BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to forming concrete beams and columns using a connectors, inner and outer rigid boards and a structural insulating core wall to form the beam and columns molds and the wall as a mold. (2) Background of the Invention
Today more and more steel or concrete post and beam buildings are being built. Construction techniques for building walls have been changing significantly including metal channel framing and stay-in-place insulated forms where concrete is installed within these forms.
Rigid insulation boards have been installed on metal channels for years Insulating walls have embedded channels within insulation blocks embedding the metal channels within the rigid insulation. Some insulated concrete forms (ICF's) have embedded plastic connectors within their rigid insulation blocks also separating the rigid foam from the plastic connectors.
There have been various attempts on creating a form mold to pour a concrete column or beam within a wall. Some patents uses metal channels to help reduce the pressure produced by using a rigid foam material to form concrete beam or columns. Another type of patents uses foam blocks with vertical and horizontal chambers to form concrete columns and beams. Another type of panel is a composite panel that uses fiber concrete boards the panel surfaces as well as interior bracing within the panel with rigid foam at the interior. Another type of panel is when the foam molds create a continuous chamber to pour a solid concrete wall.
The creation of a spacer blocks and spacer insulation walls allow various types of horizontal bracing channels and electrical chases or troughs to pass through the wall and concrete columns for additional flexibility and the various connectors to form the walls. In addition the structural insulating wall can be formed with a variety of closed cell rigid insulating materials like polystyrene, cellular light weight concrete or aerated autoclaved concrete all requiring various types of connectors.
(3) Description of Prior Art
A. Foam Block With Holes
In U.S. Pat. No. 7,028,440 (filed Nov. 29, 2003) by Brisson uses foam blocks with vertical holes to form concrete columns and uses a horizontal recess at the top of the panels to form a beam pocket. Since the holes for the concrete only support the foam, the size is limited as the concrete will deform as well as break the foam panels. Again the beam pocket is also fragile as there is not support to stop the wet concrete from deforming the beam.
A. Concrete Column & Beam Using Metal Channels
Panels are formed here using rigid boards and or rigid insulation along with metal channels to form concrete columns or beams. The light gauge framing adds support means for installing drywall or other surface building materials.
In U.S. Pat. No. 6,401,417 by LeBlang shows how a concrete column and beam can be installed within a wall using metal channels and rigid insulation/hard board or as a column and beam within a wall and or as a separate beam using a rigid board between the channels to enlarge the beams or columns.
B. Foam Block With Holes.
In U.S. Pat. No. 6,131,365 (filed Oct. 2, 1998) by Crockett has a wall unit system with a “tie down space” is in the middle of the wall for installing steel reinforcing to create a concrete column and a horizontal concrete beam is installed at the top of the wall. The interior concrete column and beam does not show any prior art plus the interior insulated structural material also does not pertain to the pending patent.
E. Triangular Stud
Light gauge metal is configured in many different shapes and therefore a forming mold should be analyzed with many different shapes.
In U.S. Pat. No. 5,279,091 (filed Jun. 26, 1992) by Williams uses a triangular flange and a clip to install a demountable building panel of drywall.
In U.S. Pat. No. 5,207,045 (filed Jun. 3, 1991), U.S. Pat. No. 5,809,724 (filed May 10, 1995), U.S. Pat. No. 6,122,888 (filed Sep. 22, 1998), by Bodnar described a triangular stud and in U.S. Pat. No. 7,231,746 (filed Jan. 29, 2004) by Bodnar shows wall studs that are wrapped and the wall stud is partially embedded into a concrete column are cast and within the framing of a precast wall.
H. Foam Tape on studs
Foam tape is shown on metal and wood channels to reduce the conductivity between different building materials.
In U.S. Pat. No. 6,125,608 (filed Apr. 7, 1998) by Charlson shows an insulation material applied to the flange of an interior support of a building wall construction. The claims are very broad since insulating materials have been applied over interior forming structures for many years. The foam tape uses an adhesive to secure the tape to the interior building wall supports.
J. Plastic or Related Panel Connectors
Connector type patents are typically full width poured concrete walls. The plastic connectors hold the panels together and are made of various configurations.
