Note: Descriptions are shown in the official language in which they were submitted.
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WATER-PROOF INSULATED CONCRETE FORMS
The present invention relates generally to an insulated concrete form
and more specifically it relates to a water-proof insulated concrete forms for
efficiently providing a quality and cost effective method of water-proofing
insulated
concrete forms on foundation walls and the like and to eliminate water
penetration
through thereof.
BACKGROUND OF THE INVENTION
Any discussion of the related art throughout the specification should in
no way be considered as an admission that such related art is widely known or
forms part of common general knowledge in the field.
Insulated concrete forms have been in use for years. Insulated
concrete forms have generally been comprised of interlocking modular units
which
are dry-stacked and filled with concrete. The insulated concrete forms are
generally
utilized as formwork for concrete that remains in place in a building as
permanent
building insulation for reinforced concrete walls, floors and roofing.
After placement of the concrete forms, it is generally desired to apply a
waterproofing membrane to the outer surface of the forms to prevent water from
penetrating and subsequently damaging the forms. The time and labor required
to
cut and affix each section of waterproofing membrane upon the outer surface of
the
forms can be very extensive. This can lead to expensive costs for both the
home
owner and the installation crew.
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In addition, inexperienced laborers can often times not precisely place the
waterproofing membrane upon the forms and/or to adequately overlap the seams
between the modular forms. This can lead to water penetrating through the gaps
between the waterproofing membrane, thus penetrating the concrete forms and
causing damage thereto. Because of the inherent problems with the related art,
there is a need for a new and improved water-proof insulated concrete forms
for
efficiently creating a prefabricated water-proof insulated concrete form for
efficiently
providing a quality and cost effective method of water-proofing insulated
concrete
forms on foundation walls and the like and to eliminate water penetration
through
thereof.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided a
prefabricated water-proof concrete form, comprising:
a first modular concrete form having a first panel, a second panel, and
a webbing retaining said first panel and said second panel in a spaced-apart
relationship; and
a waterproofing means applied to an exterior surface of said first panel
and/or said second panel, wherein said waterproofing means is applied in a
prefabricated manner;
wherein said waterproofing means includes a first flap extending
outwardly therefrom and entirely along a first end of said peripheral edge of
said first
panel and/or second panel;
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wherein said first flap is adapted to overlap a seam formed by a first
mating modular concrete form along said first end to form a watertight seal
between
thereof;
wherein said waterproofing means includes a second flap extending
outwardly therefrom and entirely along a second end of said peripheral edge of
said
first panel and/or second panel;
wherein said second flap is adapted to overlap a seam formed by a
second mating modular concrete form along said second end to form a watertight
seal between thereof.
Preferably said first panel and said second panel are comprised of an
insulated structure.
Preferably said first panel and said second panel are comprised of a
foam structure.
Preferably said waterproofing means includes a membrane covering
an entire said exterior surface of said first panel and/or said second panel.
Preferably said membrane is comprised of a tar membrane structure.
Preferably said membrane is comprised of a thermoseal membrane
structure.
Preferably said membrane has an inner layer film layer and an outer
waterproofing layer.
Preferably said outer layer is comprised of a stucco textured material.
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Preferably said first flap and said second flap are integrally formed with
said membrane.
Preferably said waterproofing means includes a spray coating covering
an entire said exterior surface of said first panel and/or said second panel.
Preferably said first flap and said second flap each have an attachment
surface upon an inner side.
Preferably said attachment surface is comprised of an adhesive.
According to a second aspect of the invention there is provided a
prefabricated water-proof construction form, comprising:
a first construction panel;
a second construction panel;
a webbing retaining connected to interior surfaces of said first
construction panel and said second construction panel and extending at least
partially therebetween to maintain said first construction panel and said
second
construction panel in a spaced-apart relationship;
a waterproof membrane applied to an exterior surface of said first
construction panel and/or second construction panel; and
at least one flap extending outwardly from and entirely along at least
one end of a peripheral edge of said first construction panel and/or second
construction panel;
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wherein said at least one flap has an adhesive attachment surface
located on an inner side and wherein said at least one flap integrally extends
from
said membrane to retain a waterproof seal between thereof.
Preferably said at least one flap includes at least two flaps each
5 extending along a respective end of said peripheral edge of said first
construction
panel and/or second construction panel.
Preferably said at least one flap includes at least three flaps each
extending along a respective end of said peripheral edge of said first
construction
panel and/or second construction panel.
Preferably said first construction panel and said second construction
panel are comprised of an insulated foam structure.
Preferably said membrane has an inner layer film layer and an outer
waterproofing layer.
Preferably said outer layer is comprised of a stucco textured material.
