1. Field of the Invention
The present invention relates generally to the construction of free-standing residential structures, and more specifically to a novel insulated concrete form method and system.
2. Description of the Prior Art
The prior art concrete form systems require the use of numerous ties to secure the forms in place. The ties create undesirable obstacles within the wall cavity during construction thereby increasing the difficulty and complexity in the installation of conduits, window and door framing as there is not a clear space between the forms. Moreover, the ties are susceptible to failure and breakage thereby reducing the strength of the system. Other types of prior art forming systems require the use of complicated bracing systems that are costly, cumbersome and time-consuming to assemble and disassemble.
Accordingly, what is needed in the art is an insulated concrete form system that reduces or eliminates the use of ties to create a clear work space between the forms for installation of windows, doors and conduits.
Another shortcoming of the prior art is that the insulated concrete forms are typically higher priced, result in a poor surface appearance and are flimsy. These prior art systems consist of small foam blocks that are either pre-formed or separate panels connected with expensive plastic or metal ties.
Yet another shortcoming in the art is a method and system to utilize forms that are easy to assemble and disassemble.
Another need in the art is for an insulated concrete system that is adjustable to different widths of walls and uses the same components to construct any size wall.
There is also a need in the art for a wall system that can withstand severe wind loads, and increased resistance to fire and structural failure.
Notwithstanding the existence of such prior art insulated concrete form systems, there is a need for an improved insulated concrete form system that is easy to assemble on site.
It is, therefore, to the effective resolution of the aforementioned problems and shortcomings of the prior art that the present invention is directed.
However, in view of the prior art at the time the present invention was made, it was not obvious to those of ordinary skill in the pertinent art how the identified needs could be fulfilled.
This invention is an insulated concrete form system comprising a pair of bottom U-shaped channels, a pair of top U-shaped channels, interior foam sheets, exterior foam sheets, exterior strongbacks, interior strongbacks, and top wall spacers. The pair of bottom U-shaped channels are secured to a concrete slab and serve as the footprint for the wall. The bottom U-shaped channels are parallel to one another and spaced apart in accordance with the design specifications. The bottom edge of the exterior foam sheet is aligned within the bottom U-shaped channel that defines the exterior surface of the wall and the top U-shaped channel is secured to the top edge of the exterior foam sheet. Similarly, the bottom edge of the interior foam sheet is aligned with the bottom U-shaped channel that defines the interior surface of the wall and the top U-shaped channel is secured to the top edge of the interior foam sheet. Accordingly, a relatively narrow wall cavity is formed between the interior and exterior foam sheets pursuant to the design width of a wall. The wall cavity provides an unobstructed area for construction elements and to install framing for windows and doors, electrical boxes, conduits, dryer tubes, vacuum tubes, wire mesh sheets, rebar or shelves. The wall cavity can be straight or curved depending on the design.
The pair of top U-shaped channels are secured together using an interior strongback and an opposing exterior strongback. The top of each strongback hooks over the top U-shaped channels and the bottom of each strongback has a lip that slips inside the bottom U-shaped channels to secure it in place. The opposing strongbacks are adjacent to the outer surface of the foam sheets and provide the structural support necessary to withstand the pressure from pouring concrete within the wall cavity. Once the concrete has set, the strongbacks are removed and can be re-used. The foam sheets remain in place providing insulation and a moisture barrier to the concrete walls. The exterior of foam sheets can be used as a base for the installation of stucco, lap siding or brick. The interior of the foam sheets can be covered with typical building materials such as drywall or plaster.
Once the concrete is poured, the foam covering window and door openings can be removed or remain in place until the windows and doors are ready for installation. Pre-cast lintels and headers are not needed above openings since the poured in place concrete wall carries the structural load. If the design requires horizontal rebar, a removable tie can be used to hold the rebar at the proper elevation.
It is therefore an object of the present invention to provide for an improvement that overcomes the aforementioned inadequacies of the prior art and provides a significant contribution to the advancement of insulated concrete form systems.
Both the foregoing general description and the following detailed description are explanatory and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute part of the specification, illustrate embodiments of the present invention and together with the general description, serve to explain principles of the present invention.
These and other important objects, advantages, and features of the invention will become clear as this description proceeds.
The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter.
For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
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Electrical conduits can be installed with the present invention by implementing the steps described below. First, join two electrical outlet boxes together and secure a conduit to the rear electrical box using appropriate connectors. Next, secure a length of cord to the inside of the electrical box and stuff the cord inside of the box for later use. Trace the back of the electrical box onto the exterior foam surface at the proper location so that the conduit with the boxes attached can be lowered from the top of the wall cavity down to the desired opening. Attach the cord directly to the closest strongback to prevent it from slipping back into the cavity during concrete placement. Additional boxes can be added to the same conduit for light switches or additional electrical outlets. Plumbing and vacuum systems can also be installed using a similar method.
The particular embodiments disclosed above and in the drawings are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention.
Now that the invention has been described,
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Number | Date | Country | |
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20090229205 A1 | Sep 2009 | US |