In U.S. Pat. No. 5,809,726 (filed Aug. 21, 1996), U.S. Pat. No. 6,026,620 (filed Sep. 22, 1998) and U.S. Pat. No. 6,134,861 (filed Aug. 9, 1999) by Spude uses a connector that has an H shaped flange at both ends of the connector and connected by an open ladder shaped web. The connector is not an ICF block type connector, but long and is used both vertically and horizontally within the wall. All the Spude patents refer to a full width poured concrete wall. Sometimes the connector is located at the exterior surface; another is embedded within the panel surface.
In U.S. Pat. No. 6,293,067 (filed Mar. 17, 1998) by Meendering uses the same H shaped flange at both ends of the connector; however the web configuration is different. Also in U.S. Pat. No. 5,992,114 (filed Apr. 13, 1998) & U.S. Pat. No. 6,250,033 (filed Jan. 19, 2000) by Zelinsky also uses the same H shaped flange at both ends of the connector, also uses a different web configuration. Also in U.S. Pat. No. 6,698,710 (filed Dec. 20, 2000) by VanderWerf also uses the same H shaped flange at both ends of the connector, also uses a different web configuration.
In U.S. Pat. No. 6,247,280 (filed Apr. 18, 2000) by Grinshpun has an inner and outer skin which has an interlocking means built-in the interior surface of the panel skins. The ends of a panel connector are V shaped and lock into the interior interlocking means of each of the building panels. The connector also can accommodate a rigid insulation board within the interior of the wall panel. The panel construction is used for a continuous concrete wall, and does not affect this patent application.
In U.S. Pat. No. 6,935,081 (filed Sep. 12, 2003) by Dunn embeds an H shaped configuration in both sides of the wall panel which is rigid insulation. The H shaped configuration also has a recessed area into which a “spreader” can be installed. The spreader is another H shaped member that can slide into the recess of each side of the wall panel.
In U.S. Pat. No. 5,566,518 (filed Nov. 4, 1994) by Martin uses rigid insulation as the sides of the wall panel. The side walls are connected by a snap-on plastic connector that fits over the edge of the side walls. When connected the rigid insulation along with the plastic connector really just form another type of ICF blocks.
In U.S. Pat. No. 6,952,905 (filed Feb. 3, 2003) by Nickel, uses connectors that have dovetail slots where bolts heads fit into and the bolt shafts fit into the stone panels. In U.S. Pat. No. 6,978,581 (filed Sep. 7, 1999) by Spakousky uses dovetail slots with connectors, however the connectors do not allow for additional fasteners to be installed after concrete is installed within the mold and the connectors have a divider with two chambers within the wall. In U.S. Pat. No. 7,415,805 (filed Aug. 26, 2008) by Nickerson uses slit slots or dovetail slots to support the anchors within a wall. Nickerson also uses a tie assembly with a shank, two clamps, a support, saddle and end caps; or a tapered plug to fit into the dovetail slots to secure the block faces.
There are many ICF's manufactured, for example, U.S. Pat. No. 6,378,260, U.S. Pat. No. 6,609,340, just to name a few.
SUMMARY OF THE INVENTION
The present invention relates to an improved wall system where a structural insulating core using spacer blocks or spacer insulation with inner and outer boards form a wall. The structural insulating core with connectors between the inner and outer boards forms concrete columns and beams, requiring connectors between the inner and outer boards.
Various types of connectors are shown including the twist connector, twist connect channel, bent flange channel and flange extension all form different connectors but maintain the function of holding the inner and outer boards together and eliminating concrete from entering the connectors or channels. In addition foam material can be added within channels to also eliminate concrete from surrounding the flanges. The horizontal bracing channel connects the structural insulating cores on both sides of the concrete columns as well as connecting the beam to the structural insulating core. A plate can be installed over the horizontal bracing channels forming chase where electric wiring can pass through the concrete columns.
The present invention relates to an improved wall system where a structural insulating core wall uses various wall forming structures and spacer blocks interconnecting between each other. The spacer blocks have vertical and horizontal interlocking tongue and groove connections that connect between the wall forming structure and the spacer blocks. The projections of the spacer blocks cover the flanges of the support channels and the thickness of the projections is the thickness of the inner and outer boards used to form the concrete beams and columns.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view of the structural insulating wall where the spacer blocks are wider and interlock between the support channels and horizontal bracing channels and horizontal tongue fit into a trough of the spacer blocks connecting to the support channels together along with the base plate connections to the spacer blocks and support channels. The horizontal bracing channel is connecting the spacer blocks. Concrete column and beams molds shown with various connectors connecting the structural insulating wall together.
