Note: Descriptions are shown in the official language in which they were submitted.
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INSULATED WALL STRUCTURE
This invention generally concerns a component and system used to build
up permanent hardenable material walls in building construction. This
invention
particularly concerns a component and system that remains in place after a
hardenable
material, such as concrete, used to form the walls hardens. This invention
more
particularly concerns such a component and system wherein at least one, and
preferably
both, of the interior and exterior surfaces of the wall constitute a portion
of the
component.
1 o In North America, concrete wall fabrication typically entails several
steps. First, construct form walls that establish a cavity or space. Second,
pour
concrete into the cavity or space. Third, allow the concrete to set or cure
sufficiently to
allow removal of the form walls. Fourth, remove the form walls.
In residential construction, concrete basement wall and other concrete
15 wall fabrication employs the above procedure. After completing concrete
wall
fabrication, one then builds wood framing as required on top of the concrete
walls;
beside the concrete walls or both. A typical next step involves inserting
insulation
between wood framing members. After that, one then finishes the wall both
inside and
out.
2 o The foregoing practices are time-consuming, inefficient, expensive and
wasteful, particularly of materials and labor used to fabricate and then
remove form
walls. As common construction practices, especially in colder climates,
dictate that all
walls, including basement walls, be insulated, the need to remove form walls
and then
build and insulate wood frame walls delays subsequent building construction
steps.
2 5 An alternate procedure, practiced for several years, particularly in
Europe, combines a number of construction steps by using a foam insulating
material to
fabricate permanent form walls. Because the foam insulating material remains
in place,
no further insulation need be installed and finishing materials may be applied
to interior
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and exterior walls as desired. This procedure works for both basement walls
and
above-ground walls.
United States Patent Number (USP) 5,657,600 discloses a building
component comprising first and second high density foam panels arranged in a
spaced
apart, parallel relationship to each other. At least two bridging members span
the space
between the panels and connect the panels to each other by being molded into
the
panels. Each bridging member has a pair of elongated end plates oriented
vertically and
abutting against outer surfaces of the foam panels. The bridging member may
take on
an X-shape and be fabricated from a plastic material such as high density,
flame-
1 o retardant polyethylene, flame-retardant polypropylene, or polystyrene.
USP 4,730,422 discloses an insulating non-removable type concrete wall
forming structure, device and system for attaching wall coverings thereto. In
modular
synthetic foamed plastic concrete form structures, a number of pairs of
modular
concrete impervious forming panels are stacked on top of each other and linked
end to
1 s end. The panel pairs include vertically spaced rows of T-shaped tie slots
into which T-
shaped ends of synthetic plastic ties slideably fit. The outer surfaces of the
slot sections
have embossed tie-locator indicia thereon that enable fasteners to be screwed
through
the panel into the synthetic plastic ties to securely anchor exterior wall
finishing
covering to the panels or wall sections.
2 o USP 4,889,310 discloses an improved concrete forming system that
comprises a series of opposed first and second polystyrene foam panels
connected in
opposed, parallel, spaced-apart relationship. The foam panels have vertically
aligned
tie slots defined along their upper and lower edges. Plastic ties fit into the
tie slots to
hold the foam panels in their spaced-apart configuration. Each tie end has
spaced-apart,
2s T-shaped inner and outer paddle members that fit against, respectively, the
inner and
outer panel surfaces. The tie ends may be broken off after the concrete
hardens if one
desires to remove either or both of the foam panels. The ties may be modular
in that
they comprise tie ends and a spacer strap that can be lengthened or shortened
as desired
to vary the spacing between the foam panels.
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USP 4,936,540 discloses ties for interlocking a pair of spaced-apart form
panels such as foam panels. The ties have at least one beveled end that allows
it to be
forced through the foam panels without first cutting a tie slot. The ties may
also have
an integrally formed end plate opposite the beveled end. Once the beveled end
passes
through both spaced-apart foam panels, a spacer may be inserted between the
panels to
maintain proper alignment and a gusset plate fitted over the beveled end to
hold the
panels in place.
USP 5,107,648 discloses an insulated wall construction using tongue-
and-groove foam boards held in a spaced-apart configuration by spacer rod
assemblies.
to The spacer rod assemblies comprise an external support plate with a rod
receiving
segment that passes through the foam board, an internal support plate that
slides over
the rod receiving segment, a spacer rod that fits into rod receiving segments
of both
boards and locking pins that hold an end of the spacer rod in place within
each rod
receiving segment. The spacer rod may take on any of a number of
configurations
i s ranging from cylindrical (both solid and hollow), through shaped (other
than
cylindrical) to externally screw threaded. In the latter configuration, the
rod receiving
segments are internally screw threaded. The external support plates provide a
foundation for covering material such as gypsum board and stucco.
