of the above described ranges are used to make the
expanded polymer particles. The resin beads used in this embodiment
can be any value or can range between any of the values recited
above.
[0139] The expandable thermoplastic particles, or resin beads can
optionally be impregnated using any conventional method with a
suitable blowing agent. As a non-limiting example, the impregnation
can be achieved by adding the blowing agent to the aqueous
suspension during the polymerization of the polymer, or
alternatively by re-suspending the polymer particles in an aqueous
medium and then incorporating the blowing agent as taught in U.S.
Pat. No. 2,983,692. Any gaseous material or material which will
produce gases on heating can be used as the blowing agent.
Conventional blowing agents include aliphatic hydrocarbons
containing 4 to 6 carbon atoms in the molecule, such as butanes,
pentanes, hexanes, and the halogenated hydrocarbons, e.g. CFC's and
HCFC'S, which boil at a temperature below the softening point of
the polymer chosen. Mixtures of these aliphatic hydrocarbon blowing
agents can also be used.
[0140] Alternatively, water can be blended with these aliphatic
hydrocarbons blowing agents or water can be used as the sole
blowing agent as taught in U.S. Pat. Nos. 6,127,439; 6,160,027; and
6,242,540 in these patents, water-retaining agents are used. The
weight percentage of water for use as the blowing agent can range
from 1 to 20%. The texts of U.S. Pat. Nos. 6,127,439, 6,160,027 and
6,242,540 are incorporated herein by reference.
[0141] The impregnated polymer particles or resin beads are
optionally expanded to a bulk density of at least 1.75 lb/ft.sup.3
(0.028 g/cc), in some circumstances at least 2 lb/ft.sup.3 (0.032
g/cc) in other circumstances at least 3 lb/ft.sup.3 (0.048 g/cc)
and in particular circumstances at least 3.25 lb/ft.sup.3 (0.052
g/cc) or 3.5 lb/ft.sup.3 (0.056 g/cc). When non-expanded resin
beads are used higher bulk density beads can be used. As such, the
bulk density can be as high as 40 lb/ft.sup.3 (0.64 g/cc). In other
situations, the polymer particles are at least partially expanded
and the bulk density can be up to 35 lb/ft.sup.3 (0.56 g/cc), in
some cases up to 30 lb/ft.sup.3 (0.48 g/cc), in other cases up to
25 lb/ft.sup.3 (0.4 g/cc), in some instances up to 20 lb/ft.sup.3
(0.32 g/cc), in other instances up to 15 lb/ft.sup.3 (0.24 g/cc)
and in certain circumstances up to 10 lb/ft.sup.3 (0.16 g/cc). The
bulk density of the polymer particles can be any value or range
between any of the values recited above. The bulk density of the
polymer particles, resin beads and/or prepuff particles is
determined by weighing a known volume of polymer particles, beads
and/or prepuff particles (aged 24 hours at ambient conditions).
[0142] The expansion step is conventionally carried out by heating
the impregnated beads via any conventional heating medium, such as
steam, hot air, hot water, or radiant heat. One generally accepted
method for accomplishing the pre-expansion of impregnated
thermoplastic particles is taught in U.S. Pat. No. 3,023,175.
[0143] The impregnated polymer particles can be foamed cellular
polymer particles as taught in U.S. patent application Ser. No.
10/021,716, the teachings of which are incorporated herein by
reference. The foamed cellular particles can be polystyrene that
are expanded and contain a volatile blowing agent at a level of
less than 14 wt %, in some situations less than 8 wt %, in some
cases ranging from about 2 wt % to about 7 wt %, and in other cases
ranging from about 2.5 wt % to about 6.5 wt % based on the weight
of the polymer.
[0144] An interpolymer of a polyolefin and in situ polymerized
vinyl aromatic monomers that can be included in the expanded
thermoplastic resin or polymer particles according to the invention
is disclosed in U.S. Pat. Nos. 4,303,756 and 4,303,757 and U.S.
Application Publication 2004/0152795, the relevant portions of
which are herein incorporated by reference.
[0145] The polymer particles can include customary ingredients and
additives, such as flame retardants, pigments, dyes, colorants,
plasticizers, mold release agents, stabilizers, ultraviolet light
absorbers, mold prevention agents, antioxidants, rodenticides,
insect repellants, and so on. Typical pigments include, without
limitation, inorganic pigments such as carbon black, graphite,
expandable graphite, zinc oxide, titanium dioxide, and iron oxide,
as well as organic pigments such as quinacridone reds and violets
and copper phthalocyanine blues and greens.
[0146] In a particular embodiment of the invention the pigment is
carbon black, a non-limiting example of such a material being EPS
SILVER.RTM., available from NOVA Chemicals Inc.
[0147] In another particular embodiment of the invention the
pigment is graphite, a non-limiting example of such a material
being NEOPOR.RTM., available from BASF Aktiengesellschaft Corp.,
Ludwigshafen am Rhein, Germany.
[0148] When materials such as carbon black and/or graphite are
included in the polymer particles, improved insulating properties,
as exemplified by higher R values for materials containing carbon
black or graphite (as determined using ASTM-C518), are provided. As
such, the R value of the expanded polymer particles containing
carbon black and/or graphite or materials made from such polymer
particles are at least 5% higher than observed for particles or
resulting walls that do not contain carbon black and/or
graphite.
[0149] The expanded polymers can have an average particle size of
at least 0.2, in some circumstances at least 0.3, in other
circumstances at least 0.5, in some cases at least 0.75, in other
cases at least 0.9 and in some instances at least 1 mm and can be
up to 8, in some circumstances up to 6, in other circumstances up
to 5, in some cases up to 4, in other cases up to 3, and in some
instances up to 2.5 mm. When the size of the expanded polymer
particles is too small or too large, the physical properties of LWC
walls made using the present LWC composition can be undesirable.