FIG. 2 shows an isometric of the spacer insulation with inner and outer boards and various connectors to connect the inner and outer boards together and to the spacer insulation.
FIG. 3 shows a plan view of H channels and U channels forming a column mold between spacer insulations on both sides of the column mold.
FIG. 4 shows various connectors and where the U channels do not face the column mold.
FIG. 5 shows one C channel is embedded into the column mold with rigid foam at the flange.
FIG. 6 is a plan view of two panels intersecting forming an “L” shaped column mold and the column showing several types con connectors.
FIG. 7 shows a plan view of the spacer blocks on either side of the column mold that is wider than the column mold with a connector being a C channels with flange extensions and the horizontal bracing channel connecting two sides of the column mold.
FIG. 8 shows a wall section with a connector attached to the inner and outer wall boards and the support channels extending into the beam mold.
FIG. 9 shows a wall section of a wide column mold above the spacer block with a twist connector and the horizontal bracing channel connected to the beam mold.
FIG. 10 shows an isometric view of the bent flange channel with a horizontal bracing channel.
FIG. 11 shows an isometric view of the twist connector channel with a horizontal bracing channel.
FIG. 12A shows an enlarged view of a twist connector flanges within an inner or outer board.
FIG. 12B shows an isometric view of a twist connector fitting into the dove tale slot prior to being twisted into place.
FIG. 12C shows an isometric of the twist connector where one side has a twist connector configuration and the opposite side having a plain end and locked into position of the dove tail groove.
FIG. 13 shows an isometric view of a U channel with various flange extensions added to the channel.
FIG. 14 shows an isometric view of a C channel with various flange extensions added to the channel.
FIG. 15 shows a snap-in-place configuration of two flange extensions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an isometric view of wall mold 81 with the structural insulating core 111 and column molds 20 and beam molds 90. The vertical support channels are the supporting wall structure of the structural insulating core 111 with the spacer blocks 56 fitting between the C channels 42. The right side shows the support channel as a C channel 42 with the horizontal bracing channel 150 shown as a horizontal U channel 155 passing through the hole 36 in the web 42a of the C channel 42. On both sides of the C channel 42 are spacer blocks 56 that have a trough 132 at the top of each spacer block 56. The horizontal U channel 155 fits through the hole 36 and into the troughs 132 of the spacer blocks 56. Another spacer block 56 is shown above the horizontal U channel 155 where a horizontal tongue 56t fits into the trough 132 of the spacer block 56 below. The trough 132 is deeper than the horizontal U channel 155 so to allow space for any mechanical/electric utilities to pass through. All the spacer blocks 56 are shown deeper than the length of the web 42a of the support channel so projection 56p can extend over the flanges 42b of the C channel 42. The spacer blocks 56 have a tongue shape 56a that fits between the lips 42c and abut the webs 42a and the lip 42c of the C channels 42 and a groove shape 56b where the groove shape abuts the web 42a of the C channel 42 and the projections 56p of the spacer block 56 extends over the flanges 42b of the C channel 42 abutting the adjacent spacer block 56. The base plate 120 is shown also as a horizontal U channel 155, however the web 155a is secured to a floor and the webs 155b are attached to the flanges 42b of the C channel 42 and the flanges 42b also slide into a groove 121 at the bottom of the spacer block 56. The left side of the figure shows three support channels at the column mold 20 where the support channels are the connectors 64 for the column mold 20 and the beam mold 90. The left connector 64 is a C channel 42 with foam material 54 between the web 42a and lip 42c and against the flange 42b. The groove side 56b abuts the web 42a of the C channel 42 and the spacer block 56 has an indentation 56i. The middle connector 64 is a twist connector channel 225, more fully explained in FIGS. 10 & 11A, is shown inserted into the dovetail groove joint 213 also shown in the enlarged view in FIG. 10. A twist connector 220 is shown above the twist connector channel 225 with a connector rod 226 passing through the cavity 38. The right connector 64 shows a C channel 42 where the tongue side 56a of the spacer block 56 fits against the web 42a and the lip 42c and the spacer block 56 does not overlap the flange 42b. The column mold 20 is complete when the inner and outer board is attached to the three connectors. When the flanges 42b of the C channel 42 face into the column mold 20, the inner and outer boards fits against the indentation 56i supporting the spacer blocks. In addition the horizontal bracing channel 150 passes through the spacer blocks 56 on the right side of the column mold 20, the horizontal bracing channel 150 passes through the holes 36 of the connectors (buried in the concrete 39 of the column mold) and into the spacer block 56 on the left side of the column mold 20. Above the spacer blocks 56 on both sides of the column mold 20 is a beam mold 90.