The present invention is an insulated, wall form comprising a first panel
2 o segment, a second panel segment, and a plurality of connectors, the first
panel segment
and the second panel segment each being generally planar structures, the first
and
second panel segments being spaced apart from each other so as to constitute a
cavity
and oriented such that the first panel segment is generally parallel to the
second panel
segment, the connectors each having a first end and a second end that is
remote from
2 5 the first end, the first end being removably attached to the first panel
segment and the
second end being removably attached to the second panel segment, the plurality
of
connectors maintaining the first and second panel segments in a spaced apart
generally
parallel orientation, the wall form defining a cavity adapted to receive a
hardenable
filler material.
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Brief Description of the Drawings
Figure (Fig.) 1 is fragmented top-plan view of a portion of one
embodiment of a panel segment.
Fig. 2 is a fragmented top-plan view of a portion of the embodiment
shown in Fig. 1 together with a portion of a connector.
Fig. 3 is a horizontal cross-sectional view of an insulated wall form that
includes two opposed panel segments of the type shown in Fig. l and a
plurality of
connectors.
Fig. 4 is a fragmented top-plan view of a portion of an alternate and
1 o preferred embodiment of a panel segment.
Fig. 1 illustrates a portion of a wall panel segment 20 suitable for use as
part of wall form 10 (shown in Fig. 3). Panel segment 20 is a laminar
structure that
includes inner layer 21 and outer layer 25. Inner layer 21 has an inner
surface 22 and a
spaced-apart, generally parallel outer surface 23. Inner layer 21 also has
defined therein
a plurality of passageways 24 that intersect and are in fluid communication
with both
the inner surface 22 and the outer surface 23. Outer layer 25 has an inner
surface 26
and a spaced-apart, generally parallel outer surface 28. Outer layer 25 also
has defined
therein a plurality of slots 27. Outer surface 23 of inner layer 21 and inner
surface 26 of
outer layer 25 are in operative contact with each other. Such operative
contact desirably
occurs by way of an adhesive material (not shown) disposed between surfaces 23
and
26. Slots 27, preferably T-shaped, are in fluid communication with passageways
24 of
inner layer 21. A combination of slots 27 and passageways 24 constitutes a
plurality of
channels that are adapted to receive connector ends (shown in Figs. 2 and 3).
The channels in wall panel segment 20, also referred to as a first panel
segment, preferably comprise an elongated aperture in inner layer 21,
preferably a foam
layer, and a cavity in outer layer 25. The aperture and cavity are in fluid
communication with each other. The cavity and the aperture each have a width.
The
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width of the cavity is preferably greater than the width of the aperture. Such
channels
readily receive connectors such as connectors 30 shown in Fig. 2.
Fig. 2 illustrates a fragmentary section of wall panel segment 20 together
with a fragmentary cross-section of a connector 30. Connector 30 has a first
end 31
and, spaced apart by way of center shaft 33, a second end 35 (shown in Fig.
3). An
intermediate portion of shaft 33 proximate to, but spaced apart from, each of
ends 31
and 35 is externally screw-threaded. Fig. 2 shows screw-threaded segment 32
proximate to end 31. Screw-threaded segment 34 (not shown) is proximate to,
but
spaced apart from, end 35 (shown only in Fig. 3). Internally screw-threaded
1 o compression fittings 36 threadably engage externally screw-threaded shaft
portions 32
and 34 (not shown) so as to hold connector 30 in a fixed position relative to
wall panel
segments 20 and 40 (shown in Fig. 3).
Although not shown in Figs. 2 and 3, wall panel segments 20 and 40
preferably further comprise a sealing means that is disposed between a
connector end,
is such as first end 31 of connector 30, and its associated compression
fitting or nut 36
such that the sealing means is in operative or sealing contact with both the
inner foam
layer 21 of panel segment 20 or inner foam layer 41 of panel segment 40,
whichever is
appropriate, and compression nut 36.
Skilled artisans readily recognize that a variety of substitutes may serve
2 o the same purpose as the combination of externally screw-threaded shaft
segments 32
and 34 and internally screw-threaded compression fittings 36. By way of
example only
and without limit, such substitutes include one or more projections from the
shaft over
which a collar slides, then twists and locks or a series of rings on the shaft
over which a
collar with internally defined ridges or lock means slides and then stays in
position.
