Patent Application
20100095623
The invention pertains to forms for forming concrete-filled walls and, more particularly, to modular, preinsulated forms readily assembled and adapted to receive concrete therein. The modular forms create a concrete-filled wall having a rough finish on both an interior and exterior surface, thereby allowing ready finishing of these surfaces.
The process of forming vertical walls from poured concrete has been known for centuries. The process, while theoretically simple, typically requires highly skilled laborers and expensive forms to accomplish. Forms may be either built for single use or may be formed from modular sections assembled to the required configuration. Upon curing of the concrete wall poured therein, the reusable forms are typically removed and stored for later use on another project.
Insulated concrete walls are sometimes constructed using form assemblies having insulation disposed as a part of the form. The form becomes part of the concrete wall. This type of construction is typically referred to as lost form construction.
Regardless of the type of form utilized to construct a poured concrete wall, two major problems remain. First, the construction or assembly of forms typically requires skilled labor and is time intensive. When forms are not properly constructed or set, finished walls may be out of square or plumb, be of the wrong dimension, and/or have bulges or other abnormalities. It is not uncommon for it to be necessary to destroy one or more of the poured walls, reset the forms, and re-pour the concrete. This results in further expense as well as delays in the construction project.
The second problem is that poured concrete walls constructed using forms of the prior art are notoriously difficult to finish.
Many attempts have been made to overcome one or more of the aforementioned deficiencies in the concrete wall formations processes of the prior art. For example, U.S. Pat. No. 1,892,605 for WALL CONSTRUCTION, issued Dec. 27, 1932 to Paul Betzler provides a series of interlocking components to facilitate constructing a hollow wall structure. The hollow wall may, optionally, be filled with concrete, the interlocking block wall constituting a lost form.
U.S. Pat. No. 3,410,044 for FOAMED PLASTIC BASED CONSTRUCTION ELEMENTS, issued Nov. 12, 1968 to Gerhard W. Moog provides construction elements that may be stacked and then, optionally, be filled with concrete. Interlocking blocks are optionally provided by MOOG.
U.S. Pat. No. 3,552,076 for CONCRETE FORM, issued Jan. 5, 1971 to Werner K. H. Gregori, discloses a self-supporting concrete form of low-density foamed polymer. Once in place, concrete may be poured into the hollow central space in the form. The forms become part of the finished concrete wall.
U.S. Pat. No. 4,075,808 for BUILDING CONSTRUCTION SYSTEM USING MORTAR-LESS MODULAR BUILDING BLOCK ELEMENTS, issued Feb. 28, 1978 to Sanford Pearlman teaches another set of interlocking form block useful for laying up a modular from for filling with concrete.
U.S. Pat. No. 4,924,641 for POLYMER BUILDING WALL FORM CONSTRUCTION, issued May 15, 1990 to James H. Gibbar, Jr.
U.S. Pat. No. 5,038,541 for POLYMER BUILDING WALL FORM CONSTRUCTION, issued Aug. 13, 1991 to James H. Gibbar, Jr. provides a form system wherein prefabricated polymer forms are assembled together and spaced apart by integrally connecting polymer blocks, spacers or spool means. The forms may then be erected on a foundation.
U.S. Pat. No. 5,107,648 for INSULATED WALL CONSTRUCTION, issued Apr. 28, 1992 to Edward F. Roby teaches an insulated form system wherein the thickness of the wall may be varied.
U.S. Pat. No. 5,323,578 for PREFABRICATED FORMWORK, issued Jun. 28, 1994 to Claude Chagnon et al. provides a prefabricated, collapsible formwork assembly.
U.S. Pat. No. 5,311,718 for FORM FOR USE IN FABRICATING WALL STRUCTURES AND A WALL STRUCTURE FABRICATION SYSTEM EMPLOYING SAID FORM, issued May 17, 1994 to Jan P. V. Trousilek discloses plastic prefabricated form system.