In FIG. 2 is another type of structural insulating core 111 where the spacer insulation 52 is between support channels and inner and outer boards cover the spacer insulation 52 and the support channels form the structural insulating core 111. The isometric view of wall mold 81 shows two column molds 20 and the left side shows a beam mold 90 above the spacer insulation 52 and the column mold 20. The beam mold 90 shows the rigid insulation 51 in ghost and the rigid board 50 needs to be extended to the height of the rigid insulation 51 to form the opposed side of the beam mold 90. The left column mold 20 show a U channel 41 as both a connector 64 and as a wall support for the structural insulating core 111. The flanges 41b enclose the sides of the spacer insulation 52 so fasteners 37 can be attached. The web 41a and the spacer insulation on the opposite side form the other sides of the column mold 20. The connector 64 in the middle of the column mold 20 is a bent flange channel 44 more fully described in FIG. 10. No steel reinforcing is shown but can be installed after the wall is installed in a vertical position. Light gauge metal channels have one flange, so the double flanges 44b and 44d allow two surfaces into which a fastener 37 can attach to and thereby increasing the strength a fastener 37 can attached to support the rigid board 50 as well as resist the force of wet concrete 39 pushing against the rigid board 50. When the wall mold 82 is erected vertically the steel reinforcing 60 is added and the column mold 20 is filled with concrete 39. Upon doing so the web 44a and the bent flanges 44b & 44d create a cavity 38 which is more clearly shown in FIG. 10. Since the cavity 38 is not filled with concrete 39 as typically the small space between the web 44a and the bent flange 44d is not large enough to allow concrete 39 to flow into. When additional materials shown (in ghost) is applied to the rigid board 50, the fastener (not shown) can then penetrate the rigid board 50 and into the bent flange channel 44 without having to penetrate into the concrete 39 within the column mold 20. Usually C channels or U channels (not shown) are between the column molds 20 to support the structural insulating core 111 between column molds 20 as well as to support the beam molds 90. The column mold 20 on the right side shows the spacer insulation 52 as the side supports for the column mold 20 and the rigid board 50 and rigid insulation 51 support the other two sides of the column mold 20. The connector 64 in the middle of the column mold shows a C channel 42 with flange extension 203 which forms a flange configuration similar to the bent flange channel 44. There are many other flange extensions besides the flange extension 203 shown in FIGS. 13 & 14. The spacer insulation 52 can be full height of a wall or shorter where several spacer insulations fit together to form a full height wall. When several spacer insulations 52 are installed together, a trough 132 of one spacer insulation 52 connects with a horizontal tongue 52t of the adjacent spacer insulation above or below the spacer insulation 52. Sometimes a horizontal bracing channel 150 passes through the holes 36 of support channels and the horizontal U channel 155 fits into the trough 132 and the horizontal tongue 52t fits into the flanges 155b. The horizontal bracing channel 150 also passes through the column mold 20 for additional support as well as shown as a connector 64 since it also connects both sides of the column mold 20. Since not all sides of the column molds 20 have support channels at the sides of the column molds 20, and the rigid boards 50 and rigid insulation 51 have fasteners 37 attached to the connectors 64 within the column molds 20 as well as the support channels within the structural insulating core wall. The beam mold 90 is formed when the connectors 64 and the support channels within the structural insulating core 111 extend above the spacer insulations 52 and the rigid boards 50 and rigid insulations 51 extend to the top of the beam mold 90 so fasteners 37 can be installed.
