Modular form for building a preinsulated, roughly finished concrete wall and method of building a structure therewith

Abstract

A system of building modules that may readily be assembled into wall structures that, when filled with concrete, form an insulated, roughly-finished wall structure ready to receive both exterior and interior wall treatments. The building modules may be readily assembled by relatively untrained personnel and form walls typically having an overall R-value in the range of approximately 30. The novel building modules eliminate the need for setting traditional concrete forms and of finishing a bare concrete wall. The modules are provided in various lengths, the lengths typically being multiples of 16 inches.

Description

FIELD OF THE INVENTION

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.

BACKGROUND OF THE INVENTION

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 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.

DISCUSSION OF THE RELATED ART

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 blocks useful for laying up a modular form 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. teaches a polymer building wall form wherein forms prefabricated of polymer are assembled together, spaced apart by integrally connecting polymer or blocks or spacers and erected upon a foundation footing through their insertion upon L-shaped ties.

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 footer or other 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 a 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 form 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. 2005/0275124 for INSULATED CONCRETE FORM SYSTEMS AND METHODS OF MAKING AND USING THE SAME, published Dec. 15, 2005 upon application by Kenneth Franklin discloses a form system wherein flat insulating panels are tied together by a plurality of tying members.

Published United States Patent Application No. 2007/0094973 for ASSEMBLAGE CONCRETE FORMS AND METHOD FOR MANUFACTURING THEREOF, published May 3, 2007 upon application by Qinjiang Zhu discloses a 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.

SUMMARY OF THE 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 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 may be shipped knocked down to a construction site and assembled thereat.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG. 1 is a perspective view of a building module in accordance with the invention having a spline and groove module to module sealing system;

FIG. 2 is a front elevational view of the building module of FIG. 1;

FIG. 3 a, is a left end elevational view of the building module of FIG. 1;

FIG. 3 b is a left end elevational view of the building module of FIG. 1 but having an end sealing member in place therein;

FIG. 4 is a perspective view of a building module in accordance with the invention having a tongue and groove module to module sealing system;

FIG. 5 a is a left end elevational view of the building module of FIG. 4;

FIG. 5 b is a left end elevational view of the building module of FIG. 4 but having an end sealing member in place therein;

FIGS. 6 a-6d are partial top plan views of four configurations of a building module using tongue and groove features for end-to-end module sealing;

FIG. 7 is a top plan schematic view of a corner building module in accordance with the invention;

FIGS. 8 a and 8b are left side and rear elevational schematic views, respectively of building module of FIG. 7;

FIG. 9 is an exploded, perspective, schematic view of a pair of building modules joined top-to=bottom using a spline;

FIGS. 10 a-10d 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 in accordance with the invention and

FIG. 11 is cross-sectional view of a typical wall constructed using the building modules of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

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 FIGS. 1, 2, and 3a, there are shown a perspective, a front elevational, and an end elevational, schematic view of a building module 100 in accordance with the invention. Module 100 is substantially hollow and has the form of a rectangular parallelepiped.

Module 100 has a pair of vertical members, front vertical member 102a and rear vertical member 102b, each having an upper edge 124, a lower edge 126, a left edge 128, aright edge 130, a width “L” 122, and a height “H” 132.

Top member 104a and bottom member 104b are both sandwiched between front vertical member 102a and rear vertical member 102b. An upper major surface, not specifically identified, of top member 104a is substantially flush with an upper edge 124 of both front and rear vertical members 102a, 102b, respectively. Likewise, a lower major surface, not specifically identified, of bottom member 104b is substantially flush with lower edge 126 of both front and rear vertical members 102a, 102b, respectively.

Top member 104a and bottom member 104b are typically secured to front vertical member 102a and rear vertical member 102b using fasteners or adhesive, neither shown. The process and hardware for joining members (for example, top member 104a to front vertical member 102a) one to another is believed to be well known to those of skill in the art and, consequently, neither is discussed in further detail herein. The invention is intended to include any and all suitable processes and/or hardware suitable for joining members one to another.

Typically, pressure treated plywood is used to form front and rear 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 front and top rear horizontal support strips 106a, 106b, respectively are fastened to respective ones of front vertical member 102a and rear vertical member 102b in respective top front and rear corners adjacent respective points of intersection with top member 104a.

