Information
-
Patent Grant
-
6820384
-
Patent Number
6,820,384
-
Date Filed
Thursday, October 19, 200024 years ago
-
Date Issued
Tuesday, November 23, 200420 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Blackwell Sanders Peper Martin LLP
-
CPC
-
US Classifications
Field of Search
US
- 052 5911
- 052 5912
- 052 426
- 052 442
- 052 565
- 052 30915
- 052 30917
-
International Classifications
-
Abstract
A foam block concrete form having a pair of opposing foam panels spaced parallel from each other, and retained in opposing fashion by a plurality of transverse ties therebetween. Each panel has opposing longitudinal edges having engaging means formed therealong for removably retaining a longitudinal edge having similar engaging means formed therealong when adjacent thereto. The plurality of substantially planar include a web portion separating a pair of opposing flange members encapsulated within respective opposing foam panels along a respective lateral axis.
Description
THE FIELD OF THE INVENTION
The present invention relates to Insulating Concrete Form Systems utilizing foam block forms and, more specifically, to improvements to the foam panels, the foam corner panels, the panel spacing ties, the corner spacing ties and the interaction of the ties with the foam panels.
BACKGROUND OF THE INVENTION
Insulating Concrete Form Systems (ICFS) are known which serve to contain fluid concrete while it solidifies as well as 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 foamed plastic panels which are retained in a spaced relationship parallel to each other by a plurality of ties.
The spacing ties are truss-like and include opposing flange portions which reside within respective opposing foam panels. The opposing flange portions are separated by an intermediate web portion connected therebetween, enabling the tie to hold and secure the panel portions. Some prior designs teach slide-in ties having flanges which are configured to be complementary with slots formed in the panels. Such block designs have the disadvantage of requiring work-site assembly.
Other prior art ICFS designs teach the use of prefabricated foam block concrete forms in which opposing flanges of each tie are molded into respective opposing foam walls of the foam block. While each of these ICFS designs teaches the use of a foam form block having a lower longitudinal edge designed to engageably receive only the upper longitudinal edge of a similar block therebelow, and an upper longitudinal edge designed to engageably receive only the lower longitudinal edge of a similar block thereupon, none teach the use of a prefabricated, continuous-concrete-wall-generating, foam form block having opposing horizontal longitudinal edges designed to engageably receive either opposing horizontal longitudinal edge of an adjacent block having a substantially similar longitudinal edge design.
It is also known in the art to design ties for a foam form block that will produce two independently structurally sound half-height blocks if cut laterally in half. However, the top half of the block becomes unusable waste, in the event that it is necessary to remove the top half of the block along the horizontal midpoint, due to the fact that these ties are not used with foam blocks that are designed to be vertically reversibly interlocking with adjacent blocks. Furthermore, these prior art tie designs fail to optimize distribution of the flow of fluid concrete across the web portion of the tie. Rather, they serve to impede even distribution of the fluid concrete between the foam panels. Finally, none of the blocks used with these prior art tie designs are premarked along their horizontal midpoint to serve as a visual guide for accurately cutting the blocks in half laterally.
The prior art teaches the use of corner ties molded within foam blocks configured to function as corner molds for concrete poured therebetween. Such corner ties are intended to serve as anchors for exterior surfaces fastened to the exterior surface of the foam-and-concrete wall. However, the forces transmitted from the exterior wall covering to the corner ties to which it is anchored can cause the corner ties to be ripped from the foam block within which it is seated, unless the corner tie has a concrete-engaging member. Of the prior art corner ties that include a concrete-engaging member, some require on-site assembly of the concrete-engaging member, while others provide a corner tie having flange dimensions that yield flanges that are incapable of functioning as anchors to an exterior facade. None teach the design of a corner tie having a concrete-engaging member that requires no on-site assembly, and having flanges configured to function as anchors for an exterior facade.
Nowhere in the prior art is it taught to design a pre-built, solid-wall-generating, foam form corner block that is vertically reversible along its longitudinal axis, that is to say, a corner block having opposing horizontal longitudinal edges that can stackably engageably receive either opposing longitudinal edge of an adjacent block having similarly designed longitudinal edges. Such a block could function as a left corner or a right corner, and could be cut in half laterally yielding two usable corner halves. Such a design would yield increased versatility of the block and, consequently, produce less waste.
