Patent Grant
9091089
The present invention relates to Insulating Concrete Form (ICF) Systems utilizing foam block forms or other forms made of other comparable materials and, more particularly, to improvements to the ICF panels and the interlocking connection means associated therewith thereby achieving product modularity with respect to ICF block forms having different heights and widths.
Insulating Concrete Form (ICF) Systems are well known in the industry and serve to both contain fluid concrete while it solidifies and provide insulation for the finished structure. Such systems utilize a plurality of individual units, panels or blocks aligned horizontally and vertically in an interlocking arrangement to create forms for concrete walls. Each block comprises a pair of panels which are retained in a spaced relationship parallel to each other through the use of a plurality of spacing or connecting tie members. As the ICF blocks are stacked, steel rebar rods are inserted at proper longitudinal and vertical integrals as in the conventional forming of a concrete wall.
There are a wide variety of different ICF systems presently available on the market, all of which are used to construct concrete walls. Some ICF systems utilize prefabricated block forms in which opposing flanges of each tie member are molded into the respective opposing walls or panels forming the block. In some prior art designs, the web portion extending between the opposed flanges of the tie are fixed relative thereto, and in some embodiments, the web portion of each respective tie member is hinged so as to allow the ICF block to be folded into a collapsed condition for transportation and storage. In still other embodiments, the ICF system is designed for field installation and the intermediate web portion associated with each respective tie member is slidably engageable with the opposed flanges of each respective tie member which are molded into the opposing walls or panels of each respective block. Once a particular wall or structure is formed using a particular ICF system, the wall or structure is braced and poured full with fluid concrete. The result is a highly energy efficient, steel reinforced, easy to construct, concrete wall having a layer of foam or other comparable material on each side of the concrete which serves as further insulation for the completed wall. The tie members which hold the ICF blocks together during the forming and pouring process also serve as furring strips for the attachment of interior (drywall) and exterior finishes.
Because the construction of each building structure is different and unique unto itself, and because of the specific needs of the building and construction industry, it is necessary to provide ICF blocks in a wide variety of different heights, widths and types including such types as straight forms, 90° and 45° corner forms, tapered top forms, ledge forms, T-wall forms, and many more. Although many different types of ICF systems are offered in the marketplace, the preassembled flat wall ICF system dominates the marketplace. In this regard, most of the major ICF companies offer five different widths and one height of ICF blocks to accommodate various construction needs. As a result, as the width of the respective ICF blocks change, so does the size and shape of the respective connecting tie members. If you wanted to also change the height of the respective blocks, not only does the size and shape of the connecting tie members change, but the size of the block panels likewise changes. All of these changes in block height and width also require tooling changes to produce the many different variations in ICF block heights and widths.
Due to the high capital costs required to make the molding tools for both the tie members and the ICF blocks in multiple widths, ICF companies have not been able to offer a more modular system that offers a standard line of ICF blocks in multiple heights as well as multiple widths. Currently, besides being costly, the ICF tools which are used to form the connecting tie members and the opposed block panels are extremely inflexible in their design, use and implementation. As a result, each different height of ICF block requires a different ICF tool for both forming the opposed foam panels of each respective block and for forming the connecting tie members associated therewith. The same is likewise true with respect to each different width of ICF block. In this regard, a separate plastic injection tie tool must also be purchased for each plastic tie used in a particular ICF block depending upon the width and height involved. If five different widths of tie members are used in one height of a particular ICF block, five different plastic injection tie tools must be used in order to make five different widths in one height. As a result, once a particular ICF tool is hung for use, it can only make one type of block, for example, a straight block in only one width. If a user needs an 11-inch straight block, an ICF company must hang its 11-inch wide straight tool of one particular height and it will then make 11-inch wide straight blocks of one particular height. When 13-inch wide straight blocks are needed, the 11-inch wide straight tool must be taken down and the 13-inch wide tool is hung. This process occurs every time a different type of block of a specific width needs to be produced.
As the height of each ICF block changes, so does its tooling requirements. The height of each ICF block requires a different size tool cavity for each different height. Having to switch out tools in this matter is time consuming and costly for two reasons. First, it currently takes most ICF manufacturers an average of several hours to unload one ICF block tool and hang another tool. This reduces the number of ICF blocks that can be produced in a particular day on a particular machine and therefore increases the respective costs of those blocks actually made. Secondly, each ICF block tool that is hung can only make a certain number of ICF blocks in each forming cycle. Tools made only a couple of years ago were made to run on smaller machines and therefore have fewer cavities. Most existing ICF block tools have only two cavities. Increasing the number of cavities in each respective tool likewise increases productivity and reduces cost as more blocks can be made within the same forming cycle. As a result, because of the costs involved in purchasing all of the various tooling for providing a full line of ICF products having different widths and heights, most ICF manufacturers only provide the most common and highest volume ICF block widths and heights.