Preferably said membrane is comprised of a thermoseal membrane
structure.
According to a third aspect of the invention there is provided a
prefabricated water-proof concrete form, comprising:
a first modular concrete form having a first panel, a second panel, and
a webbing retaining said first panel and said second panel in a spaced-apart
relationship;
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wherein said first panel and said second panel are comprised of an
insulated foam structure;
wherein said first panel and said second panel each include an
interlocking system along a face of a peripheral edge to receive and secure
mating
concrete forms thereto;
a waterproof membrane applied to an exterior surface of said first
panel, wherein said waterproof membrane is applied in a prefabricated manner
to an
entire exterior surface of said first panel;
wherein said membrane has an inner layer film layer adjacent said
exterior surface of said first panel and an outer waterproofing layer and
wherein said
membrane is comprised of a thermoseal membrane structure;
a first waterproof flap integral with said waterproof membrane and
extending outwardly from and entirely along a first end of said peripheral
edge of
said first panel;
wherein said first flap has an adhesive surface upon an entire inner
side;
wherein said first flap has a removable film to temporarily cover said
adhesive surface;
wherein said first flap is adapted to overlap a seam formed by a first
mating modular concrete form along said first end and adhesively attach
thereto to
form a watertight seal between thereof; and
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second waterproof flap integral with said waterproof membrane and
extending outwardly from and entirely along a second end of said peripheral
edge of
said first panel;
wherein said second flap has an adhesive surface upon an entire inner
side;
wherein said second flap has a removable film to temporarily cover
said adhesive surface;
wherein said second flap is adapted to overlap a seam formed by a
second mating modular concrete form along said second end and adhesively
attach
thereto to form a watertight seal between thereof.
As described hereinafter, the arrangement described herein proves a
system for efficiently providing a quality and cost effective method of water-
proofing
insulated concrete forms on foundation walls and the like and to eliminate
water
penetration through thereof. The invention generally relates to an insulated
concrete
form which includes a first panel, a second panel, webbing retaining the
panels in a
spaced-apart relationship, and a waterproofing means applied in a
prefabricated
manner to an exterior surface of at least one of the panels. The waterproofing
means includes a first flap extending outwardly from and entirely along a
first end of
the peripheral edge of the panel and a second flap extending outwardly from
and
entirely along a second end of the peripheral edge of the same panel. The
first flap
and the second flap are adapted to overlap a seam formed by a first mating
modular
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concrete form along the first end and a second mating modular concrete form
along
the second end to form a watertight seal between thereof.
There has thus been outlined, rather broadly, some of the features of
the invention in order that the detailed description thereof may be better
understood,
and in order that the present contribution to the art may be better
appreciated.
There are additional features of the invention that will be described
hereinafter and
that will form the subject matter of the claims appended hereto. In this
respect,
before explaining at least one embodiment of the invention in detail, it is to
be
understood that the invention is not limited in its application to the details
of
construction or to the arrangements of the components set forth in the
following
description or illustrated in the drawings. The invention is capable of other
embodiments and of being practiced and carried out in various ways. Also, it
is to
be understood that the phraseology and terminology employed herein are for the
purpose of the description and should not be regarded as limiting.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the
present invention will become fully appreciated as the same becomes better
understood when considered in conjunction with the accompanying drawings, in
which like reference characters designate the same or similar parts throughout
the
several views, and wherein:
FIG. 1 is an upper perspective view of the present invention.
FIG. 2 is a side view of the present invention.
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FIG. 3 is a top view of the present invention.
FIG. 4 is a magnified view of the bottom flap extending from the
peripheral edge of the first panel.
FIG. 5 is a magnified view of the bottom flap extending from the
peripheral edge of the first panel, showing an alternate embodiment of the
membrane, wherein the membrane is comprised of a stucco structure.
FIG. 6 is a magnified view of the bottom flap extending from the
peripheral edge of the first panel, showing an alternate embodiment of the
membrane, wherein a spray coating is used for the body portion of the
membrane.
FIG. 7 is an upper perspective view of a series of modular forms
connected together and sealed in a watertight manner via the overlapping
membrane flaps.
FIG. 8 is a side view of an alternate embodiment of the membrane.