SUMMARY OF THE INVENTION
The apparatus of the present invention overcomes the weaknesses and disadvantages associated with prior art designs and teaches a more versatile tie and block design. The block of the present invention is a preconstructed unit including a plurality of tie members spaced apart from, and parallel to, one another.
The block of the present invention can be constructed in any of a variety of configurations including, but not limited to, a substantially planar or straight block and a 90° corner block. The block is designed to yield a solid, continuous concrete wall construction when connected horizontally and vertically to blocks of similar construction.
Either block configuration includes an opposing pair of foam panels. Identical arrays of alternating teeth and sockets are formed along opposing horizontal longitudinal edges of each panel to enable it to removably engage either opposing horizontal longitudinal edge of a vertically adjacent block panel having a substantially identical array of teeth and sockets formed along either longitudinal edge. Similarly, identical arrays of alternating teeth and sockets are formed along opposing vertical end edges of each panel to enable it to removably engage either opposing vertical end of a horizontally adjacent block panel having a substantially identical array of teeth and sockets formed along either vertical end edge.
As a result, a planar block of the present invention can vertically and horizontally engageably receive adjacent whole or half planar or corner blocks of the present invention, regardless of vertical orientation with regard to its horizontal longitudinal axis and regardless of horizontal orientation with regard to its vertical axis. Likewise, a corner block of the present invention can vertically and horizontally engageably receive adjacent whole or half planar or corner blocks of the present invention, regardless of vertical orientation with regard to its horizontal longitudinal axis and regardless of horizontal orientation with regard to its vertical axis. The corner block of the present invention can, therefore, function as a left corner block or a right corner block, as well as provide two functional half corner block units when the corner block is divided along its horizontal midpoint. To facilitate separating a block of either planar or corner configuration along its horizontal midpoint, the outer surface of either opposing panel of each block is pre-marked along its horizontal midpoint.
The horizontal dimension of a tooth along the longitudinal axis of the panel will determine the minimum increment to which a block can be vertically separated and yield a functioning block segment. Therefore, versatility of a foam form block to be separated into vertical segments is inversely proportional to the horizontal longitudinal tooth dimension. Conversely, the greater the cross-sectional area of the teeth, the stronger the teeth and the greater the cross-sectional area of the cavities. The greater the cross-sectional area of the cavities, the easier it is to remove contaminants therefrom to allow the block to be fully seated upon or below an adjacent block. Consequently, the optimum tooth dimension must balance the need for versatility in trimming the block into vertical segments with the need for tooth strength and easy removal of cavity contaminants.
Each tie has a web portion connecting opposing truss and flange members molded within opposing foam panels. The web is designed to provide centralized structural support not only within a whole block, but also within the half blocks created by dividing a whole block along its horizontal midpoint. At the same time, the tie web is designed to optimize the flow of liquid concrete poured between the opposing foam panels.
The web has 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 associated whole or half, planar or corner, block with respect to its horizontal longitudinal axis. The rebar-retaining seats of each tie are of sufficient dimension to allow unstraight rebar to be retained therein without imparting undesirable torque forces to the tie member. Furthermore, the seat dimensions allow for overlapping ends of longitudinally adjacent rebar members to be retained therein to create, in effect, a wireless contact splice when the ends are imbedded in hardened concrete.
The corner block of the present invention includes a corner tie having a pair of corner flanges connected to a structural web member, all of which are encapsulated within a foam outer corner panel member to which the exterior siding will be attached. A concrete-engaging member extends inwardly from the structural web of the corner tie beyond the inner surface of the outer corner panel to serve as an anchor, when surrounded by concrete poured between opposing corner panels, to prevent the corner tie from being ripped from the corner foam block unit when exterior siding is anchored thereto.
These and other objects and 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 of reference refer to similar structures in each of the separate views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG.
1
. is an elevational view of one embodiment of a tie of the present invention.
FIG.
2
. is a front elevational view of a preconstructed straight foam form block of the present invention.
FIG.
3
. is a plan view of the block shown in FIG.
2
.
FIG.
4
. is an end elevational view of the block shown in FIG.
2
.
FIG.
5
. is an enlarged plan view of a segment of the block shown in FIG.
2
.
FIG.