FIG. 3 shows a plan view of wall mold 17 with the structural insulating core 111 on both sides of the column mold 20. The structural insulating core 111 consists of the spacer insulation 52 between the rigid board 50 and rigid insulation 51 with support channels spaced between the spacer insulations 52. The column mold 20 has a support channel on both ends of the column mold 20 shown as a U channel 41 or as a connector 64 since the U channel 41 is part of the column mold 20. Both U channels 41 have the flanges 41b facing toward the spacer insulation 52 and the web 41a form the sides of the column mold 20. Since the rigid board 50 and the rigid insulation 51 are separate elements to the spacer insulation 52, the inner and outer walls are part of the structural insulating core 111 and the column mold 20. The two connectors 64 are shown as H channels 40 that have grooves 121 formed into the rigid board 50 and rigid insulation 51. The H channel 40 on the left shows two rigid board 50 and two rigid insulation 51 meeting at the H channel 40 requiring groove 121 to be installed at the edges. The other H channel 40 shows a groove 121 formed as a T shape to conform to the end configuration of the H channel 40. Various screws 122 are used to support the column mold 20 together as well as a means of attaching additional inner and outer boards to the column mold 20 and the structural insulating core 111. Depending on the size of the column mold 20, additional H channels 40 along with additional rigid board 50 and rigid insulation 51 can be installed between the H channels 40 forming a longer column mold 20.
FIGS. 4 & 5 both show a column mold 20 between a structural insulating core 111 walls on both sides of the column mold 20. The various connectors 64 as shown in FIGS. 1, 2 or 3 can be used in FIGS. 4 & 5. Both FIGS. have a support channels from the structural insulating core 111 shown at the sides of the column mold 20 and since the C channels 42 are part of the column mold 20 the support channels are also connectors 64. The C channels 42 in FIG. 4 show the flanges 42b and lips 42c facing toward the spacer blocks 56 where each C channel 42 is connected by the tongue side 56a of each spacer block 56. FIG. 5 shows the C channel 42 facing in the same direction causing the C channel 42 on the left side of the column mold 20 to have the groove side 56b of the spacer block 56 abut the web 42a of the support channel. In order to make a strong connection an indentation 194 is installed in the spacer block 52. On the right side of the column mold 20, the tongue side 56a fits between the flanges 42b and the lip 42c and extends to the web 42a the width extends past the lips 42c to the other edge of the spacer block. The rigid board 50 and the rigid insulation 52 are attached to the flanges 42b of the C channel 42. The horizontal bracing channels 150 are shown passing through the holes 36 shown in FIGS. 1 & 2 connecting the support channels together. The column mold 20 can also be formed as ICF block molds 96 with rigid foam block faces 88 and connectors 64 made of plastic. There are many insulated concrete forms (ICF's) on the market with many different types of connectors. None of the ICF's form column molds 20 nor beam molds 90 (shown if FIGS. 8 & 9) with structural insulating cores 111 on either side using support channels and the horizontal bracing channel as connectors to form column molds 20.
FIG. 6 shows two wall panels 65 intersecting at a corner forming a column mold 20 that is L shaped. The wall panel 65 in wall molds 19 & 19′ consists of a rigid board 50 and rigid insulation 51 using connectors 64 between the inner and outer surfaces of wall panels 65. The column molds 20 in each panel form an “L” shape column mold with the various connectors 64 shown in some of the previous figures include: a foam material 54 attached to C channel 42, bent flange channel 44, twist connector 220, twist connector channel 225 and a twist connector rod 226, while another wall panel 65 shown as wall mold 19′ has the C channel 42 with flange extensions 200, a bent flange channel 44 connected to the rigid board 50 and rigid insulation 51. A door (shown in ghost) has the foam material 54 shown on the interior side of web 42a of the C channel 42 so the door (shown in ghost) can be attached to the wall panel 65 after the concrete 39 has cured. The “L” shaped column mold is partially formed in wall mold 19, and partially formed in wall mold 19′. When the wall mold 19 & 19′ are installed vertically and connected together, column mold 20 is formed. Additional steel reinforcing 60 is installed within the column mold 20 and concrete 39 is installed when the walls are erected in a vertical position creating an L shaped column. Typically the column mold 20 would be used when two walls molds intersect at 90 degrees or at any angle. The “L” shaped column at the corner of a building has the integrity of a solid concrete wall or shear wall (more commonly used like diagonal bracing for wind shear), but in not a solid concrete wall since the spacer insulation 52 separates each concrete column 35 within a building structure. The horizontal bracing channel 150 shown as a horizontal U channel passes through the holes of the various connectors and into the structural insulating core 111 connecting the wall panels 65 together.