The average particle size of the expanded polymer particles can be
any value and can range between any of the values recited above.
The average particle size of the expanded polymer particles can be
determined using laser diffraction techniques or by screening
according to mesh size using mechanical separation methods well
known in the art.
[0150] In an embodiment of the invention, the polymer particles or
expanded polymer particles have a minimum average cell wall
thickness, which helps to provide desirable physical properties to
LWC walls made using the present LWC composition. The average cell
wall thickness and inner cellular dimensions can be determined
using scanning electron microscopy techniques known in the art.
[0151] The expanded polymer particles can have an average cell wall
thickness of at least 0.15 .mu.m, in some cases at least 0.2 .mu.m
and in other cases at least 0.25 .mu.m. Not wishing to be bound to
any particular theory, it is believed that a desirable average cell
wall thickness results when resin beads having the above-described
dimensions are expanded to the above-described densities.
[0152] In an embodiment of the invention, the polymer beads are
optionally expanded to form the expanded polymer particles such
that a desirable cell wall thickness as described above is
achieved. Though many variables can impact the wall thickness, it
is desirable, in this embodiment, to limit the expansion of the
polymer bead so as to achieve a desired wall thickness and
resulting expanded polymer particle strength. Optimizing processing
steps and blowing agents can expand the polymer beads to a minimum
of 1.75 lb/ft.sup.3 (0.028 g/cc).
[0153] This property of the expanded polymer bulk density, can be
described by pcf (lb/ft.sup.3) or by an expansion factor
(cc/g).
[0154] As used herein, the term "expansion factor" refers to the
volume a given weight of expanded polymer bead occupies, typically
expressed as cc/g.
[0155] In order to provide expanded polymer particles with
desirable cell wall thickness and strength, the expanded polymer
particles are not expanded to their maximum expansion factor; as
such an extreme expansion yields particles with undesirably thin
cell walls and insufficient strength. Further, the polymer beads
can be expanded at least 5%, in some cases at least 10%, and in
other cases at least 15% of their maximum expansion factor.
However, so as not to cause the cell wall thickness to be too thin,
the polymer beads are expanded up to 80%, in some cases up to 75%,
in other cases up to 70%, in some instances up to 65%, in other
instances up to 60%, in some circumstances up to 55%, and in other
circumstances up to 50% of their maximum expansion factor. The
polymer beads can be expanded to any degree indicated above or the
expansion can range between any of the values recited above.
Typically, the polymer beads or prepuff beads do not further expand
when formulated into the present concrete compositions and do not
further expand while the concrete compositions set, cure and/or
harden.
[0156] The prepuff or expanded polymer particles typically have a
cellular structure or honeycomb interior portion and a generally
smooth continuous polymeric surface as an outer surface, i.e., a
substantially continuous outer layer. The smooth continuous surface
can be observed using scanning electron microscope (SEM) techniques
at 1000.times. magnification. SEM observations do not indicate the
presence of holes in the outer surface of the prepuff or expanded
polymer particles. Cutting sections of the prepuff or expanded
polymer particles and taking SEM observations reveals the generally
honeycomb structure of the interior of the prepuff or expanded
polymer particles.
[0157] The polymer particles or expanded polymer particles can have
any cross-sectional shape that allows for providing desirable
physical properties in LWC-walls. In an embodiment of the
invention, the expanded polymer particles have a circular, oval or
elliptical cross-section shape. In embodiments of the invention,
the prepuff or expanded polymer particles have an aspect ratio of
1, in some cases at least 1 and the aspect ratio can be up to 3, in
some cases up to 2 and in other cases up to 1.5. The aspect ratio
of the prepuff or expanded polymer particles can be any value or
range between any of the values recited above.
[0158] In particular embodiments of the invention, the light-weight
concrete includes from 10 to 90 volume percent of a cement
composition, from 10 to 90 volume percent of particles having an
average particle diameter of from 0.2 mm to 8 mm, a bulk density of
from 0.028 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and
from 10 to 50 volume percent of sand and/or other fine aggregate,
where the sum of components used does not exceed 100 volume
percent.
[0159] Light-weight concrete compositions that are particularly
useful in the present invention include those disclosed in
co-pending U.S. application Ser. No. 11/387,198, the relevant
portions of the disclosure are incorporated herein by
reference.
[0160] The concrete wall forming system provided in the present
invention is less likely to deform and/or fracture due to lateral
concrete pressure when used as compared to prior art insulated
concrete forms. In the present wall forming system stress
concentrations are reduced by providing internal column form
surfaces designed such that the lateral pressure from concrete is
as evenly distributed as possible. In prior art all-foam ICFs, the
internal surfaces have edges that lead to stress concentrations at
the corners. By eliminating the stress concentrations in the
present wall forming system, the pressure at which deformation
and/or failure occurs is increased, reducing the likelihood of
deformation and/or failure of the wall forming system. Ultimately,
this allows the wall forming system to be made from lower density
foam (for the same performance as a higher density foam with
another design) or, at the same density, the present wall forming
system can be used for greater concrete pour heights.
[0161] When lightweight concrete is used in conjunction with the
present wall forming system, the density of the mold units can be
decreased further or, even greater concrete pour heights can be
used at the same mold unit density.
[0162] The present invention has been described with reference to
specific details of particular embodiments thereof. It is not
intended that such details be regarded as limitations upon the
scope of the invention except insofar as and to the extent that
they are included in the accompanying claims.
* * * * *