6
. is an enlarged plan view of the corner tie of the present invention.
FIG.
7
. is a plan view of a corner foam form block of the present invention including the corner tie illustrated in FIG.
6
.
FIG.
8
. Is a right end elevational view of the corner block shown in FIG.
7
.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of a tie
10
of the present invention is shown in FIG.
1
. The tie
10
comprises a pair of flange members
12
separated by, and connected to, a web portion
14
. The web portion
14
includes a pair of opposing truss members
16
connected by a pair of substantially identical transverse bridge members
18
having a plurality of rebar-retaining seats
20
molded therein. In a preferred embodiment, the tie
10
is constructed from polypropylene. In other embodiments, the tie is constructed of metal, or other suitable materials.
The rebar seats
20
are substantially identical to each other in configuration, and are arranged in a pair of opposing rows along each transverse bridge
18
. Each seat
20
consists of a substantially U-shaped well formed by a pair of adjacent fingers
22
. An inwardly spanning lateral knuckle
24
is formed in either distal end of adjacent fingers
22
, creating a distance between opposing knuckles
24
that is substantially less than the lateral distance between the proximal ends of adjacent fingers
22
.
The length of the fingers
22
is chosen in conjunction with the lateral distance between proximal ends of adjacent fingers
22
to create a substantially U-shaped well that is capable of retaining a pair of rebar rods diagonally therein. Alternatively, the seats
20
are of such dimension that a single unstraight length of rebar may be retained therein without imparting undesirable torque to portions of the web
14
. The knuckles
24
associated with the given seat
20
serve to help retain the rebar therein.
A substantially straight or planar foam form block
30
having at least one substantially planer rectangular segment is shown in
FIG. 2
having a pair of parallel opposing foam panels
32
retained in spaced relationship to each other by a plurality of ties
10
. As can be seen from
FIGS. 3 and 4
, the plurality of ties extends transversely between opposing inner surfaces
34
of the opposing panels
32
. As can further be seen from
FIGS. 3 and 4
, the opposing flanges
12
and trusses
16
of each tie
10
are substantially retainably encapsulated within respective opposing foam panels
32
such that each flange
12
is seated inwardly from the outer surface
36
of the panel
32
within which it is encapsulated.
An array of alternating, equi-dimensional square teeth
38
and square sockets
40
are formed in opposing horizontal longitudinal edges of the panels
32
,
72
and
78
, as is best shown in FIG.
5
. In a preferred embodiment, the array consists of two longitudinal rows of alternating teeth
38
and sockets
40
, the rows being offset from each other by the distance of one side of one tooth
38
. In addition, as best seen in
FIG. 2
, the teeth
38
associated with one of the opposed horizontal longitudinal edges of the panels
32
,
72
and
78
are vertically aligned with the sockets
40
associated with the other of the opposed horizontal longitudinal edges of the panels
32
,
72
and
78
; and the sockets
40
associated with one of the opposed horizontal longitudinal edges of the panels
32
,
72
and
78
are vertically aligned with the teeth
38
associated with the other of the opposed horizontal longitudinal edges of the panels
32
,
72
and
78
. It is also important to recognize that the pair of panels
32
or
72
and
78
are positioned relative to each other such that the teeth
38
associated with the row of alternating teeth
38
and sockets
40
located adjacent the outer surface
36
of one of the pair of panels
32
forming the block
30
, or adjacent the outer surface
76
or
82
of one of the pair of panels
72
or
78
forming the block
70
, are horizontally aligned with the sockets
40
associated with the row of alternating teeth and sockets located adjacent the outer surface of the other of the pair of panels forming blocks
30
and
70
, and the teeth
38
associated with the row of alternating teeth
38
and sockets
40
located adjacent the inner surface
34
of one of the pair of panels
32
forming the block
30
, or adjacent the inner surface
74
or
80
of one of the pair of panels
72
or
78
forming the block
70
, are horizontally aligned with the sockets
40
associated with the row of alternating teeth and sockets located adjacent the inner surface of the other of the pair of panels forming blocks
30
and
70
. Employing such a tooth
38
and socket
40
configuration along opposing longitudinal edges of a given panel
32
,
72
or
78
, yields a panel
32
,
72
or
78
having opposing longitudinal edges capable of engageably receiving either opposing longitudinal edge of an adjacent, similarly configured, panel
32
,
72
or
78
of a straight block
30
or a corner block
70
in stacked fashion. As a result, straight or corner blocks
30
and
70
employing panels
32
,
72
and
78
having opposing longitudinal edges of this configuration can be engageably stacked upon and below adjacent blocks
30
and
70
of substantially the same configuration, regardless of the vertical and/or horizontal orientation of the panels
32
,
72
and
78
around their respective longitudinal axes. Thus, in the event that it is desirable to cut a planar or corner block
30
and
70
in two pieces/half vertically or horizontally, both resultant pieces/halves of the block
30
and
70
are usable, thereby reducing the waste generated by prior art block designs. This engaging means thereby reduces the overall construction cost and time.