Likewise, bottom front and bottom rear horizontal support strips 108a, 108b, respectively are fastened to respective ones of front vertical member 102a and rear vertical member 102b in respective bottom front and rear corners adjacent respective points of intersection with bottom member 104b.

Optional front and rear middle horizontal support strips 150a, 150b may be fastened to respective ones of front vertical member 102a and rear vertical member 102b proximate a vertical, midpoint thereof.

In the embodiment chosen for purposes of disclosure horizontal support strips 106a, 106b, 108a, 108b, 150a, and 150b are typically formed from pressure treated 1×2 “nailer” strip or furring strip material. Horizontal support strips 106a, 106b, 108a, 108b, 150a, and 150b typically extend continuously across the entire width, not specifically identified, of respective ones of front vertical member 102a and rear vertical member 102b.

Referring now also to FIG. 3b, there is shown an end, elevational view of building module 100 with a sealed end. In building modules 100 that must have an end sealed, horizontal support strip 106a, 106b, 108a, 108b, 150a, and 150b may be shortened by an amount equal to the thickness of an end sealing member 158 that is sandwiched between front vertical member 102a, rear vertical member 102b, top member 104a, and bottom member 104b. An outer major surface, not specifically identified, of end sealing member 158 is disposed substantially flush with left edge 128 of both front and rear vertical members 102a, 102b, respectively. It will be recognized that FIG. 3b shows the left end of building module 100 sealed. However, the right end, not shown, of building module 100 may likewise be sealed by installing an end sealing member 158 at the right end thereof. End sealing members 158 are typically used to leave window and door openings or the like in the concrete wall to be constructed using building modules 100.

Building module 100 has grooves 156 disposed in at least one edge, not specifically identified of front vertical member 102a and rear vertical member 102b. In addition top grooves 152 may be formed along a top edge, not specifically identified, of front and rear vertical members 102a, 102b, respectively. Finally, bottom grooves 154 may be formed along a bottom edge, not specifically identified, of front and rear vertical members 102a, 102b, respectively. Grooves 152, 154, 156 are sized and configured to receive a spline 160, best seen in FIG. 9. Spline 160 is used to provide a seal between horizontal and/or vertical seams formed between adjacent building modules 100. Note that FIG. 9 shows spline 160 only between vertically stacked building modules 100. It will be recognized that a similar construction, not shown, may be used to provide end-to-end sealing between a pair of horizontally aligned building modules 100.

Rebar-accepting holes 114 and half-holes 116 are provided to stabilize reinforcing bar (i.e., rebar) once building modules are laid up into a wall structure and before pouring concrete. The use of rebar to reinforce concrete walls is believed to be well known to those of skill in the art and neither rebar nor its use is further described herein.

Front and rear foam insulation sheets 110a, 110b, respectively are attached to inward-facing surfaces of corresponding ones of horizontal support strips 106a, 108a, 106b, 108b, 150a, and 150b, 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 inward-facing surfaces of horizontal support strips 106a, 108a, 106b, 108b, 150a, and 150b, respectively, using a suitable adhesive or any other suitable attachment method such as caulk, small nails or screws, staples, or other similar fasteners believed to be known to those of skill in the art.

Front and rear air spaces 112a, 112b, respectively, are formed between respective surfaces of front and rear insulation sheets 110a, 110b, and vertical members 102a, 102b.

Openings 118 are provided in top and bottom members 104a, 104b, respectively, to allow pouring concrete into the central, interior space, not specifically identified, remaining within building modules 100. The assembly and filling of multiple building modules 100 is described in detail hereinbelow.

It will be recognized by those of skill in the art that commercially available foam backed plywood may be used for front and rear vertical members 102a, 102b, respectively, thereby eliminating the need for foam insulation 110a, 110b and horizontal support strips 106a, 108a, 106b, 108b, 150a, and 150b. However, it should be noted that this construction eliminates front and rear air spaces 112a, 112b, respectively. Elimination of front and rear air spaces 112a, 112b lowers the overall R-value of the finished concrete wall.