U.S. Pat. No. 5,570,550 for INSULATED WALL CONSTRUCTION, issued Nov. 5, 1996 to Edward F. Roby teaches another insulated form system wherein the thickness of the wall may be varied.
U.S. Pat. No. 5,625,989 for METHOD AND APPARATUS FOR FORMING OF A POURED CONCRETE WALL, issued May 6, 1977 to Thomas R. Brubaker et al. discloses a form system wherein two identically configured panel members each define slots adapted to receive interconnecting flanges of connecting members.
U.S. Pat. No. 5,860,262 for PERMANENT PANELIZED MOLD APPARATUS AND METHOD FOR CASTING MONOLITHIC CONCRETE STRUCTURES IN SITU, issued Jan. 19, 1999 to Frank K. Johnson teaches an interconnectable system of panels useful for casting a concrete wall.
U.S. Pat. No. 6,170,220 for INSULATED CONCRETE FORM, issued Jan. 9, 2001 to James Daniel Moore, Jr. shows an insulated concrete form system having at least one longitudinally-extending side panel and at least one web member partially disposed in the side panel.
U.S. Pat. No. 6,178,711 for COMPACTLY-SHIPPED SITE-ASSEMBLED CONCRETE FORMS FOR PRODUCING VARIABLE-WIDTH INSULATED SIDEWALL FASTENER-RECEIVING BUILDING WALLS, issued Jan. 30, 2001 to Andrew Laird et al. discloses a form system of polymer sheets (e.g., polyurethane or expanded polystyrene) that may be fabricated on site to provide concrete forms.
U.S. Pat. No. 6,263,628 for LOAD BEARING BUILDING COMPONENT AND WALL ASSEMBLY METHOD, issued Jul. 24, 2001 to John Griffin G. E. Steel Company provides a panelized from system that may be erected and then filled with concrete.
U.S. Pat. No. 6,321,498 for FORMWORK FOR BUILDING WALLS, issued Nov. 27, 2001 to Salvatore Trovato teaches a formwork consisting of a plurality of pairs of facing panels connected together to form an inside space to receive concrete.
U.S. Pat. No. 6,363,683 for INSULATED CONCRETE FORM, issued Apr. 2, 2002 to James Daniel Moore, Jr. provides another insulated concrete form system having at least one longitudinally-extending side panel and at least one web member partially disposed in the side panel.
U.S. Pat. No. 6,438,918 for LATCHING SYSTEM FOR COMPONENTS USED IN FORMING CONCRETE STRUCTURES, issued Aug. 27, 2002 to James Daniel Moore, Jr. et al provides latching mechanisms for frictionally holding connectors or the like in position within a concrete form assembly.
U.S. Pat. No. 6,691,481 for CORNER FORM FOR MODULAR INSULATING CONCRETE FORM SYSTEM, issued Feb. 17, 2004 to Donald L. Schmidt provides a corner form module.
Published United States Patent Application No. for INSULATED CONCRETE FORM SYSTEMS AND METHODS OF MAKING AND USING THE SAME, published Dec. 15, 2005 upon application by Kenneth Franklin discloses a from system wherein flat insulating panels are tied together by a plurality of tying members.
Published United States Patent Application No. for ASSEMBLAGE CONCRETE FORMS AND METHOD FOR MANUFACTURING THEREOF, published May 3, 2007 upon application by Qinjiang Zhu discloses from form system where steel mesh plates and a plurality of joining pieces in cooperation with insulating sheets are assembled to construct a concrete form.
None of the patents and published patent applications, taken singly, or in any combination are seen to teach or suggest the novel building module form units of the present invention.
In accordance with the present invention there is provided a novel system of building modules that may readily be assembled into wall structures that, when filled with concrete, form a roughly-finished wall structure ready to receive both exterior and interior wall treatments. The modules may readily be assembled by relatively untrained personnel. Finished walls constructed using the novel building modules typically have an overall R-value in the range of approximately 30. The novel building modules eliminate the need for setting traditional concrete forms and for finishing bare concrete walls.