The length of each tooth
38
laterally along the longitudinal axis of a panel
32
,
72
or
78
determines the usable incremental portions of a block
30
and
70
when vertically separated. Thus, the smaller the lateral length of the tooth
38
along the longitudinal axis of the panels
32
,
72
and
78
, the greater the quantity of available usable vertical increments of the blocks
30
and
70
. However, the greater the lateral cross-sectional area of a tooth
38
, the greater the strength of the tooth
38
.
In a preferred embodiment, each tooth
38
is substantially one inch along each side of its lateral cross-sectional perimeter, and projects outwardly from the panels
32
,
72
and
78
a distance of substantially one-half of an inch. It has been found that teeth
38
of this dimension yield blocks
30
and
70
that are able to be cut into a sufficient quantity of usable vertical increments, while providing a tooth
38
of sufficient strength to effectively resist breakage. Furthermore, in a preferred embodiment, the resultant socket
40
formed between adjacent teeth
38
is of such dimensions as to enable the socket
42
to snugly and engageably receive a tooth
38
therewithin. Advantageously, a bevel
46
is formed along at least a portion of the perimeter of the distal end of each tooth
38
to serve as a guide to direct the tooth
38
within a corresponding socket
40
. In one embodiment, shown in
FIG. 5
, the bevel
46
is formed along and throughout the perimeter of the distal end. In another embodiment, (not shown), the bevel
46
is formed only along and throughout the three sides of the perimeter of the distal end that are not coplanar with the outer surface
36
of the panel
32
.
As with the opposing longitudinal edges of the panels
32
,
72
and
78
, the opposing vertical ends of the panels
32
,
72
and
78
have an array of teeth
42
and sockets
44
formed therein to engageably receive either opposing vertical end of similarly configured panels
32
,
72
and
78
, thereby yielding blocks
30
and
70
that can engageably receive horizontally adjacent blocks
30
and
70
, regardless of the horizontal orientation of their vertical ends. In a preferred embodiment, the array consists of two vertical columns of alternating teeth
42
and sockets
44
offset from each other by the length of one tooth
42
. Here again, the location of the teeth
42
associated with one of the vertical longitudinal edges of the panels
32
,
72
and
78
correspond with the location of the sockets
44
associated with the other of the vertical longitudinal edges of the panels
32
,
72
and
78
; and the location of the sockets
44
associated with one of the vertical longitudinal edges of the panels
32
,
72
and
74
correspond with the location of the teeth
42
associated with the other of the vertical longitudinal edges of the panels
32
,
72
and
78
.
The blocks
30
and
70
can be divided into a maximum of two, equal, usable horizontal increments. Consequently, an elongated tooth
42
having a longitudinal length substantially equal to half the vertical height of a block
30
or
70
provides the maximum tooth strength for the maximum quantity of usable horizontal block increments. The elongated tooth
42
extends laterally inwardly from the adjacent surface of the panels
32
,
72
and
78
for substantially half the thickness of the panels
32
,
72
and
78
, while extending uniformly outwardly from the vertical end of the panels
32
,
72
and
78
for a distance of substantially half an inch. The elongated socket
44
dimensions resulting from adjacent elongated teeth
42
are such that an elongated tooth
42
can be engageably received therein.
In the event that it is desirable to laterally divide a straight block
30
in half, the exterior surface
36
of each panel
32
includes a mark or indicator
48
along its central longitudinal axis. Likewise, in the event that it is desirable to laterally divide a corner block
70
in half, the exterior surface
76
and
82
of the inner and outer corner panels
72
and
78
, respectively, include a mark or indicator
84
along their respective central longitudinal axis. The marks or indicators
48
and
84
aid in accurately severing a block
30
and
70
laterally into equal halves.