Each building module 100 has an overall length “L” 122 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 to FIGS. 4, 5a, and 5b, there is shown an alternate embodiment of a building module 100 (FIG. 1) having a tongue and groove module to module sealing system, generally at reference number 100′. FIG. 4 shows a perspective, schematic view of building module 100′ while FIGS. 5a and 5b show a left end elevational view of the building module 100′ of FIG. 4, and a left end elevational view of the building module 100′ of FIG. 4 but having an end sealing member in place therein, respectively. The only difference between building modules 100 and 100′ is that building module 100 is equipped with square grooves 152, 154 on upper and lower surfaces, respectively, each adapted to receive a spline 160 whereas building module 100′ is equipped with protruding tongues 162 on an upper surface and a curvilinear groove 164 on lower surfaces, the curvilinear groove 164 being sized and configured to receive tongue 162.

It will be recognized that similar tongue and groove arrangements may be provided on ends of module 100′ to facilitate side-to-side sealing of modules 100′ one to another. It will be further recognized that four module configurations may be provided. Referring now to FIGS. 6a-6d, there are shown top plan, schematic views of four possible end configurations of module 100′. In FIG. 6a, module 100′ has vertical grooves 168 on a left end and vertical tongues 166 on a right end. In FIG. 6b, module 100′ has vertical tongues 166 on a left end and vertical grooves 168 on a right end. In FIG. 6c, module 100′ has vertical grooves 168 at both a right and a left end thereof. Finally, in FIG. 6d, module 100′ has vertical tongues 166 at both a left and a right end thereof.

Referring now also to FIG. 7, there is shown top plan view of a building module 200 adapted for forming corners in cooperation with building modules 100/100′. A vertically disposed front member 202a, a vertically disposed rear member 202b, a vertically disposed inside side member 202c, a vertically disposed outside side member 202d each has a top edge, a bottom edge, a left edge, and a right edge, an inward facing major surface, and an outward facing major surface, none of which are specifically identified.

Vertically disposed front member 202a and vertically disposed outside side member 202d are disposed in a mutually orthogonal relationship, meeting at outside corner 204. A vertically oriented, substantially square member 208 is disposed at corner 206 contacting the inward facing major surface of vertically disposed front member 202a adjacent the right edge thereof and the inward facing major surface of vertically disposed outside side member 202d adjacent a left edge thereof. Vertically disposed front member 202a and vertically disposed outside side member 202d are attached to vertically disposed member 208 using any suitable hardware or other fastening method. Dimensions of vertically oriented, substantially square member 208 are chosen to be compatible with the interior construction of building module 200 (i.e., with dimensions of other internal members thereof).

Likewise, vertically disposed rear member 202b and vertically disposed inside side member 202c are disposed in a mutually orthogonal relationship and meet at an inside corner 206, a right edge of vertically disposed rear member contacting a forward facing edge of vertically disposed inside side member 202c.

An L-shaped planar top member 222a has a front edge 224, a right edge 226, a first portion of a rear edge 228, a first portion of a left edge 230, a second portion of a rear edge 232, a second portion of a left 234. L-shaped planar top member 222a is sandwiched between vertically-oriented members 202a, 202b, 202c, 202d such that front edge 224 is abutted against an inward-facing major surface of vertically-disposed front member 202a; right edge 226 is abutted against an inward-facing major surface of vertically oriented outside side member 202d; first portion of left edge 230 is abutted against an inward-facing major surface of vertically-disposed inside side member 202c; and second portion of rear edge 232 is abutted against an inward-facing major surface of vertically-disposed rear member 202b. An outward-facing major surface of L-shaped planar top member 222a is aligned with an upper edge of all of vertically disposed members 202a, 202b, 202c, and 202d.

Referring now also to FIGS. 8a and 8b, there are shown left side and rear elevational views, respectively of building module 200 of FIG. 7.