2 s Skilled artisans also recognize that compression fittings 36 and any of
the alternatives
need not be solid or continuous shapes. In fact, for ease of installation, the
fittings
preferably have a slot that communicates between an external edge of the
fitting and a
central aperture of the fitting such as the internally screw-threaded portion
of fittings
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36. The slot allows the fitting to slide onto the center shaft 33 of connector
30 at a field
or assembly site.
Fig. 3 illustrates wall form 10. Form 10 comprises wall segment 20,
wall panel segment 40 and a plurality of linked connectors 30. Wall panel
segment 40
may be, and preferably is, a mirror-image of wall segment 20 save for the
material from
which outer layers 25 and 45 are fabricated. Accordingly, wall panel segment
40 is a
laminar structure that includes inner layer 41 and outer layer 45. Inner layer
41 has an
inner surface 42 and a spaced-apart, generally parallel outer surface 43.
Inner layer 41
also has defined therein a plurality of passageways 44 that intersect and are
in fluid
1 o communication with both the inner surface 42 and the outer surface 43.
Outer layer 45
has an inner surface 46 and a spaced-apart, generally parallel outer surface
48. Outer
layer 45 also has defined therein a plurality of slots 47. Outer surface 43 of
inner layer
41 and inner surface 46 of outer layer 45 are in operative contact with each
other. Such
operative contact desirably occurs by way of an adhesive material (not shown)
disposed
between surfaces 43 and 46. Slots 47, preferably T-shaped, are in fluid
communication
with passageways 44 of inner layer 41. Like the combination of slots 27 and
passageways 24 shown in Fig. 1, a combination of slots 47 and passageways 44
yields a
plurality of channels that are adapted to receive connector ends (shown in
Figs. 2 and
3).
2 o The channels in wall panel segment 40, also referred to as a second
panel segment, preferably comprise an elongated aperture in inner layer 41,
preferably a
foam layer, and a cavity in outer layer 45. As with their counterparts in
layers 21 and
25, the aperture and cavity are in fluid communication with each other and
each has a
width with the width of the cavity preferably being greater than that of the
aperture.
The channels are preferably adapted to receive connector ends such as those of
connectors 30 shown in Figs. 2 and 3.
The connectors, such as connectors 30, are preferably disposed in a
number of connector assemblies. Each connector assembly more preferably
comprises
a lattice wherein each connector is oriented so as to be spaced apart from and
generally
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parallel to at least one other connector. The orientation is desirably
maintained by way
of at least one connector link between each of two adjacent connectors within
a
connector assembly. As shown in Fig. 3, the plurality of connectors 30 are
linked
together or interconnected by way of a plurality of links 32. Fig. 3 shows two
links 32
between each pair of connectors 30. While two links 32 per pair of connectors
30 yield
very satisfactory results in terms of simplicity and spacing uniformity, one
may use a
greater or lesser number of links without departing from the scope or spirit
of the
invention. In fact, one may eliminate the links altogether if so desired. The
links 32
may be flexible to accommodate storage and handling before use as part of wall
form
l 0 10. Links 32 may also be rigid to provide additional stability before
disposing a
hardenable material into a cavity formed by inner surfaces 22 (Fig. 1 ) and 42
of
corresponding panel segments 20 and 40.
Ends 31 and 35 of connectors 30 may take on any of a variety of shapes
without departing from the spirit and scope of the present invention. The
shape simply
needs to accommodate a slideable engagement with at least a portion of slots
27 (Fig.2)
and 47 of corresponding panel segments 20 and 40. The shape desirably provides
frictional, but slideable engagement with surfaces of slots 27 and 47. Shapes
include,
for example, squares, rectangles, parallelograms, trapezoids, polygons (e.g.
hexagons
and octagons), circles and ellipses. While the shapes preferably have a
thickness that is
2 o at least equal to the width of slots 27 and 47, they more preferably have
a thickness that
slightly exceeds that width in order to provide a good friction fit.
A particularly preferred connector is a foldable connector such as that
disclosed in Design Patent 383,373, USP 4,706,429, USP 4,730,422 and USP
4,885,888. The relevant teachings of the four patents are incorporated herein
by
2 5 reference. By using such connectors, one can assemble the insulated wall
form of the
present invention and then collapse or fold it about the connectors into a
flattened
configuration for shipping or transport. When ready for use at a job site, one
can
simply unfold it about the connectors and set it into place.