A corner tie
50
is shown in
FIG. 6
including a pair of flange members
52
sharing a common end and extending perpendicularly from each other, each flange member
52
having an outer surface
54
and an inner surface
56
. An array of web members
58
connects the inner surfaces
56
of each flange
52
. A concrete-engaging member
60
extends inwardly from the web
58
at substantially a 45° angle from either flange
52
.
A corner block
70
is shown in
FIG. 7
including an inner corner panel
72
having an inner surface
74
and an outer surface
76
, an outer corner panel
78
having an inner surface
80
and an outer surface
82
, and a plurality of ties
10
having opposing flange ends
12
, each opposing flange
12
being encapsulated within a respective panel
72
and
78
, thereby retaining the inner surfaces
74
and
80
of the corner panels
72
and
78
, respectively, in opposing fashion. The corner block
70
includes planar rectangular segments which are disposed at approximately 90° to each other in an angular relationship. As illustrated in
FIGS. 7 and 8
, the flange members
52
and web members
58
of the corner tie
50
are completely encapsulated within the outer corner panel
78
at its corner, offset vertically from the central horizontal axis of the block
70
. The concrete-engaging member
60
extends from the web
58
inwardly beyond the inner surface
80
of the outer block
78
, enabling the concrete-engaging member
60
to be completely encapsulated by concrete when it is poured between the corner panels
72
and
78
.
In the field, pre-constructed planar or straight blocks
30
and corner blocks
70
are shipped to a construction site that has been prepared in readiness for a concrete wall to be constructed thereon. Due to the tooth
38
and socket
40
design formed along opposing longitudinal edges of the straight blocks
30
and corner blocks
70
, the tooth
42
and socket
44
design formed in the opposing vertical ends of the straight blocks
30
and corner blocks
70
, and the functionally vertical reversible design of the rebar-retaining seats
20
of the ties
10
, the straight blocks
30
and corner blocks
70
are functionally vertically reversible and horizontally reversible. That is to say that the planar blocks
30
and corner blocks
70
can engageably receive a planar block
30
or a corner block
70
there below, thereupon, or adjacent its opposing vertical ends regardless of vertical orientation of its opposing longitudinal edges and regardless of horizontal orientation of its opposing vertical ends. More specifically, the top longitudinal edges of the panels forming blocks
30
and
70
will removably engage both the top and bottom longitudinal edges of the panels forming another similarly constructed block
30
and/or
70
, and the bottom longitudinal edges of the panels forming blocks
30
and
70
will removably engage both the top and bottom longitudinal edges of the panels forming another similarly constructed block
30
and/or
70
. Furthermore, rebar rods may be retainably placed within rebar seats
20
of a straight block
30
or a corner block
70
regardless of vertical orientation of the longitudinal edges of the blocks
30
and
70
and regardless of whether the blocks
30
and
70
have been laterally cut in half. This versatility of the straight blocks
30
and corner blocks
70
provides an ICFS that can be more rapidly constructed than prior art designs, thereby appreciably reducing labor costs.
Furthermore, due to the open web
14
design of the ties
10
, optimal concrete flow is realized. As a result, even a viscous concrete mix can be poured without creating unwanted gaps and voids, thereby minimizing time spent pouring the concrete and enabling a greater variety of usable concrete mixes. Consequently, a wall of optimal concrete strength can be constructed in a reduced amount of time while producing a minimum of product waste and, ultimately, reducing labor costs.
The opposing flanges
12
of each tie
10
run substantially the vertical height of the block
30
, thereby providing strength throughout the height of the block
30
sufficient to prevent the opposing panels
32
from being displaced by the outward forces created when concrete is poured there between. In a preferred embodiment, the flanges
12
are 14¾ inches in height, 1½ inches wide and {fraction (3/16)} of an inch thick, thereby providing a flange
12
that can serve as a stud to which interior and exterior facades can be anchored. The inner surface
34
and outer surface
36
of the block
30
, as well as the outer surface
76
and outer surface
82
of the inner corner panel
72
and outer corner panel
78
, respectively, are substantially flat surfaces. The panels
32
, the inner corner panels
72
and the outer corner panels
78
are approximately 2½ inches thick with the flanges
12
being positioned inwardly from the outer surface of the panels
32
,
72
and
78
by ½ inch. To facilitate locating the flanges
12
to serve as anchoring studs, flange indicators
86
are molded into the outer surface of the panels
32
,
72
and
78
, as shown in FIG.