An L-shaped planar bottom member 222b also has a front edge 224, a right edge 226, a first portion of a rear edge 228, a first portion of a left edge 230, and a second portion of a rear edge 232, a second portion of a left 234. L-shaped planar bottom member 222b is sandwiched between vertically-oriented members 202a, 202b, 202c, 202d such that front edge 224 is abutted against an inward-facing major surface of vertically-disposed front member 202a; right edge 226 is abutted against an inward-facing major surface of vertically oriented outside side member 202d; first portion of left edge 230 is abutted against an inward-facing major surface of vertically-disposed inside side member 202c; and second portion of rear edge 232 is abutted against an inward-facing major surface of vertically-disposed rear member 202b. An outward-facing major surface of L-shaped planar bottom member 222b is aligned with a lower edge of all of vertically disposed members 202a, 202b, 202c, and 202d.

Top front and top rear horizontal support strips 210a, 210b, respectively are fastened to respective ones of front vertical member 202a and rear vertical member 202b in respective top front and rear corners adjacent respective points of intersection with L-shaped planar top member 222a.

Top left and top right horizontal support strips 210c, 210d, respectively are fastened to respective ones of left vertical member 202c and right vertical member 202d in respective top front and rear corners adjacent respective points of intersection with L-shaped planar top member 222a.

Likewise, bottom front and bottom rear horizontal support strips 236a, 236b, respectively are fastened to respective ones of front vertical member 202a and rear vertical member 202b in respective bottom front and rear corners adjacent respective points of intersection with L-shaped planar bottom member 222b.

Likewise, bottom left and bottom right horizontal support strips 236c, 236d, respectively are fastened to respective ones of left vertical member 202c and right vertical member 202d in respective bottom front and rear corners adjacent respective points of intersection with L-shaped planar bottom member 222b.

Optional front and rear middle horizontal support strips 238a, 238b, respectively, may be fastened to respective ones of front vertical member 202a and rear vertical member 202b, respectively, proximate a vertical midpoint of each thereof.

Optional left and right middle horizontal support strips 238c, 238d, respectively may be fastened to respective ones of left vertical member 202c and right vertical member 202d, respectively, proximate a vertical midpoint of each thereof.

In the embodiment chosen for purposes of disclosure horizontal support strips 210a-210d, 236a-236d, and 238a-238d are typically formed from pressure treated 1×2 “nailer” strip or furring strip material. Horizontal support strips 210a-210d, 236a-236d, and 238a-238d typically extend continuously across the entire width, not specifically identified, of respective ones of front vertical member 202a, rear vertical member 202b, left vertical member 202c, and right vertical member 202d. Top, bottom and middle horizontal support strips 210a, 238a, 236a, respectively, abut vertically oriented, substantially square member 208 proximate outside corner 204

Front foam insulation sheet 212a, is attached to inward-facing surfaces of front horizontal support strips 210a, 236a, 238a.

Rear foam insulation sheet 212b, is attached to inward-facing surfaces of rear horizontal support strips 210b, 236b, 238b.

Left foam insulation sheet 212c, is attached to inward-facing surfaces of left horizontal support strips 210c, 236c, 238c.

Right foam insulation sheet 212d, is attached to inward-facing surfaces of right horizontal support strips 210d, 236d, 238d.

Foam insulation sheets 212a-212d are typically attached to inward facing surfaces of respective horizontal support strips 210a-210d, 236a-236d, and 238a-238d using an adhesive. Suitable construction grade adhesives are believed to be well known to those of skill in the art and, consequently, are not further described herein.

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 (FIG. 11) when building modules 100, 100′ or 200 are assembled in the manner described in detail hereinbelow.

Concrete accepting Openings 220a, 220b, 220c, 220d are disposed in L-shaped planar top member 222a and a corresponding L-shaped planar bottom member 222b 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.

As previously mentioned, building modules (e.g., building modules 100, 100′, 200) may need to have an end sealed. FIG. 3b shows a building module 100 having end sealing member 158 sealing one end thereof. The same techniques may be used to seal an end of building module 200. Consequently, sealing an end of building module 200 is not discussed in further detail herein.

Building modules 100, 100′, and 200 are adapted for interconnection, both top-to-bottom and end-to-end with other building modules. 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 (i.e., intermodule leakage) during the concrete pouring process. To accomplish this necessary sealing, each building module 100, 100′, 200 may be equipped with grooves to accommodate a spline or a tongue-and-groove arrangement.