It is therefore desirable to provide an improved fully integrated ICF system which would reduce the number of tools required to form a plurality of different ICF blocks having both different widths and different heights, which would promote modularity between the different types, widths and heights of ICF blocks such that the same connecting tie members can be used for all variations thereof, and which improves the efficiency and flexibility in the ICF manufacturing process. It is also desirable to provide improved connecting tie members which are both modular and foldable such that the same basic tie member can be used in a single tool to make ICF blocks of varying heights and such that all of the various ICF block embodiments can fold flat for packaging, storage, shipping, sight storage and sight staging. Other additional improvements to the overall ICF block and tie design are likewise desirable to improve the stacking and engaging features of the respective ICF blocks as they are stacked vertically and horizontally to construct different types of concrete walls.
Accordingly, the present invention is directed to overcoming one or more of the problems as set forth above and will enable an ICF manufacturer to go from making 18 to 20 standard ICF blocks to offering an integrated ICF product line of more than 160 different preassembled folding and field assembled ICF block configurations.
In accordance with the teachings of the present invention, several embodiments of an improved ICF tie member as well as improved opposed ICF panel members are disclosed wherein all such improvements promote efficiency, flexibility and modularity in manufacturing ICF blocks of varying widths and heights. The present improvements therefore overcome the weaknesses and disadvantages associated with prior art ICF block, panel and tie designs and teach a more versatile and flexible modular tie, panel and block design. In one aspect of the present invention, the present ICF blocks are pre-constructed units including a plurality of foldable tie members spaced apart from, and parallel to, one another. In another aspect of the present invention, the present ICF blocks are field assembled and the plurality of tie members used in association therewith are non-foldable and slidably engageable with opposed side wall brackets embedded in the respective ICF panel members. Although the present ICF blocks and panels disclosed herein will be discussed in conjunction with a substantially planar or straight block configuration, it is recognized and anticipated that the ICF blocks and panels of the present invention can be constructed in any of a variety of different configurations including, but not limited to, a 90° corner block, a 45° corner block, a taper top block, a ledge form block, a T-wall shaped block and other configurations. All of the present ICF blocks are designed to yield a solid, continuous concrete wall construction when connected horizontally and vertically to blocks of similar construction.
Each of the present block configurations includes an opposing pair of ICF panels made of foam or some other comparable material. Identical arrays of alternating teeth and sockets are formed along opposing horizontal longitudinal edges of each panel forming the present ICF block so as to enable it to be removably engaged with either opposing horizontal longitudinal edge of a similarly constructed ICF block when such blocks are vertically stacked one on top of another. The array of alternating teeth and sockets are placed in the center of each of the opposed horizontal longitudinal edges of each of the present ICF panels away from the opposed side edge portions thereof. This median location of the array of alternating teeth and sockets facilitates a cleaner outside exterior wall surface and reduces the amount of wall preparation work that will be needed with certain exterior finish applications. In one embodiment, the opposing vertical end edges of respective panels may also include any number of alternating teeth and sockets which will mate with a substantially identical array of alternating teeth and sockets formed along either vertical end edge of a similarly constructed block for creating an interlocking bond therebetween when such horizontally adjacent panels are mated with each other.
As a result, all of the present ICF blocks constructed in accordance with the teachings of the present invention can vertically and horizontally engageably receive adjacent whole or partially whole blocks of the present invention regardless of the vertical orientation with regard to its horizontal longitudinal axis and regardless of the horizontal orientation with regard to its vertical axis. This is true whether the present ICF blocks are preassembled as a single unit or field assembled at the construction site. The same is likewise true with respect to any other block configuration such as a 90° corner block or other configuration. In addition, the medial location of the array of alternating teeth and sockets likewise enables each tooth to engage a corresponding socket on all four sides of each respective tooth thereby improving the overall strength of the interlocking engagement.
In another aspect of the present invention, one embodiment of a connecting tie member includes a stackable folding tie member having a pair of opposed side wall brackets, a pair of connector link members, and a plurality of pin members for pivotally attaching the connecting link members to each other and to the respective side wall brackets for enabling the opposed ICF panels to fold flat relative to each other for packaging, storage, shipping, site storage and site staging. This folding capability also allows the same basic tie member construction to be used in a single ICF block tool for producing ICF blocks of different widths. The respective side wall brackets are each respectively encapsulated within one of the pair of ICF panels forming the particular ICF block. Each side wall bracket includes a fastening plate having an overlapping extension portion associated with each opposite end portion thereof, a shut-off plate positioned in parallel relationship thereto, and a plurality of bridging members for connecting the fastening plate to the shut-off plate. When encapsulated within a particular ICF panel, the shut-off plate is positioned adjacent the inner wall of each respective panel member and the fastening plate is positioned either adjacent the outer wall of each respective ICF panel, or spaced therefrom depending upon the thickness of the ICF panel.
The fastening plate overlapping extension members may have engaging means associated therewith designed to cooperatively engage the fastening plate overlapping extension members associated with a similarly constructed side wall bracket associated with a similarly constructed ICF panel. The overlapping extension members extend into the teeth area of each respective opposed horizontal longitudinal edge of each panel and will allow mated ICF blocks to further lock in place when stacked on top of each other. This feature also allows a plurality of side wall brackets to be encapsulated within a particular ICF panel in interlocking relationship to each other so as to form a plurality of different heights of ICF blocks as will be hereinafter discussed.