In an alternate embodiment, the outer walls of the building modules may be shipped to a building site where they may be assembled using metal width bars in lieu of solid top and bottom members. This may reduce the bulk and weight of the building modules being delivered to a construction site.
It is, therefore, an object of the invention to provide a building module that may be combined with other like building modules to create a pre-insulated, lost form concrete wall.
It is another object of the invention to provide a building module that is readily assembled into a form for receiving concrete by relatively untrained personnel.
It is an additional object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that is readily finishable on both an interior and an exterior surface.
It is a further object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that, when finished, has an R-value of approximately 30.
It is an additional object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that achieves a high R-values using a combination of insulating materials and air spaces while minimizing the amount of insulating material.
It is a still further object of the invention to provide a building module in varied lengths, typical lengths being multiples of 16 inches.
It is yet another object of the invention to provide a building module that utilizes metal spacing bars in lieu of solid top and bottom members.
It is an additional object of the invention to provide a building module that my be shipped knocked down to a construction site and assembled thereat.
Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
a-5d are schematic elevational views showing the layout of a front, right side, back, and left side of a typical building constructed using the building modules of
The present invention provides a system of modular building units that may be readily assembled and used to construct an insulated, roughly-finished concrete-filled wall. The modular building units are adapted to receive both exterior and interior wall surface treatments.
In the United States as well as other localities, standardized dimensions for construction have emerged over the years. For example, sheet materials such as plywood, wallboard, particleboard, etc. are typically supplied in 4-foot widths and 4, 8, 10, or 12-foot lengths. Many building codes require that studs (i.e., upright vertical posts in a building framework or wall) typically be placed on 16-inch centers, a spacing that conveniently accommodates standard 4-foot wide panels. Other such standard measurements for window widths and heights, door widths and heights, etc. have also emerged. The building modules of the present invention are sized and configured to accommodate such standard dimensions.
Referring first to
Typically, pressure treated plywood is used to form vertical members 102a, 102b and top and bottom member 104a, 104b, respectively. As used herein in, the term “pressure treated” is intended to encompass any wood treatment method or material wherein the wood is protected from rot, fungus, insect attack, or any other similar wood-degrading conditions. In the embodiment chosen for purposes of disclosure, a nominal thickness of ¾ inch has been found satisfactory for vertical members 102a, 102b and ½ inch nominal thickness for top and bottom members 104a, 104b, respectively. It will be recognized by those of skill in the art that other materials, dimensions or treatments may be chosen to meet a particular operating circumstance or environment. Consequently, the invention is not considered limited to the particular materials, dimensions, or treatments chosen for purposes of disclosure. For example, polymers, metals, fiberglass, etc. may all be substituted for plywood chosen for purposes of disclosure.
Top horizontal support strips 106a, 106b and bottom horizontal support strips 108a, 108b are fastened in respective top and bottom corners adjacent the points of intersection of respective top member 104a and vertical members 102a and 102b as well as bottom member 104b and vertical members 102a and 102b. In the embodiment chosen for purposes of disclosure, a pressure treated 1×2 “nailer” strip has been found suitable for the application. In alternate embodiments ¾″ spacers may be substituted for horizontal support strips 106a, 106b and bottom horizontal support strips 108a, 108b.
Foam insulation sheets 110a, 110b are attached to inward-facing surfaces of horizontal support strips 106a, 108a and 106b, 108b, respectively. Insulation sheets 110a, 110b are typically polyisocyanurate insulation. An exemplary insulation is Thermax® manufactured by Dow Building Solution division of Dow Chemical. Foam sheets 110a, 110b may be attached to vertical members 102a, 102b, respectively, using a suitable adhesive or any other suitable attachment method such as caulk, small nails or screws, or other similar fasteners believed to be known to those of skill in the art.