Referring now also to FIG. 9, there is shown an exploded, perspective, schematic view of a pair of building modules 100 being joined top-to-bottom to one another with an intervening spline 160. It will be recognized that if tongue-and-groove sealing as shown in FIGS. 4, 5a, 5b, and 6a . . . 6d is used, no spline 160 is necessary.

It will further 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.

As previously stated, building modules 100, 200 are adapted to be assembled into a desired wall configuration. Referring now to FIGS. 10a-10d, there are shown front, right-side, rear, and left-side elevational views, respectively of a small building illustrating the use of the novel building modules 100, 200 in accordance with the invention. The terms front, right side, etc. are, of course, arbitrary. The numbers inside the building module blocks are typical lengths, typically in inches conforming to United States building practices. It will be recognized that any combination of module lengths may be combined to make a desired building structure.

In FIG. 10a, a door 502 and a window 504 are shown. In FIG. 10b, an “overhead” or garage door 506 may be placed. In FIG. 10c, two windows 508, 510 are shown. In FIG. 10d, a single window 512 is shown. The presence and/or placements of door 502, windows 504, 508, 510 and 512, and overhead door 506 are arbitrary and only used to illustrate the flexibility of using building modules 100, 200 in varying lengths.

Referring now to FIG. 11, there is shown a cross sectional, elevational view of a typical wall built in accordance with the building modules and method of the present invention, generally at reference number 600.

Building modules 100, 200 are designed for ease of use by persons of minimum skill. To erect a building, 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. It will be recognized that footer 602, bolts 606, and nuts 608 as well as any additional associated hardware, not shown, necessary to fasten U-shaped starting channels 604 to footer 602 form no part of the invention and are shown merely to show building modules 100, 100′, 200 in the intended usage environment.

U-shaped channels 604 are typically placed at all seams, not specifically identified, between building modules 100, 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 FIGS. 10a-10d.

As each building module 100, 200 is abutted to its neighbor, a spline 160 is inserted in grooves 156 (FIG. 1) as discussed hereinabove. Corner building modules 200 (FIG. 7) are used to form corners.

When a first course of building modules 100, 200 is complete, a spline 160 is inserted into top grove 152. As each building module 100, 200 is placed above a lower course, the spline 160 forms a guide to align the next course of building modules 100, 200, being received in bottom groove 154 of the next course of building modules 100, 200.

It will be recognized that no spline is required when using building modules 100′ that have tongue-and-groove structures (e.g., 162, 164, 166, 168) that provide sealing between building modules 100′.

When all courses of building modules 100, 200 are laid up, rebar 614 may be placed vertically in 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 inch 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 FIG. 6, methods and materials for aligning and bracing concrete forms are believed to be well known to those of skill in the construction trades. Consequently, such material and methods are not further discussed herein.

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, 220a, 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 FIG. 6 is approximately 30. The R-value contribution of each of the wall components is shown in Table 1.

TABLE 1
Siding with building paper, 2
etc.
Outer plywood               1
¾″ Air gap                  1
½″ foam                     7
Concrete                    1
½″ foam                     7
¾″ air gap                  1
Inner plywood               1
1″ foam                     8
½″ air gap                  1
½″ drywall                  1
Total                       31

The use of novel building modules 100, 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.

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.