In another embodiment, each side wall bracket of the present tie member may further include interlocking mechanisms in the form of a pair of offset members associated with each opposite end portion thereof, the interlocking mechanisms associated with one tie member likewise extending into the teeth area of each respective opposed horizontal longitudinal edge of each ICF panel for cooperatively engaging corresponding interlocking mechanisms associated with a similarly constructed tie member associated with a similarly constructed ICF panel so as to allow mated ICF blocks to further lock in place when stacked on top of each other.
Each shut-off plate likewise includes a side wall bracket hinge configuration adapted to receive corresponding hinge members associated with the connection link members. This connection is made through a pin member which pivotally attaches one end portion of each respective connection link member to a corresponding side wall bracket. The opposite end portion of each pair of connection link members likewise includes cooperatively engageable hinge members which are likewise connected together through the use of a similar pin member. When the pair of connection link members are pivotally attached to each other and to the respective side wall brackets, a complete folding tie member is formed. Depending upon the length of each respective preassembled ICF block, a plurality of the present tie members will be spaced longitudinally along its length thereby enabling each respective ICF block to fold flat for packaging, shipping and storage. Once the forms are ready to be stacked for use at a particular construction site, they are simply opened, stabilized and stacked to build the walls of a particular structure.
The modularity of the present tie members enables the present ICF blocks to be manufactured in a wide variety of different heights and widths. In this regard, the width of a particular ICF block can be easily changed by merely changing the overall length of the respective pair of connection link members. The corresponding side wall brackets will remain the same and the pivotally attaching connection means associated with both the shut-off plate of each respective side wall bracket and the opposite end portions of each connection link member will likewise remain the same. As a result, only the length of the connection link members need be changed in order to change the width of a particular ICF block. This saves both tooling costs and manufacturing costs since only the connection link members need to be retooled for a different width.
Changing the overall height of a particular ICF panel is likewise easily achieved due to the modularity of the present ICF tie member. Depending upon the overall height selected for the present stackable folding tie member, various ICF block heights based upon multiples of the pre-selected height of the tie member can be easily fabricated by simply stacking any plurality of the present stackable folding tie members within a particular ICF block molding tool and forming the same. For example, if the present ICF stackable folding tie member is 6 inches in height, ICF blocks having heights of any multiple of 6 inches such as 12 inches, 18 inches and 24 inches, can be easily fabricated without changing the design or tooling requirements associated with fabricating the tie members associated therewith. A 12-inch tall ICF block will utilize a pair of the present 6-inch tie members stacked on top of each other at spaced locations along the longitudinal length of the particular ICF block. An 18-inch tall ICF block will require the stacking of 3 of the present 6-inch tie members and a 24-inch tall ICF block will require the stacking of 4 of the present 6-inch tie members. This stackability in conjunction with the locking feature associated with each of the respective side wall bracket members enables an ICF manufacturer to produce ICF block heights in multiples of the selected tie member height. This ability saves time and cost since the same basic ICF tie member is used in multiples of each other to produce ICF blocks of varying heights. It is also recognized that all ICF blocks can be made of a single height such as 6 inches tall and the blocks can be stacked in multiples to achieve a desired height based upon multiples of the pre-selected height of the ICF block. It is also recognized that the ICF blocks can be made of several different heights such as 6-inch tall and 8-inch tall blocks and these blocks can then be stacked using any combination of such blocks to achieve a desired height based upon the pre-selected heights of the ICF blocks. This ability also gives a designer more design flexibility and will allow a designer to hit different wall heights more easily and efficiently thereby reducing labor time and costs as will be hereinafter further explained.
Each of the connection link members likewise includes a plurality of rebar-retaining seats formed thereon so that a rebar rod can be gravitationally placed within a given seat regardless of vertical orientation of the ICF block with respect to its horizontal longitudinal axis. The rebar-retaining seats of each tie member are of sufficient dimension to allow at least one or two rebar rods to be retained therein without imparting undesirable torque forces to the tie member.
In another aspect of the present invention, a field assembled ICF block is disclosed utilizing an improved field assembled connecting tie member. The field assembled connecting tie member is likewise modular in form and includes a pair of side wall brackets which are embedded or encapsulated in opposed relationship to each other in the opposed ICF panel members foaming one of the present ICF blocks, and a single web member which is slidably engageable with the respective side wall brackets. The side wall brackets associated with the field assembled tie member are substantially similar to the side wall brackets associated with the present folding tie member except that the bracket hinge members associated with the shut-off plate have been eliminated and a slot has been formed in the shut-off plate for cooperatively receiving one end portion of the web member. In some embodiments, the slot associated with the respective shut-off plates may be tapered and/or enlarged at each opposite end portion to enable the web member to be easily inserted at any intermediate location along the height of a particular ICF panel or block. In all other respects, the side wall brackets associated with the field assembled tie member are substantially identical to the side wall brackets associated with the present folding tie member including having overlapping engagement means associated with the fastening plate and/or interlocking mechanisms in the form of a pair of offset members associated with each opposite end portion thereof for stackably engaging any plurality of the field assembled tie members as previously explained with respect to the present stackable/folding tie member.