FIG. 7 is a plan view of a column mold 20 comprising of a rigid board 50 and a one piece mold 212 that is U shaped having two sides 212a and a back 212b. The sides 212a of the one piece mold 212 fits between the structural insulating cores 111 and is connected to the C channel 42 within the structural insulating cores 111. A connector 64 shows a C channel 42 within the one piece mold 212 is installed at the sides 212a and back 212b within the one piece column mold 212 for additional strength. The connector 64 has flange extensions 200 and enlarged in FIGS. 13 & 14 are shown attached to the C channel 42 within the one piece mold 212 for easy installation of additional wall materials like drywall (not shown). The one piece mold 212 can be a rigid material like polystyrene or aerated autoclave concrete. The same material shown in the one piece mold 212 is shown as a rigid board 50 installed over the structural insulating cores 111 as well as another rigid board 50 is shown as forming the fourth side of the one piece mold 212. The one piece mold and the rigid board 50 can all be connected to the C channels 42 within the structural insulating core 111 by fasteners 37 (not shown). A horizontal bracing channel 150 is shown passing through the one piece mold 212 between the structural insulating cores 111 on both sides of the one piece mold 212 and connected to the vertical reinforcing steel 60.
FIGS. 7 & 9 are similar because the same rigid board 50 is attached to the structural insulating core 111 and the beam mold 90. Not all rigid boards have similar insulating properties, and therefore must be distinguished to be of different materials. FIG. 9 is a wall section showing the structural insulating core 111 with the rigid boards 50 attached. The rigid board 50 can either be glued to the structural insulating core 111 or attached with fasteners (not shown) to the C channels 42. The beam mold 90 can be formed as one piece mold 212 having 2 sides 212a and a bottom 212b. The one piece mold 212 can be of the same material as the rigid board 50. A base plate 120 (not shown) can be installed over the structural insulating core 111 so an anchor bolt 74 can be installed through the web 120a into the beam mold 90. Concrete 39 and reinforcing steel 60 are installed within the beam mold 90. The connector 64 is shown as a twist connector 220 can be used to support the 2 sides 212a of the beam mold 90. The twist connector 220 is shown in more detail in FIGS. 12A, 12B & 12C. The smaller spacer insulation 55s is shown below the beam mold 90 with a vertical hole 36v and an anchor bolt 74 that attaches the horizontal bracing channel 150 to the reinforcing steel 60 within the beam mold 90.
FIGS. 7, 8 & 9 are similar since both figures use a one piece mold 212 for the column mold 20 and the beam mold 90 along with the structural insulating core 111. Both figures show the rigid board 50 attached to the structural insulating core 111 and FIG. 7 uses the rigid board 50 as part of the column mold 20. FIG. 8 also uses a one piece mold 212 to form the beam mold 90 above the structural insulating core 111. The support channels from the structural insulating core 111 pass through the one piece mold 212 connecting the structural insulating core 111 to the concrete 39 (not shown) into the beam mold 90. In FIG. 8 the one piece mold 212 is shown as three pieces, two sides—212A and one bottom—212B which could also be formed using rigid boards 50 as shown in previous figures. Concrete 39 and reinforcing steel 60 are installed within the beam mold 90. A twist connector 220 can be used to support the 2 sides 212a of the beam mold 90. The twist connector 220 is shown in more detail in FIG. 12B & 12C. The smaller spacer insulation 55s is shown below the beam mold 90 with a vertical hole 36v and an anchor bolt 74 that attaches the horizontal bracing channel 150 to the reinforcing steel 60 within the beam mold 90.
FIG. 10 is a bent flange channel 44 which is similar to the C channels 42 previously described. The bent flange channel 44 has a web 44a, a flange 44b that is perpendicular to the web 44a, a bent flange 44d being parallel to the web 44a with a hole in the web 44a. The bent flange channel 44 has a web 44a which is the same width as the spacer insulation 52. The bent flanges consist of two parts, the flange 44b is adjacent to the rigid insulation 51 and the remainder of the bent flange 44d is bent again to be close to the web 44a. The double bending of flange 44b & 44d allows a fastener 37 to secure the bent flange channel 44 at two spots that is the flange 44b and 44d. The light gauge metal used in forming metal channels has limited strength. By using two double flanges 44b and 44d, the two surfaces increase the strength of the channel as well as increasing the strength of the connection with the fastener 37. FIG. 2 shows the bent flange channel 44 also as a connector 64 where the flanges 44b abut the rigid board 50 and the rigid insulation 51 and screws 122 as well as secured to the bent flange 44d. Additional finishes (not shown) can be installed into the bent flange channel 44 after concrete 39 has been installed into the column mold 20 by installing the screws 122 through the flange 44a into the cavity 38. FIG. 6 shows the bent flange channel 44 as a support channel and as a connector 64 since the web 44a is part of the column mold 20 and the flange 44b and the return flange 44c are connected to the inner and outer boards and the spacer insulation 52 fits between the return flanges 44c. In addition, the bent flange channel 44 shows foam material 54 installed between the flange 44b and the inner and outer boards, as well as within the cavity 38.