Claims

1. A building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall, comprising: a} a pair of vertically disposed, spaced apart planar front and rear members each having a height, a width, a thickness, a top edge, a bottom edge, a right edge and a left edge, and inward facing major surface and an outward facing major surface, said inward facing major surface of said front member facing said inward facing major surface of said rear member;b) an elongated planar top member having a front edge and a rear edge disposed parallel to a major axis thereof, an inward-facing major surface, and an outward facing major surface, said top member being disposed between said vertically disposed front member and said vertically disposed rear member, said front edge of said top member abutting said inward facing major surface of said vertically disposed front member, said rear edge of said top member abutting said inward facing major surface of said vertically disposed rear member, said outward facing surface of said top member being aligned evenly with said top edge of each of said vertically disposed front member and said vertically disposed rear member, said left edge of said top member being aligned with said left edge of each of said vertically disposed front member and said vertically disposed rear member and said right edge of said top member being aligned with said right edge of each of said vertically disposed front member and said vertically disposed rear member;c} an elongated planar bottom member having a front edge and a rear edge disposed parallel to a major axis thereof, an inward-facing major surface, and an outward facing major surface, said bottom member being disposed between said vertically disposed front member and said vertically disposed rear member, said front edge of said bottom member abutting said inward facing major surface of said vertically disposed front member, said rear edge of said bottom member abutting said inward facing major surface of said vertically disposed rear member, said outward facing surface of said bottom member being aligned evenly with said bottom edge of each of said vertically disposed front member and said vertically disposed rear member, said left edge of said bottom member being aligned with said left edge of each of said vertically disposed front member and said vertically disposed rear member and said right edge of said bottom member being aligned with said right edge of each of said vertically disposed front member and said vertically disposed rear member, said planar bottom member being disposed substantially parallel to said planar top member, said vertically disposed front member, said vertically disposed rear member, said planar top member and said planar bottom defining a rectangular parallelepiped having a hollow interior region;d) at least one opening into said hollow interior region disposed in at least one of said planar top member and said planar bottom member, said at least one opening being sized and configured to receive poured concrete for placement in said hollow interior space;e) at least two parallel horizontal support strips each having a length, a height, a thickness, a left edge, and a right edge disposed on and attached to said inward facing major surface of both of said vertically disposed front member and said vertically disposed rear member, said at least two horizontal support strips being disposed substantially parallel to said respective top and bottom edges of respective ones of said vertically disposed front member and said vertically disposed rear member, said left edge of each of said at least two horizontal support strips being aligned with said left edge of a respective one of vertically disposed front member and said vertically disposed rear member, said right edge of each of said at least two horizontal support strips being aligned with said right edge of a respective one of vertically disposed front member and said vertically disposed rear member;f) an insulation sheet having a top edge, a bottom edge, a left edge, a right edge, and an outward-facing major surface attached to an inward facing surface of each of said at least two horizontal support strips, said top edge and said bottom edge of said insulation sheet abutting said inward facing major surface of a respective one of said planar top member and said planar bottom member, said right edge and said left edge of said insulation sheet being aligned with respective ones of said right edge and said left edge of respective ones of said vertically disposed front member and said vertically disposed rear member; andg) an air gap formed between said outward facing major surface of said insulation sheet and an inward facing surface of a respective one of said vertically disposed front member and said vertically disposed rear member.

2. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1, further comprising: h) a planar end sealing member having a top edge, a bottom edge, a left edge, a right edge, and an outward facing major surface, disposed at least one position selected from the group: proximate said right edge of said vertically disposed front member, and proximate said left edge of said vertically disposed front member, said planar end member being disposed substantially perpendicular to, each of said vertically disposed front member, said vertically disposed rear member, said planar top member, and said planar bottom member, said top edge of planar end sealing member abutting said inward facing major surface of said planar top member, said bottom edge of planar end sealing member abutting said inward facing major surface of said planar bottom member, said left edge of planar end sealing member abutting said inward facing major surface of a respective one of said vertically disposed rear member and said vertically disposed front member, said right edge of planar end sealing member abutting said inward facing major surface of a respective one of said vertically disposed rear member and said vertically disposed front member, said outward facing major surface thereof being aligned with respective ones of said left edges and said right edges of all of said vertically disposed front member, said vertically disposed rear member, said planar top member, and said planar bottom member.

3. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1, further comprising: h) means for supporting rebar disposed in at least one of said planar top member and said planar bottom member.

4. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 3, wherein said means for supporting rebar comprises a first through-hole in said planar top member and a second through-hole in said planar bottom member, said first through-hole and said second through-hole being aligned to define an axis substantially perpendicular to a major surface of said top member and substantially parallel to said vertically disposed front member and said vertically disposed rear member, said axis being disposed approximately equidistant from each of said vertically disposed front member and said vertically disposed rear member.

5. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1, further comprising: h) means for sealing a first of said building modules to a second adjacent one of said building modules to prevent egress of concrete poured into said interior region.

6. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 5, wherein said means for sealing comprises means for sealing an end surface of said building module to and end surface of a second building module abutted end-to-end thereto.

7. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 5, wherein said means for sealing comprises means for sealing at least one of a top surface and a bottom surface of a first building module to at least one of a top surface and a bottom surface of a second building module vertically aligned with and adjacent to said first building, module.

8. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 5, wherein said means for sealing comprises means at least one selected from the group: a tongue-and-groove seal, and a groove and spline arrangement.

9. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1, wherein said building module comprises a corner building module comprising a first portion and a second portion contiguous with and orthogonal to said first portion.

10. The building module adapted for modular construction of a roughly finished, insulated, lost form concrete wall as recited in claim 1, wherein each of said front vertical member, said rear vertical member, said top member, and said bottom member comprise pressure treated plywood.

11. The building module adapted for modular construction of an insulated, lost form concrete wall as recited in claim 10, wherein each of said front vertical members and said rear vertical member have a nominal thickness of approximately ¾ inch.

12. The building module adapted for modular construction of an insulated, lost form concrete wall as recited in claim 10, wherein each of said top member and said bottom member have a nominal thickness of approximately ½ inch.

13. The building module adapted for modular construction of an insulated, lost form concrete wall as recited in claim 1, wherein said top front horizontal strip, said bottom front horizontal strip, said top rear horizontal strip, said bottom rear horizontal strip, said middle front horizontal strip, and said rear middle horizontal strip comprise pressure treated lumber having a nominal dimension of approximately 1×2 inches.

14. A method of erecting a concrete wall, the steps comprising: a) providing a foundation adapted to receive a modular, insulated, lost concrete form;b) attaching a U-shaped starter channel to an upper surface of said foundation;c) providing a plurality of building modules adapted for modular construction of an insulated, lost form concrete wall, each of said building modules comprising a hollow, rectangular parallelepiped adapted to receive concrete in a hollow interior region thereof, each of said building modules comprising at least two horizontal support strips disposed within said hollow interior region substantially parallel to a major axis thereof and attached to least one of a front vertical member, and a rear vertical member adjacent at least one of a top member and a bottom member and comprising sheet insulation attached to an inward-facing surface of said at least two horizontal support strips, said insulation sheet forming an air cavity between an outward-facing surface thereof and inward-facing surface of a respective one of said front vertical member and said rear vertical member, and an opening sized and configured to receive poured concrete in said interior region disposed in at least one of said top member and said bottom member;d) placing a first course of said plurality of building modules in said U-shaped starter channel, said plurality of building modules being placed in an abutting, end-to-end arrangement;e) placing subsequent courses of said plurality of said building modules atop a lower course of said plurality of building modules, said plurality of building modules of each of said subsequent courses being placed in an abutting, end-to-end arrangement to define at least one wall structure;f) upon completion of said at least one wall structure, placing alignment braces on an interior face of said at least one wall structure; andg) filling said at least one wall structure with concrete.

15. The method of erecting a concrete wall as recited in claim 14, the steps further comprising: h) when required, placing a spline in at least one of the positions: between an end surface of a first of said plurality of building modules and an end surface of an adjacent, abutted one of said plurality of building modules, and between at least one of a top surface and a bottom surface of a first one of said plurality of building modules and a corresponding one of said top surface and said bottom surface of an corresponding one of said plurality of building modules in an adjacent course of building modules.

16. The method of erecting a concrete wall as recited in claim 14, wherein said providing step (c) comprises providing at least one building module comprising a corner building module comprising a first portion and a second portion contiguous with and orthogonal to said first portion.

17. The method of erecting a concrete wall as recited in claim 16, wherein said placing step (d) comprises placing said at least one building module comprising a corner building module comprising a first portion and a second portion contiguous with and orthogonal to said first portion.

18. The method of erecting a concrete wall as recited in claim 17, the steps further comprising: h) when required, placing a spline in at least one of the positions: between an end surface of a first of said plurality of building modules and an end surface of an adjacent, abutted one of said plurality of building modules, and between at least one of a top surface and a bottom surface of a first one of said plurality of building modules and a corresponding one of said top surface and said bottom surface of an corresponding one of said plurality of building modules in an adjacent course of building modules.