The web member associated with the field assembled tie member is likewise designed to provide centralized structural support to the ICF block when cooperatively engaged with its corresponding side wall brackets. In this regard, the opposite end portions of the field assembled web member may include cooperatively engageable means for slidably engaging the respective slots associated with the shut-off plate of the respective side wall bracket members. The opposite end portions of the web member likewise may include a plurality of teeth or other engaging means for cooperatively engaging a corresponding set of teeth or other engaging means associated with the side wall bracket slots for holding the web member in proper position when engaged with the respective side wall brackets. In another embodiment, the web member may also include a resilient hook type or snap locked member at one or both opposite ends of each opposed end portion for engaging the respective side wall brackets for holding the web member in proper position when engaged with the side wall brackets. Similarly, the web member likewise includes a plurality of rebar-retaining seats formed thereon for receiving a rebar rod placed therein prior to pouring the fluid concrete between the respective ICF panels. Because the present field assembled web member is slidably engageable with its corresponding side wall brackets, the ICF panel members can be individually formed and shipped to a particular construction site in its unassembled state thereby saving space for packaging, storage and shipping of the respective ICF panel members to a particular location. This likewise reduces the on-site storage room needed and reduces the staging costs associated with larger multi-story ICF structures. The present field assembled ICF blocks can be easily assembled on site by merely engaging the corresponding web members with a pair of corresponding side wall brackets to complete the assembly process.
Like the present stackable/foldable spacing tie members, the modular nature of the present field assembled tie members likewise promotes economy of scales with respect to manufacturing ICF blocks of different widths and heights. As with the present stackable/foldable tie member, the web member associated with the present field assembled tie member can likewise be made in different widths while utilizing the same side wall brackets. Here again, this reduces tooling costs and enables a manufacturer to produce a variety of different web member lengths to achieve the desired ICF block widths required by the industry. In similar fashion, field assembled ICF blocks of varying heights can likewise be easily produced in heights corresponding to the multiple heights of the field assembled tie members or corresponding to the multiple heights of the pre-selected ICF blocks as previously explained with respect to the present stackable/foldable tie member. The present field assembled tie member can likewise be made in the same widths and heights as the present stackable/foldable tie member thereby yielding field assembled ICF blocks having the same widths and heights as the present pre-assembled folding ICF blocks.
As a result, the various embodiments of the present tie member facilitate producing a wide variety of different ICF block widths and heights while saving tooling costs and manufacturing costs. Currently, a separate ICF tool must be made to produce each type of block in each width and in each height. In addition, the use of a triple hinged folding tie member likewise provides a manufacturer the ability to redesign its ICF molding tools in a way that will allow more than one size of ICF block to be made in each respective tool. This advancement is discussed in Applicant's co-pending application, the disclosures of which are incorporated herein by reference. The interchangeability of the present stackable/folding and field assembled side wall brackets enable the present ICF blocks to be made in a wide variety of different widths and different heights and also opens the door for more creative block designs and configurationg due to its modular capability. The different embodiments of the present tie members can be incorporated into any ICF block structure in accordance with the teachings of the present invention.
These and other advantages of the present invention will become more apparent to those skilled in the art after consideration of the following specification taken in conjunction with the accompanying drawings wherein similar characters or reference numbers refer to similar structures in each of the separate views.
For a better understanding of the present invention, reference may be made to the accompanying drawings.
Referring to the drawings more particularly by reference numbers wherein like numbers refer to like parts, the numeral 10 in
The present stackable/foldable tie member 10 is modular in form as best illustrated in
Each side wall bracket member 12 includes a fastening plate 18, a spaced apart shut-off plate 20, and a plurality of bridging members connected therebetween forming a truss structure 22 therebetween. The truss structure 22 provides support and stability to the respective plate members 18 and 20 and to the overall side wall bracket 12.
The shut-off plate 20 includes a plurality of spaced apart projections 24 as best illustrated in
The opposite end portion of one of the respective connection link members 16A and 16B, such as link member 16A likewise includes at least a pair of spaced apart projections or hinge members 36 each including a respective opening 38 extending therethrough. The other connection link member, such as link member 16B, includes three (3) complimentary spaced apart projections or hinge members 36 each likewise including a respective opening 38 extending therethrough. The hinge projection members 36 associated with one end portion of the connection link member 16A are likewise positioned and located as best illustrated in
Use of five (5) cooperatively engageable hinge projection members 36 at the center of the overall tie member 10 improves the strength and durability of the center hinge. Nevertheless, it is recognized that any number of hinge projection members 36 may be used at the center of the overall tie member 10 including the use of the same number of hinge projection members 36, such as a pair of projection members 36, if so desired without departing from the spirit and scope of the present invention. In this event, the projection members 36 associated with one of the link members would be slightly offset from the projection members 36 associated with the other link member so that such projection members can be cooperatively engaged with the other. It is also recognized that any plurality of hinge projection members can be utilized on either end of each link member 16A and 16B as well as with each shut-off plate 20 so long as they are compatible with each other and with the hinge projection members associated with the shut-off plates 20.