FIG. 11 shows an isometric view of a twist connector channel 225 which has a web 225a with a hole 36 and connected by flange heads 225b at both ends of the twist connector channel 225. The horizontal bracing channel 150 is shown passing through the hole 36 in the web 225a. The flange heads 225b is shown in FIG. 12A and described as a part of the connector 64. Since the twist connector channel 225 has a web 225a, the twist connector channel 225 must be slid into an inverted V shaped slot 64a as shown in FIG. 12A. Shorter sections or brackets of the twist connector channel 225 can be installed within the V shaped slot allowing several brackets to be used as connectors between the inner and outer boards.
FIG. 12A shows an enlarged plan view of connector 64 installed within a rigid board 50 or the connector 64 shown in FIGS. 8 & 9. After the rigid board 50 or rigid insulation are cut into slabs, the material needs to be cut or routed to form a dove tail shape or an inverted V shape 64a into which the flange heads 225b or connector heads 220a can be slid into the inverted V shape 64a of the rigid board 50 or rigid insulation 51 as shown in FIG. 1. The inverted V shape 64a can be of any shape as long as there is sufficient friction on the connector end 64b from being pulled from the inverted V shape 64a within the inner and outer boards, and is similar to the dovetail joint 213 in FIGS. 12B & 12C. Also shown in FIG. 12A is an extended leg 64c of the connector 64. The extended leg 64c is shown to add additional resistance and strength to the holding capacity of the connector 64. The connector web 64d is also referred to as a web 225a of the twist connector channel 225 in FIG. 11 and as a connector shaft 220b of the twist connector 220 in FIGS. 12B & 12C. In FIGS. 4 & 5 the rigid foam block faces 88 & 88′ can be interchanged with rigid board 50 or rigid insulation 51. In addition, the connector 64 can be of rigid plastic as well as metal as described earlier. The connector 64 as described has a cavity 38 similar to the cavity 38 of the bent flange channel 44 in FIG. 10. The inverted V shape 64a conforms to the two sides 64e, the extend leg 64c and the connector end 64b of the connector 64.
FIGS. 12B and 12C show a twist connector 220 in an inserting position FIG. 12B and the fixed position 12C. As stated earlier the twist connector 220 is shown installed in the beam mold 90 in FIG. 9 in the one piece mold 212 and also in FIG. 1 between the rigid board 50 and the rigid insulation 51 in the dovetail joint 213. The dovetail joint 213 is similar to the invert V shaped 64a shown in FIG. 12A; however the dovetail joint 213 has a wide opening at the interior side shown as L1 and a wider opening within the middle of the side wall 210a shown as L2. The twist connector 220 shown in FIG. 12B & 12C has two connector heads 220a connected by a connector shaft 220b. The connector heads 220a are shown having a narrow width L1′ with a longer length of L2′. FIG. 12B shows the connector head 220a shown in a vertical position; where the smaller connector head L1′ is inserted through the interior side L1 of the dovetail joint 213. The connector head 220a is then turned or twisted 90 degrees within the dovetail joint 213, so that the long length L2′ of the twist connector 220 is turned the full width L2 of the dovetail joint 213. When the twist connector 220 is turned 90 degrees within the dovetail joint 213, the twist connector 220 is locked into position within the side wall 211a. The twist connector shaft 220b is rectilinear in shape and when the twist connector 220 is in the locked position, the twist connector shaft has a rebar depression 220c so steel reinforcing (not shown) can be installed in the rebar depressions 220c as shown in FIG. 9. In FIG. 12C one of the twist connector heads 220a is shown having the flange heads 225b as shown in FIGS. 11 & 12A.