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Fig. 4 shows an alternate preferred embodiment of a panel segment
designated by reference numeral 20'. Panel segment 20' differs from panel
segment 20
in that outer layer 25' has no slots defined therein whereas outer layer 25
has slots 27
defined therein. Like segment 20, segment 20' is a laminar structure that
includes inner
s layer 21' and outer layer 25'. Inner layer 21' has an inner surface 22' and
a spaced-
apart, generally parallel outer surface 23'. Inner layer 21' also has defined
therein a
plurality of passageways 24' that intersect and are in fluid communication
with both the
inner surface 22' and the outer surface 23'. Passageways 24' preferably have a
T-shape
similar to that provided by a combination of passageways 24 and slots 27 of
panel 20.
1 o Although Fig. 4 shows passageways 24' as being located proximate to or
intersecting
with outer surface 23' of inner layer 21', passageway may also be displaced
toward
inner surface 22' so that it a) is entirely located within inner layer 21 ",
b) intersects only
with inner surface 22' and c) is in fluid communication only with inner
surface 22'.
Outer layer 25' has an inner surface 26' and a spaced-apart, generally
parallel outer
15 surface 28'. Outer surface 23' of inner layer 21' and inner surface 26' of
outer layer 25''
are in operative contact with each other. As with panel 20, such operative
contact
desirably occurs by way of an adhesive material (not shown) disposed between
surfaces
23' and 26'.
T-shaped passageways 27 and 24' may be fabricated by any suitable
2 o means. For example, one may use a router or other similar device to cut
the
passageways after placing inner layer 21' and outer layer 25' in operative
contact with
each other. A more preferred technique uses narrow (relative to outer layer
25') strips
of inner layer 21'. The outer surface 23' of inner layer 21' has defined
therein a
longitudinal step or shoulder on each side such that when two strips of inner
layer 21'
2 5 are placed proximate to, but not in physical contact with, each other,
they define a T-
shaped passageway 24'.
Outer panel 40 may be, and preferably is, modified in the same manner
as inner panel 20 to yield an outer panel 40' (not shown). Similarly, an
alternate and
preferred wall form 10' includes inner panels 20' and outer panels 40' in
place of inner
3o panels 20 and outer panels 40. One may, of course, mix and match the panels
to
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provide, for example an inner panel 20 and an outer panel 40', two inner
panels 20, 20'
or a combination of one panel 20 and one panel 20', or two outer panels 40,
40' or a
combination of one panel 40 and one panel 40' depending upon factors such as
design
choice and wall location.
Inner panels 20 and 20' are laminar structures that comprise at least two
layers, an inner layer that comprises an insulating foam material and an outer
layer that
comprises an interior surface material. The interior surface material is
selected from
gypsum board, wallboard, wood, paneling, brick, fiberboard, vinyl boards or
any other
material that provides acceptable aesthetic performance, functional
performance or
1 o both.
Outer panels 40 and 40' are laminar structures that comprise at least two
layers, an inner layer that comprises an insulating foam material and an outer
layer that
comprises an exterior surface material. The exterior surface material is
selected from
wood, brick, stucco, concrete block, cementitious board laminate, fiberboard,
vinyl
15 siding, wood laminates, brick veneer, or any other material that provides
acceptable
functional performance and, desirably, aesthetic appeal.
The insulating foam material may be any cellular insulating material that
is rigid enough to substantially maintain its shape during the construction
and use of the
wall form. Preferably, the insulating foam panel is a cellular polymeric foam.
It may
2 o be made from a thermosetting or thermoplastic polymer. Suitable polymers
include
polyethylene (including low density polyethylene (LDPE), linear low density
polyethylene (LLDPE), high density polyethylene (HDPE) and substantially
linear
ethylene interpolymers), polypropylene, polyurethane, polyisocyanurate,
ethylene- vinyl
acetate copolymers, polyvinyl chloride, phenol-formaldehyde resins, ethylene-
styrene
2 5 interpolymers and alkenyl aromatic polymers and copolymers, including
those derived
from alkenyl aromatic compounds such as styrene, alphamethylstyrene,
ethylstyrene,
vinyl benzene, vinyl toluene, chlorostyrene, and bromostyrene. A preferred
alkenyl
aromatic polymer is polystyrene. Minor amounts of monoethylenically
unsaturated
compounds such as C2_6 alkyl acids and esters, ionomeric derivatives, and C4_6
dimes
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may be copolymerized with alkenyl aromatic compounds. Examples of
copolymerizable compounds include acrylic acid, methacrylic acid, ethacrylic
acid,
malefic acid, itaconic acid, and acrylonitrile. Blends of any two or more of
the
foregoing or blends of any of the foregoing with another polymer or resin are
suitable.