In similar fashion, each pin member 34 is substantially identical in construction and includes a slotted end portion 35 associated with each opposite end portion thereof. The respective slotted end portions 35 are formed by flange portions 37 which are arrowhead in shape. The slots 35 enable the pin member flange portions 37 to flex inwardly during insertion into any one of the openings 26, 30 and 38 associated with the respective hinge members 24, 28 and 36. The arrowhead shape associated with the tip or end portion of each respective pin flange portion 37 likewise facilitates insertion of the respective pin members 34 within the respective openings. The arrowhead shaped end portion associated with each pin flange portion 37 likewise includes a tip or edge portion 39 which functions as a stop member and serves to stop the pin member 34 during the assembly process and prevents the pin from being pulled out since the top and bottom pin edge portions 39 will engage the top and bottom hinge projection members 24 and 36 once properly position therethrough. The center pin member 34 in
The top and bottom hinge projection members 36 associated with the pivotally joined connection link member 16B may include a thicker outer flange 42 to provide additional strength and stability to the pivotal connection. As illustrated in
The fastening plate 18 associated with each opposed side wall bracket 12 likewise includes an overlapping extension end portion 44 positioned at each respective end portion thereof for allowing the respective ends of the tie fastening plate 18 to overlap each other and align themselves when the tie members 10 are stackably arranged one on top of the other as will be hereinafter further explained with reference to
Still further, each side wall bracket 12 further may include a reinforcing pad or an area of extra material 48 located on one side portion of the shut-off plate directly behind and opposite the side wall bracket hinge members 24 to increase the tensile strength of the shut-off plate 20 in the area of pivotable rotation of the connection link members 16A and 16B. The reinforcing pad 48 also increases the tensile strength of the folding capability of the overall tie structure.
In addition, as best illustrated in
As best illustrated in
A substantially straight or planar ICF block 60 having a pair of parallel opposing panel members 62 retained in spaced apart relationship to each other by a plurality of the present tie members 10 is illustrated in
An array of alternating teeth 68 and sockets 70 are formed in opposing horizontal longitudinal edges of the ICF panel members 62 as is best illustrated in
In addition, as best seen in
The space or socket 70 formed between adjacent teeth 68 is of such dimensions as to enable the socket 70 to snuggly and engageably receive a tooth 68 therewithin. Advantageously, the teeth 68 associated with one block 60 will overlap with the teeth of a stacked block 60 when the teeth 68 are positioned within corresponding sockets 70 a total of at least one inch. This overlapping arrangement is greater than the overlapping teeth configuration presently utilized in the marketplace and will further improve the strength of the interlocking teeth friction fit of the stacked blocks. In addition, a bevel (not shown) can be formed along at least a portion of the perimeter of the distal end of each tooth 68 to serve as a guide to direct the tooth 68 within a corresponding socket 70. In one embodiment (not shown), the bevel can be formed along and throughout the entire perimeter of the distal end. In another embodiment (not shown), the bevel can be formed along only a portion of the perimeter of the distal end such as along the two opposing sides of the teeth 68 that will engage the teeth 68 on either side of the corresponding socket 70. In this regard, it is recognized and anticipated that the length, width, height and configuration of the respective teeth 68 and sockets 70 can vary depending upon the particular application. The greater the lateral cross-sectional area of a tooth 68, the greater the strength of the tooth and the interlocking connection between respective blocks 60.
The opposing vertical ends 74 of the panels 62 may likewise include an array of alternating teeth 76 and sockets 78 formed therein as best illustrated in
As best illustrated in
It is also recognized and anticipated that the same offset folding capability can be achieved with a double hinge arrangement by merely hinging a substantially straight, one-piece web member between the respective side wall bracket hinge members 24. In this regard, the pair of connection link members 16 can be formed into a single, one-piece member having only hinge members 28 associated with the opposite end portions thereof for cooperative engagement with the hinge members 24 associated with the respective shut-off plates 20. Other double hinge configurations are likewise possible and will achieve the same offset folding configuration as illustrated in
Use of the third hinge means located between the respective connection link members 16 in a straight line configuration as illustrated in
Due to the high capital costs required to make ICF plastic injection tie tools as well as the ICF block tools in multiple heights and multiple widths, companies have not been able to offer a more modular system that offers a standard line of ICF blocks in multiple heights. The basic structure of the present tie member 10 in conjunction with a new set of innovative tooling designs and manufacturing processes covered in Applicant's co-pending application, the disclosure of which is incorporated herewith, will allow a company to efficiently and more cost-effectively offer an improved ICF product line in multiple heights and widths. As best illustrated in
As best illustrated in
In similar fashion, the same plurality of ICF block heights based upon any multiple of the height of the tie member 10 can likewise be made in a plurality of different widths. The modularity of the present tie member 10 enables the width of a particular ICF block to be easily changed by merely changing the overall length of the respective pair of connection link members 16 forming the web portion 14. The shape, construction and fabrication of the respective side wall brackets 12 will remain the same and the pivotal connection arrangement between the shut-off plate 20 and a corresponding connection link member 16 will likewise remain the same. In fact, the design and shape of the respective connection link members 16 will remain the same, the only difference being its overall length. As a result, only ICF plastic injection tie tools forming the respective connection link members 16 need be changed in order to produce multiple width tie members. The ICF plastic injection tie tools for forming the respective side wall brackets 12 will remain the same. Only the length of the connection link members 16 need be changed in order to change the width of a particular ICF block such as any one of the blocks 60, 80 or 82. As a result, all of the present ICF blocks can be made in multiple heights and multiple widths by using the same ICF plastic injection tie tools for the side wall brackets 12, the pin members 34, and the various ICF panel heights using a minimum number of ICF block tools as explained in Applicant's co-pending application.