DETAILED DESCRIPTION OF THE INVENTION
A. Overview.
Turning now descriptively to the drawings, in which similar reference
characters denote similar elements throughout the several views, FIGS. 1
through 8
illustrate a water-proof insulated concrete forms 10, which comprises a first
panel
21, a second panel 24, webbing 30 retaining the panels 21, 24 in a spaced-
apart
relationship, and a waterproofing means applied in a prefabricated manner to
an
exterior surface 23 of at least one of the panels 21, 24. The waterproofing
means
generally includes a membrane having a first flap 44a extending outwardly
therefrom
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and entirely along a first end of the peripheral edge of the panel 21 and a
second
flap 44b extending outwardly therefrom and entirely along a second end of the
peripheral edge of the same panel 21. The first flap 44a and the second flap
44b
are adapted to overlap a seam formed by a first mating modular concrete form
along
5 the first end and a second mating modular concrete form along the second end
to
form a watertight seal between thereof. Alternately, a third flap 44c may be
formed
and used along a third end of the panel 21 to form a water tight seal with a
third
mating concrete form.
B. Modular Form.
10 The modular forms 20 of the present invention are generally comprised
of concrete forms that may be attached together via an interlocking system 27
to
form a wall in which to receive and hold concrete. In the preferred
embodiment, the
modular forms 20 include a first panel 21 and a second panel 24 having
substantially
similar construction and each having peripheral edges that preferably align
with each
other.
The panels 21 are maintained in a spaced-apart and parallel
relationship via a webbing 30. The webbing 30 is generally comprised of a
plurality
of separate structures spaced apart along a linear internal axis of the form
20 and
each having a first mount 31 upon an interior surface 22 of a first panel 21,
a second
mount 32 along an interior surface 25 of the second panel 24, and a connecting
structure 33 to connect the first mount 31 to the second mount 32 and also
serve to
support and strengthen the concrete poured between the first panel 21 and the
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second panel 24. The first mount 31 and the second mount 32, in addition to
stabilizing the panels 21, serve as studs for attaching objects (e.g.
sheetrock) to the
exterior surfaces 23, 26 of the panels 21. The webbing 30 is generally
comprised of
a plastic material and may have notches to allow for proper rebar placement.
The first panel 21 and the second panel 24 are preferably comprised of
an insulated material and are further preferably comprised of an extruded
polystyrene foam material.
The foam panels 21 and the webbing 30 are preferably prefabricated
to a single modular form 20 prior to installation at the job-site.
Each of the panels 21 preferably include an interlocking system 27
surrounding an outer face of the peripheral edge of the panels 21. The
interlocking
system 27 allows for other modular forms to be easily attached and detached
thereto
to form the wall receiving the concrete in a building-block type manner. The
interlocking system 27 of each form 20 preferably includes knobs 28a and
recesses
28b which mate with a like structure of an adjacent form 20. The forms 20 are
generally stacked in an overlapping manner. The knobs 28a and recesses 28b of
the interlocking system 27 are generally only located at the top and bottom of
the
panels 21, wherein rigid interlocking grooves 29 are located along the
longitudinal
ends.
It is appreciated that the forms 20 utilized with the present invention
may be comprised of various other embodiments, all which generally include at
least
a first panel 21. The panels 21 may comprise various other construction
related
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materials and may be used for various supporting applications, similar to or
different
than concrete. In addition, the forms 20 may be uninsulated in various
embodiments
and applications of the present invention. The forms 20 may also be
rectangular in
shape, be shaped to fit a corner, or various other shapes may be appreciated.
C. Waterproofing Means.
The waterproofing means of the present invention is preferably applied
to the exterior surface 23 of the panel(s) 21 in a prefabricated manner, such
as
during manufacturing of the forms 20, so that the waterproofing means is
attached to
a respective form 20 prior to installation. Generally, the waterproofing means
includes a membrane 40 which includes a body portion 41 that is applied to the
entire exterior surface 23 of the first panel 21 and a plurality of flaps 44a,
44b, 44c
extending from the body portion 41 beyond the peripheral edge of the body
portion
41 and the first panel 21 of the form 20 to attach to a mating concrete form
and
comprise a watertight seal between thereof. Thus, the peripheral edge of the
body
portion 41 matches and follows the peripheral edge of the exterior surface 23
of the
first panel 21.
It is also appreciated that the membrane 40 may be applied to the
exterior surface 26 of the second panel 24 in different applications; however
it is
generally only needed to apply waterproofing to the panel 21 being on the
exterior of
the foundation wall, above ground wall, or the like. The waterproofing means
also
provides increased insulation properties to the panels 21 as appreciated.
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The membrane 40 is generally comprised of a tar membrane structure
and has an outer layer 42 and an inner layer 43. The outer layer 42 is
preferably
comprised of a 56 mil thick polymeric waterproofing structure and the inner
layer 43,
which underlies the outer layer 42, is preferably comprised of a 4 mil thick
gross
laminated polyethylene carrier film 46. The outer layer 42 and the inner layer
43 are
laminated together under a quality-controlled production process and
subsequently
added to the first panel 21 under adequate heat after the form 20 leaves the
mold.