Air spaces 112a, 112b are formed between respective surfaces of insulation sheets 110a, 110b, and vertical members 102a, 102b.
Holes 114 and half-holes 116 are provided to receive rebar 614 (
Openings 118 are provided in top and bottom members 104a, 104b, respectively, to allow pouring concrete into the central, interior space remaining within building modules 100. The assembly and filling of multiple building modules 100 is described in detail hereinbelow.
Optional end members 122a, 122b may be provided to seal an end of building module 100, 200 when a window or door opening (see
It will be recognized by those of skill in the art that commercially available foam backed plywood may be used for form vertical members 102a, 102b, thereby eliminating the step of applying foam insulation 106a, 106b to the vertical members 102a, 102b formed from non-foambacked plywood or other materials.
Each building module 100 has an overall length “L” 120 typically chosen to be a multiple of 16 inches, for example, 16″, 32″, 48″, 64″, 80″, 96″, etc. It will be recognized that other lengths may be provided as needed to construct a particular wall configuration.
While a 16″ fundamental length has been chosen for purposes of disclosure, it will be recognized that other fundamental module lengths compatible with building codes, practices, or traditions in regions other than the United States may be substituted therefore. Consequently, the invention is not limited to the particular dimensions chosen for purposes of disclosure.
Referring now also to
A substantially square member 208 is provided to help join vertical members 202a and 202d. Dimensions of square member 208 are chosen to be compatible with the interior construction of building module 200.
Top horizontal support strips 210a, 210b, 210c, 210d and corresponding bottom horizontal support strips, not shown, are fastened in respective top and bottom corners 204, 206 to respective vertical members 202a, 202b, 202c, 202d. In the embodiment chosen for purposes of disclosure, pressure treated 1×2 “nailer” strips have been found suitable for the application. Spacers may be substituted for horizontal support strips 210a, 210b, 210c, 210d. ¾″ diameter spacers have been found suitable for the application although other similar spacers may be substituted therefore.
Foam insulation sheets 212a, 212b, 212c, 212d are attached to inward-facing surfaces of horizontal support strips 210a, 210b, 210c, 210d and corresponding bottom horizontal support strips, not shown, respectively.
Air spaces 214a, 214b, 214c, 214d are formed between respective inner surfaces of insulation sheets 212a, 212b, 212c, 212d, and vertical members 202a, 202b, 202c, 202d.
Holes 216 and half-holes 218 are provided to receive rebar 614 (
Openings 220a, 220b, 220c, 220d are provided in top member 222 and a corresponding bottom member, not shown, to allow pouring concrete into the central space remaining within building modules 200. The assembly and filling of multiple building modules 100, 200 is described in detail hereinbelow.
Building modules 100, 200 are adapted for interconnection, both top-to-bottom and end-to-end. Because, while building modules 100, 200 are structural elements in their own right, they rely upon a concrete core for final structural integrity. However, until filled, they must be viewed as concrete forms. Consequently, it is important that block-to-block sealing be maintained to avoid concrete blow out during the concrete pouring process. To accomplish this necessary sealing, each building module 100, 200 may be equipped with grooves to accommodate a spline or a tongue-and-groove arrangement.
Referring now to
Likewise, grooves 404 and 408 are provided in the top surface of top member 104a and along the top edge of vertical member 102b, respectively, to allow sealing the building module 100, 200 to a corresponding building module, not shown, placed above the illustrated building module 100, 200. Grooves 404, 408 also receive splines, not shown, during assembly to prevent concrete blowout along horizontal seams between adjacent building modules 100, 200.
It will be recognized that inter-module sealing may not be necessary in certain operating environments. Therefore, such structures as grooves, tongues, and splines may be eliminated.
It will be recognized that in alternate embodiments, building modules 100, 200 could be provided with a tongue-and-groove sealing system replacing the groove and spline system chosen for purposes of disclosure. Consequently, the invention is not considered limited to the groove and spline system chosen for purposes of disclosure but includes tongue-and-groove sealing systems as well.