Still further, the modularity of the present tie members 10 also facilitates the creation of a new modular ICF block system which is now based on a common pre-determined interval of height based upon the height of the tie member 10. This modular capability will likewise enable heights based upon any multiple of the present tie member height to be severed or cut laterally at a plurality of different locations between the respective rows of stacked tie members 10 depending upon the height of the particular ICF block. For example, an 18-inch tall ICF block comprised by stacking three 6-inch tie members 10 vertically during the formation of the block as illustrated in
Still further, as best illustrated in
Still further, in another aspect of the present invention, a wide plurality of ICF block heights can be achieved by making at least two different predetermined block heights each utilizing a single row of spaced apart tie members 10 extending along the length of each respective block. For example, referring again to
In still another aspect of the present invention,
Similar to the fastening plate offset overlapping extension members 44A and 44B, the interlocking mechanism 120 associated with the top and bottom portions of the pair of side wall bracket members 110 associated with the tie member 108 positioned adjacent the opposed horizontal longitudinal edges of each ICF panel forming a particular ICF block likewise extend into the teeth area associated with the opposed horizontal longitudinal edges of each respective ICF panel to provide an additional locking feature when ICF blocks are stacked on top of each other. As more clearly illustrated in
When two similarly constructed ICF blocks are vertically engaged, the interlocking members 122 and 124 associated with the horizontal longitudinal edge of each panel member forming one ICF block will have its corresponding projection 126 and groove 128 extending into an adjacent socket 70 and such interlocking members 122 and 124 will be inserted into the corresponding sockets 70 associated with the horizontal longitudinal edge of each panel member forming the other ICF block to which it is being attached. This engagement will happen at each tie member location along the length of the respective ICF blocks so joined. As such, the snap lock feature 120 associated with each respective tie member 108 at each opposed side wall bracket 110 will cooperatively engage when two ICF blocks are joined. This additional locking feature associated with each side wall bracket member 110 will therefore create a still further positive connection between the stackable tie members 108 at each tie location. This functions as still a further locking feature when similarly constructed ICF blocks are stacked on top of each other. This interlocking connection between two side wall bracket members 110 associated with similarly constructed and stacked ICF blocks is illustrated in
In all other respects, the tie member 108 is substantially identical to the tie member 10 in that it likewise includes similarly constructed shut-off plates 20 each including a plurality of spaced-apart projections 24 as previously explained for attaching to the web portion 14 which includes a pair of cooperatively engageable connection link members 16A and 16B as previously described with respect to
Still further, it is also recognized and anticipated that the interlocking mechanism 120 associated with tie member 108 can be used in combination with the fastening plate overlapping extension portions 44A and 44B including in combination with the gripping means 46 associated with each respective extension member 44A and 44B. It is also recognized and anticipated that the interlocking mechanism 120 can likewise be utilized in combination with the fastening plate overlapping extension portions 44A and 44B without use of the gripping means 46 associated respectively therewith since the interlocking members 122 and 124 foam a positive double-snap locking arrangement between vertically stacked tie members 108 and between vertically stacked similarly constructed ICF blocks. Still further, it is recognized and anticipated that the interlocking mechanisms 120 can be used by themselves without utilizing the fastening plate overlapping extension portions 44A and 44B discussed above. In this regard, the side wall bracket members could be fashioned substantially identically to the side wall bracket members 110 except that the fastening plate extension members 44A and 44B can be removed and a substantially flat continuous fastening plate could be utilized in its stead. In such an embodiment, the interlocking mechanism 120 would provide the only positive interlocking connection between vertically stacked tie members and between similarly constructed ICF blocks. In all other respects, the tie member 108 functions substantially similarly to the tie member 10 including being pivotally foldable and collapsible as illustrated in
In still another aspect of the present invention,
Each side wall bracket member 140 is substantially similar to the side wall bracket members 12 in that they likewise include the same fastening plate 18, a spaced apart shut-off plate 92 which is slightly different from shut-off plate 20, and the same identical plurality of bridging members connected therebetween forming substantially the same identical truss structure 112 therebetween. The fastening plate 18 likewise includes substantially identical overlapping extension end portions 44A and 44B positioned in offset relationship to each other at the respective opposite end portions thereof for allowing the respective tie members 132 to likewise cooperatively engage other similarly constructed tie members 132 which are stackably arranged one on top of the other as previously explained with respect to tie member 10. The extension members 44A and 44B may or may not include engaging members 46 as previously explained with respect to tie member 10. In all other respects, the side wall bracket member 140 components 18, 22, 44A, 44B are constructed, function and operate as previously explained with respect to the identical components associated with tie members 10 and 108.