The excess membrane 40 extending from the peripheral edge of the first panel
21
forms the waterproof flaps 44a, 44b, 44c which will be described in the next
section.
The described materials are meant to be utilized in below-ground applications,
such
as a basement foundation. It is appreciated that various thicknesses and types
of
materials may be utilized rather than the preferred embodiment.
For instance, in an alternate above ground embodiment of the present
invention, wherein the outer layer 42 is generally visible, the outer layer 42
may be
comprised of a more finished appearance that would be suitable for the outside
of a
building. One example of a finished outer layer 42 is a texture similar to
stucco for
the outer layer 42. A protective film 48 that can be pulled off at the end of
the
construction to prevent damage to the finished appearance is also generally
used.
Various colors may also be appreciated with the outer layer 42.
The inner layer 43 also generally is comprised of a type of adhesive
that retains the membrane 40 to the first panel 21 over a prolonged period and
is
especially suited for being affixed to the foam type materials. The body
portion 41
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and the first panel 21 are then maintained in a parallel relationship with the
planar
body portion 41 being tightly affixed to the exterior surface 23 of the first
panel 21 of
the form 20 via the inner layer 43.
Alternately, the body portion 41 of the waterproofing means may
comprise a spray coating 50 that is applied to the exterior surface 23 of the
first
panel 21 of the form 20. Like the membrane 40, the coating 50 is comprised of
a
waterproof composition to prevent water from penetrating the first panel 21
through
the coating 50. The membrane 40 and/or the coating 50 may also be comprised of
thermo seal structures in addition to the waterproofing capabilities.
D. Flaps.
The waterproofing means also includes flaps 44a, 44b extending from
the first end of the peripheral edge of the body portion 41 of the membrane 40
and/or coating 50 and extending from the second end of the peripheral edge of
the
body portion 41 of the membrane 40 and/or coating 50. The flaps 44a, 44b are
generally integral with the membrane 40 to provide a one-piece structure and
thus a
watertight seal between the flaps 44a, 44b and the membrane 40. In the case of
the
coating 50, the flaps 44a, 44b are also generally sealed to the coating 50 in
a
watertight manner to prevent any water penetration between the connecting
point of
the flaps 44a, 44b and the coating 50.
The flaps 44a, 44b extend outwardly from the peripheral edge of the
first panel 21 of the form 20 both entirely along a first end of the form 20
and entirely
along a second end of the form 20. The first end and the second end may be
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comprised of various ends; however it is appreciated that the first end is
generally
one of the vertically oriented ends (along opposing longitudinal ends) and the
second end is preferably a horizontally oriented end (along opposing top and
bottom
ends), thus being adapted to efficiently seal all seams between mating forms
20. A
5 third flap 44c may also be utilized to extend from a third end of the first
panel 21
(opposite the first end) and seal a seam defined by a third mating structure.
Each of the flaps 44a, 44b, 44c generally includes an attachment
surface 45 which is integral with the inner layer 43 of the membrane 40 and
also
have the integral outer surface, which can be of the various described
materials
10 (below ground and above ground applications). The attachment surface 45 is
preferably comprised of a waterproof adhesive material to be adhered to a
mating
form. The attachment surface 45 generally has a removable film 46 thereon that
protects the attachment surface 45 from engagement with foreign objects prior
to
installation and attachment with the mating form.
15 E. Operation of Preferred Embodiment.
In use, the modular forms 20 are stacked in a preferred manner to
comprise a wall to receive concrete therein. As the forms 20 are stacked, the
removable film 46 from each flaps 44a, 44b is removed when a mating form(s)
extends along an entire end of the form 20 having the flap 44a, 44b. The film
46 is
removed and the attachment surface 45 of the flap 44a, 44b is adhered to the
parallel and coplanar first panel of the mating form thus effectively creating
a
watertight seal between the forms over the seams.
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Unless otherwise defined, all technical and scientific terms used herein
have the same meaning as commonly understood by one of ordinary skill in the
art
to which this invention belongs. Although methods and materials similar to or
equivalent to those described herein can be used in the practice or testing of
the
present invention, suitable methods and materials are described above. All
publications, patent applications, patents, and other references mentioned
herein
are incorporated by reference in their entirety to the extent allowed by
applicable law
and regulations. In case of conflict, the present specification, including
definitions,
will control. The present invention may be embodied in other specific forms
without
departing from the spirit or essential attributes thereof, and it is therefore
desired that
the present embodiment be considered In all respects as illustrative and not
restrictive. Any headings utilized within the description are for convenience
only and
have no legal or limiting effect.