Rigid polyurethane, polystyrene, polyisocyanurate and phenolic foams are
preferred,
with polystyrene and polyisocyanurate foams being especially preferred. The
foams
may be used as is or they may have an external surface mechanically modified.
Mechanical modification includes operations such as sanding, scraping, planing
or any
other action that alters the external surface from its as-formed state.
1 o Suitable alkenyl aromatic polymers include those derived from alkenyl
aromatic compounds such as styrene, alphamethylstyrene, ethylstyrene, vinyl
benzene,
vinyl toluene, chlorostyrene, and bromostyrene. A preferred alkenyl aromatic
polymer
is polystyrene. Minor amounts of monoethylenically unsaturated compounds such
as
C2_6 alkyl acids and esters, ionomeric derivatives, and C4-6 dimes may be
15 copolymerized with alkenyl aromatic compounds. Examples of copolymerizable
compounds include acrylic acid, methacrylic acid, ethacrylic acid, malefic
acid, itaconic
acid, acrylonitrile, malefic anhydride, methyl acrylate, ethyl acrylate,
isobutyl acrylate,
n-butyl acrylate, methyl methacrylate, vinyl acetate and butadiene. Preferred
foams
comprise substantially (i.e., greater than 95 percent) and most preferably
entirely of
2 o polystyrene.
Any conventional process may prepare insulating foam materials, with
extrusion foaming being preferred.
In order to ease fabrication of wall forms 10 and 10' as well as decrease
assembly time thereof, one may dispose a lubricating material on surfaces of
connector
25 ends 31 and 35 that will come in contact with slots 27 and 47 of wall panel
segments 20
and 40 or slots 24' and 44' (not shown) of wall panel segments 20' and 40'.
Suitable
lubricating materials include mineral oils, synthetic oils and fluorocarbons.
Wall forms 10 and 10' define a cavity designed to accommodate and
shape a load-bearing material, preferably a hardenable material such as
concrete, fiber-
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reinforced concrete or rebar-reinforced concrete. If desired, the cavity may
further
comprise a cavity liner. The cavity liner, when used, is adjacent to and in
physical
contact with at least a surface portion of the inner surfaces of the selected
combination
of inner and outer panels 20, 20', 40 and 40'. The inner and outer surfaces
are,
respectively, 22, 22', 42 and 42' (not shown). The cavity liner comprises a
film made
of a thermoplastic polymer that is a polyolefm such as polypropylene, low
density
polyethylene, high density polyethylene or linear low density polyethylene, a
polyamide, an alkenyl aromatic polymer such as polystyrene, a polyvinyl
chloride), a
polycarbonate, an acrylic polymer, or a polyester. The film may be non-
oriented,
1 o uniaxially oriented or biaxially oriented. The film may contain one or
more
conventional additives such as fillers, pigments, colorants, antioxidants,
ultraviolet light
stabilizers, fire retardant materials (it being recognized that all organic
materials will
burn under the right conditions), and process aids.
Any load-bearing material may be used that will provide adequate strength and
rigidity. In simpler or less expensive wall constructions, the load-bearing
material can
be, for instance, wood, stone, dirt, sand, metal. These are advantageously
used in a
particulate form so they can be readily poured into the form assemblage as a
loose fill.
However, this invention is particularly adapted for use with a load-bearing
material that
is poured into place after the system of wall panels, insulating foam panels
and panel
2 o connectors is assembled, and then hardened. Accordingly, any of the many
forms of
cement such as Portland cement, aluminous cement and hydraulic cements are
suitable,
as are hardenable clays such as adobe, mortar, and hardenable mixtures of
clays and
cement. It is generally preferred for reasons of cost and properties to use
concrete,
which is an aggregate of a material such as gravel, pebble, sand, broken
stone, slag, or
2 5 cinders, in a hardenable matrix, usually mortar or a form of cement such
as Portland,
aluminous or hydraulic cement. Generally, any concrete or aggregate that is
useful in
preparing load-bearing building walls is suitable for use with this invention.
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