The shut-off plate 92 associated with side wall bracket member 140 differs from shut-off plate 20 in that it does not include any hinge means such as the projections 24 associated with shut-off plate 20. Instead, shut-off plate 92 includes a slot 94 adapted to receive the correspondingly shaped opposed end portions 138 of the web member 134 when a respective end portion 138 is insertably positioned within the slot 94. In this regard, the web member 134 is slidably engageable with a pair of opposed side wall bracket members 140 when the bracket members 140 are each respectively encapsulated within an ICF panel member such as panel member 62. Each slot 94 includes an intermediate narrower slot portion 94B which is flanked on each opposite end thereof by a wider slot portion 94A as best shown in
In this regard, the respective slot portions 94A are formed by side wall portions 142, 144 and 146 as best illustrated in
Each side wall bracket member 140 likewise includes a pair of interlocking mechanisms 120 as previously explained with respect to tie member 108. In this regard, the truss structure 112 of field assembled tie member 132 is substantially identical to truss structure 112 associated with foldable tie member 108 and includes top and bottom bridging members 114 and 116 which each include a platform member 118 which is sized and shaped to hold the interlocking mechanism 120 as best illustrated in
In this regard, the interlocking mechanisms 120 associated with the top bridging member 114 associated with a respective pair of side wall bracket members 140 are cooperatively engageable with the interlocking mechanisms 120 associated with the lower bridging member 116 associated with a corresponding pair of side wall bracket members 140 when a pair of similar tie members 132 are vertically stacked one on top of the other as previously explained with respect to tie member 108. The interlocking mechanism 120 associated with the top portion of each respective side wall bracket member 140 is a mirror image of the interlocking mechanism 120 associated with the lower opposite end portion of each respective side wall bracket member 140 as best illustrated in
It is recognized that any plurality of teeth or projections 148 and 150 can be associated with the interlocking members 122 and 124 including a greater number of teeth associated with one interlocking member as compared to the other interlocking member. Still further, it is recognized and anticipated that interlocking member 122 can include a pair of teeth or projection members 152 for engaging a corresponding pair of grooves 154 associated with interlocking member 124 as best illustrated in
It is also recognized and anticipated that other cooperatively engagement means can be associated with interlocking members 122 and 124 in order to achieve a snap lock engagement therebetween. Still further, it is recognized that the position and location of the interlocking mechanism 120 between the fastening plate 18 and the shut-off plate 92′ can be varied and that the interlocking mechanism 120 can be located at any position therebetween so long as the interlocking mechanism 120 associated with the tie members 108 and 132 positioned adjacent the opposed horizontal longitudinal edges of each ICF panel forming a particular ICF block likewise extends into the teeth area associated with the opposed horizontal longitudinal edges of each respective ICF panel such as illustrated in
Still further, as best illustrated in
As best illustrated in
As the bottom end portion of each web end portion 138 continues its movement through slot portion 94B and back into the lower slot portion 94A, the resilient projection stop member 160 is allowed to move back at least partially towards its original non-flexed position. As projection member 160 associated with the top portion of each respective web end portion 138 approaches slot portion 94B, because of the orientation of the upper stop member 160, the surface 163 associated with resilient member 160 will engage the ledge portion 164 positioned and located between slot portion 94A and slot portion 94B. This engagement of stop member 160 with ledge portion 164 prevents the web member 134 from passing completely through corresponding slots 94 and functions to hold the web member 134 in proper position and engagement with the side wall bracket members 140 as best illustrated in
If stop members 160 are utilized at each opposite end portion of each of the opposed web end portions 138, the web member 134 is locked into position within the respective side wall brackets 140 and cannot be removed therefrom once engaged therewith. On the other hand, if only the top stop members 160 are utilized in association with the top end portion of each respective web end portion 138, such stop members function to stop the travel of the web member 134 when positioned within the opposed slots 94 and likewise function to properly position and hold the web member in place within a particular ICF block. In this arrangement, the web member can be removed from the corresponding side wall bracket members 140 by moving the web member 134 upwardly and out of the corresponding slots 94. It is also recognized that one stop mechanism 136 can be utilized at the top portion of one of the web end portions 138 so as to stop the travel of the web member 134 when positioned within the corresponding slots 94 associated with a pair of side wall bracket members 140, and it is also recognized and anticipated that a single stop mechanism 136 can be associated with the top portion of one of the web end portions 138 and another stop mechanism 136 can be associated with the bottom portion of the other web end portion 138 so as to both stop and physically hold the web member 134 in proper position within the corresponding slots 94 associated with a pair of side wall bracket members 140 thereby likewise preventing the web member 134 from being removed from engagement with the bracket members 140. Any of these various configurations and arrangements can be utilized including a different type of lock mechanism 136 to hold and/or secure the web member 134 in proper engaged position with a pair of side wall bracket members 140.