As previously stated, building modules 100, 200 are adapted to be assembled into a desired wall configuration. Referring now to
In
Referring now to
Building modules 100, 200 are designed for ease of use by persons of minimum skill. The procedure for erecting a building is first, an appropriate footer 602 is placed in accordance with local building codes or accepted practices using conventional techniques.
Next, U-shaped starting channels 604 are secured to footer 602, typically using bolts 606 embedded in footer 602 and secured with nuts 608 to the footer 602. U-shaped channels 604 are typically placed at all seams of building modules 100, 200 and at least every 4 feet along the footer 602. U-shaped channels 604 are bolted or otherwise fastened to footer 602 using techniques believed to be well known to those of skill in the art. Consequently, such techniques are not further discussed herein.
Once U-shaped channels 604 are in place, building modules 100, 200 are placed within U-shaped channels 604 in a pattern such as one of the patterns of
As each building module 100, 200 is abutted to its neighbor, a spline, not shown is inserted in grooves 402, 406 (
When a first course of building modules 100, 200 is complete, a spline, not shown, is inserted into grove 408. As each building module 100, 200 is placed above a lower course, the spline, not shown, forms a guide to align the next course of building modules 100, 200.
When all courses of building modules 100, 200 are laid up, rebar 614 may be placed vertically through-holes 114, 116, 216 and 218.
Vertical alignment braces 616 are attached to the surface facing the interior of the building being constructed using building modules 100, 200. Typically 2×2 material disposed on 16″ centers is used. The vertical alignment braces 616 become the “studs” for later attaching an interior finish layer 620 to the wall 600 being constructed.
Prior to pouring concrete, the laid-up assembly of building modules 100, 200 is braced to keep the form securely plumb during the pouring and curing of the concrete. While no bracing is shown in
Once the rebar 614 is positioned and the wall is adequately braced, concrete 618 is poured into the interior cavities of building modules 100, 200 through openings 118, 200a, 220b, 220c, and 220d.
After the concrete 618 cures, an exterior finish, typically at least some combination of building paper, Tyvek® wrap, foam insulation board, etc. 610 is covered by siding 612. In alternate construction, a masonry veneer finish (e.g., brick, stone, etc.), not shown, may be applied to the exterior face of the wall in lieu of siding 612.
Interior wall finish is typically accomplished by placing foam insulation, not shown, between the studs formed by vertical alignment braces 616. Dry wall 620 may then be applied and finished using conventional finishing techniques.
It is estimated that the R-value of the wall of
The use of novel building modules 100, 200 to construct concrete-filled walls is also environmentally advantageous. A smaller quantity of insulating foam is required to achieve a predetermined “R” value than in conventional wall construction. This results in less pollution from the foam manufacturing process and a smaller amount of scrap foam eventually reaching landfills or other disposal sites.
As shown in
Referring now to
Spacing bars 700 are formed from sheet material formed into a U-shape having and elongated, central surface 702 and a pair of end surfaces 704, 706 perpendicular thereto. A plurality of inwardly projecting spikes 708 may be formed in central surface 702 proximate each of end surfaces 704, 706. A hole 114 is formed proximate the midpoint of central surface 702. Optionally, holes 710 may be provided in one or both of end surfaces 704, 706.
Referring now also to
Inner spikes 708b are disposed so as to engage an edge of foam sheets 110a, 110b.
Building modules 100 or 200 may readily be assembled by selecting two vertical members 102a, 102b and positioning them as shown in
Referring now also to
One additional advantage resulting from assembling the building modules 100, 200 using spacer bars 700 is that some thermal bridging from solid top and members 104a, 104b (
It will be recognized that the length of spacer bars 700 may be varied to readily control the overall thickness of a wall constructed with building modules 100, 200.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.