FIGS. 13, 14 & 15 shows various types of connectors 64, but are referred to as flange extensions 200 since the extensions are added to the end of the connectors 64. The flange extensions 200 are different configurations that are added to the U channel 41 and/or C channel 42 that changed the shape of the flanges 41b or 42b of the U channel 41 or C channel 42. The bent flange channel 44 in FIG. 10 shows a flange variation 205 in FIG. 13 where the flange variation 205 is shown attached to the U channel 41 at 205a, then bent at 205b around the flange 41b of the U channel 41 and continues at an angle shown at 205c to the web 41a forming a cavity 38. The flange variation 205 is full height of the connectors 64 since the cavity 38 is meant to allow fasteners (not shown) to be connected to the U channel 41, through the flange variation 205 and into the cavity 38. Another flange extension 200 shows the flange variation 201 being added to the flange 41b by creating a depression 201a to the sides of the flange 41b. The flange variation 201 is wrapped at the interior of the flange 41b, and then turned 90 degrees at 201b and again forming 201a. The side 201 shows a depression 201a″ between two protruding elements 201a′. When a hard board 40 is installed over the depression 201a a cavity 38 is formed limiting the amount of thermal conductivity passing through the U channel 41. The flange extension 200 shows the flange variation 202 attached to the U channel 41 at 202a, then bent at 202b around the flange 41b, however a cavity 38 is formed between the flange 41b and the continuation of the flange variation 202 at 202c. The cavity 38 is formed so as to install a foam spacer 55 not shown between the flange 41b and the side 202c.
FIG. 14 shows a another flange extension 200 where the flange variation 203 also appears like the bent flange channel 44 in FIG. 10 except the flange variation 203 is installed by friction rather than a fastener 37 as shown in FIG. 13. The flange variation 203 has one leg 203a that rests against the lip 42c and the other leg 203b rests against the web 42a of the C channel 42. The leg 203b is at an angle to the web 42b similar to the flange variation 205. When the leg 203b fits against the lip 42c and other leg 203c rests against the web 42a, friction against the leg 203b to the web 42b holds the loose flange variation 203 in place. The flange extension 200 is also shown as a flange variation 204 which is rectangular tubular shape having sides 204a, 204b & 204c. The flange variation 204 can also be “C” using sides 204a and two sides 204b forming the “C” shape. By forming the rectangular tubular shape and the “C” shape a cavity 38 is formed so not to allow concrete (not shown) to flow into the cavity 38 of the column molds 20 and beam molds 90 shown in the previous figures.
FIG. 15 shows two additional flange extensions 200 shown as flange variation 206 & 207 attached to a C channel 42. The flange variation 206 wraps around the lip 42c of the C channel 42 forming a hook shape 206h shown as 206a, 206b, 206c & 206d. The hook shape 206h start at 206a at the inside of the lip 42c, then wraps around the lip 42c at 206b, then extends the full length of the lip 42c, then turns again 90 degrees onto the flange 42b. By wrapping the hook shape 206h around the lip 42c and making the 90 degree turn onto the flange 42b, the hook snaps into place. The end of the flange variation 206 turns 90 degrees away for the flange 42b at 206e and turns 90 degrees similar to flange variation 202. The flange variation 207 has the same hook shape 207h as does 206h. The end of the hook shape 207h the flange variation 207 turns 90 degrees shown as 207e then forms a “T” shape 207t at the end similar to the end of an H channel 40 shown in FIG. 3.
The flange extensions 200 shown a flange variations 201-207 can be short brackets or full length depending on the height of the wall as shown in FIG. 24 and can be manufactured of plastic or metal. The flange extensions 200 are attached to the U channel 41 or C channels 42 when embedded into any of the previous described concrete molds in order to have a cavity 38 into which drywall (not shown) can be installed into the concrete molds.
CONCLUSION AND SCOPE OF INVENTION
The structural insulating core wall consists of structural support members with spacer blocks or spacer insulation with inner and outer boards between the support members. The spacer blocks interlock between spacer blocks and/or the spacer insulation with its inner and outer boards also interlock between each other. The structural insulating cores are used to form column and beam molds which require various types of connectors to support the column and beam molds into which concrete is poured into the molds when erected vertically. The beam molds use various types of connectors, the structural insulating core, the structural support members within the wall extending above the structural insulating core and the inner and outer boards. The column mold is also formed by the sides of the structural insulating core, connectors, support channel and flange extensions plus the inner and outer boards. Several joint shapes within the inner and outer boards are required depending on the shape of the channels, connectors or flange extensions.
It is understood that the invention is not to be limited to the exact details of operation or structures shown and describing in the specification and drawings, since obvious modifications and equivalents will be readily apparent to those skilled in the art. The flexibility of the described invention is very versatile and can be used in many different types of building applications.
Patent Application
20120186180