As best illustrated in
As with side wall brackets 12, the side wall brackets 140 are likewise similarly encapsulated within a corresponding ICF panel member similar to the encapsulation and placement of the side wall brackets 12 and 110 associated with tie members 10 and 108. As such, since the web member 134 is likewise slidably engageable with a pair of side wall bracket members 140 embedded in opposed ICF panel members, the respective ICF panel members can be individually formed and shipped to a particular construction site in their unassembled state in a substantially flat form thereby again saving space for packaging, storing and shipping to a particular location. The present field assembled ICF blocks can then be easily assembled on-site by merely engaging the corresponding web members 134 with a pair of corresponding side wall brackets 140 associated with two opposed ICF panel members to complete the assembly process. Once engaged with a pair of opposed side wall bracket members 140, the field assembled web member 134 provides centralized support to the ICF block when cooperatively engaged with the corresponding side wall brackets 140.
It is also recognized and anticipated that the interlocking mechanism 120 associated with tie members 108 and 132 can take on a wide variety of different types of locking mechanisms so long as the locking mechanism is associated with both the top and bottom portions of the respective side wall bracket members. In this regard, it is also recognized that interlocking mechanism 120 can also be associated with fastening plate 18, with shut-off plates 20 and 92, or with any other side wall bracket member structure associated with the top and bottom portions of the side wall bracket members. This allows for variation in the structure of the side wall bracket members depending upon the size and shape of the particular ICF panel and/or block being used.
Still further, each side wall bracket member 140 may further include a reinforcing support member such as the member 168 illustrated in
Like tie members 10 and 108, the modular nature of the present field assembled tie member 132 likewise promotes economy of scales with respect to manufacturing ICF blocks of different widths and different heights. As with tie members 10 and 108, the web member 134 associated with the present field assembled tie member 132 can likewise be made in different widths while utilizing the same side wall bracket members 140. Here again, this reduces tooling costs and enables a manufacturer to produce a wide variety of different web member lengths to achieve the desired the ICF block widths. In similar fashion, field assembled ICF blocks of varying heights can likewise be easily produced in heights corresponding to the multiple heights of the field assembled tie member 140 as previously explained with respect to the tie member 10, or any number of a single pre-selected block height and corresponding field assembled tie member height can be used to stack multiple blocks one on top of the other to achieve a desired height based upon multiples of the pre-selected block heights.
In still a further aspect of the present invention,
Connection link members 176A and 176B differ in structure from link members 16A and 16B previously discussed with respect to foldable tie members 10 and 108 in the formation and positioning of the plurality of spaced projections 178 and 180 associated with the opposite end portions of the respective link members 176A and 176B which pivotally connect together. Like link members 16A and 16B, one end portion of each of the respective link members 176A and 176B includes a complimentary plurality of spaced projections 28 having an opening 30 extending respectively therethrough, the projections 28 being positioned and located so as to be slidably received within the spaces 32 located between the side wall bracket projections 24 as best illustrated in
Importantly, the opposite end portions of each of the connection link members 176A and 176B likewise include cooperatively engageable projections 178 and 180 each having a respective opening 182 adapted to receive the pin member 34 as previously explained. As best illustrated in
Still further, it is important to note that each of the spaced projections 24 associated with the respective side wall bracket members 178 include a terminal end surface portion 186 as best illustrated in
In all other respects, tie member 172, side wall bracket members 178, connection link members 176A and 176B, the interlocking mechanism 120, pin members 34, tool engaging slots 52, and rebar seats 54 all function and operate as previously described with respect to tie members 10 and 108.
It should also be recognized that field assembled blocks constructed in accordance with the teachings of the present invention will stack on pre-assembled folding blocks constructed according to the teachings of the present invention such as the blocks 60 illustrated in
It is likewise recognized and anticipated that any combination of the overlapping extension members 44A and 44B, the gripping means 46, and the interlocking mechanisms 120 can be used with any of the various folding and field assembled tie members discussed above.
As a result, the various embodiments of the present tie members 10, 108, 132 and 172 facilitate producing a wide variety of different ICF block widths and heights while saving tooling costs and manufacturing costs as previously explained.
Although ICF blocks 60, 80, 82 and 183 represent a substantially planar ICF form construction, it is recognized and anticipated that any angularly oriented block form construction can be constructed in accordance with the teachings of the present invention wherein each opposing panel forming a particular block construction can include two substantially planar sections positioned and located at any angular orientation relative to each other depending upon the particular application. This angular orientation can vary between 0° and 90° depending upon the particular application. In addition, any plurality of the present tie members 10, 108, 132 and 172 can be used to form any pre-selected ICF block height and width. Also, importantly, the present side wall bracket members 12, 110, 140 and 178 with the extension portions 44A and 44B and/or interlocking mechanisms 120 can be utilized with any tie member construction including an integrally formed one-piece tie member, any type of foldable tie member, and any type of slidably engageable tie member.
As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein and it is therefore contemplated that other changes, modifications, variations and other uses and applications of the present invention, or equivalents thereof, will become apparent to those skilled in the art after considering this specification and the accompanying drawings. All such drawings, modifications, variations and other uses and applications which do not depart from the spirit and scope of the present invention are deemed to be covered by the present invention which is limited only by the claims which follow.
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