5
.
In one embodiment, shown in
FIGS. 1
,
3
,
4
,
7
and
8
, the ties
10
are twelve inches wide and the panels
32
,
72
and
78
are two and a half inches thick, yielding a block
30
or
70
thirteen inches thick and a concrete wall eight inches thick. In another embodiment, (not shown), the ties
10
are ten inches wide and the panels
32
,
72
and
78
are two and a half inches thick, yielding a block
30
or
70
eleven inches thick and a concrete wall six inches thick. In yet another embodiment, (not shown), the ties
10
are seven inches wide and the panels
32
,
72
and
78
are two inches thick, yielding a block
30
or
70
eight inches thick and a concrete wall four inches thick. It is understood that any of a variety of tie
10
, panel
32
,
72
or
78
, and block
30
or
70
dimensions may represent a preferred embodiment for a given ICFS application.
In a preferred embodiment, the blocks
30
have panels that are 48 inches long and 16 inches high, and employ
8
ties
10
spaced at 6 inch intervals.
As with the flanges
12
of the ties
10
, the flanges
52
of the corner ties
50
serve as anchoring studs for exterior facades fastened to the corner block
70
. In a preferred embodiment, the flanges
52
are spaced inwardly from their respective outer surface
82
by a distance of ½ inch. Flange
52
indicator markings (not shown) located in the outer surface
82
of the outer corner panel
72
facilitate locating the flanges
52
for anchoring the facade thereto. Once the poured concrete has cured, the concrete/engaging member
60
prevents the corner tie
50
from being displaced from the corner block
70
due to anchor forces incurred by the facade mounted thereto.
Facade corner covers (not shown) include a pair of planar surfaces joined along a common edge in angular relationship to each other and having apertures for receiving fastening hardware therethrough spaced outwardly from the common edge. When installed, the planar surfaces are spaced outwardly from a respective outer surface
82
of an outer corner panel
78
, with the common edge being spaced outwardly from, and aligned with, the outer corner edge of the corner block
70
. In a preferred embodiment, the flanges
52
extend laterally from their common end a sufficient distance to enable fastening hardware inserted through the corner cover apertures to be engageably anchored to a respective flange
52
when the facade corner cover is positioned for installation.
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 modifications and applications, or equivalents thereof, will occur to those skills in the art. It is accordingly intended that the claims shall cover all such modifications and applications that do not depart from the spirit and scope of the present invention.
Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims.
Claims
- 1. A foam block concrete form having ton and bottom longitudinal edges comprising:a pair of opposing foam panels spaced parallel from each other, each panel having at least one substantially planar rectangular segment having a horizontal pair of opposing longitudinal edges, a vertical pair of longitudinal edges, and inner and outer surfaces; engaging means formed along the horizontal and vertical pairs of longitudinal edges associated with each panel for removably engaging one block form with other block forms having similar and complimentary engaging means associated therewith when placed both side-by-side and vertically adjacent thereto; the engaging means associated with the horizontal pair of opposing longitudinal edges of each panel including two rows of alternating teeth and sockets along each edge, one row being offset from the other row by the distance of one side of one tooth, the teeth associated with one of the opposed horizontal longitudinal edges being vertically aligned with the sockets associated with the other of the opposed horizontal longitudinal edges and the sockets associated with one of the opposed horizontal longitudinal edges being vertically aligned with the teeth associated with the other of the opposed horizontal longitudinal edges; said pair of opposing panels forming said block form being disposed relative to each other such that the teeth associated with the row of alternating teeth and sockets located adjacent the outer surface of one of said pair of panels are horizontally aligned with the sockets associated with the row of alternating teeth and sockets located adjacent the outer surface of the other of said pair of panels, and the teeth associated with the row of alternating teeth and sockets located adjacent the inner surface of one of said pair of panels are horizontally aligned with the sockets associated with the row of alternating teeth and sockets located adjacent the inner surface of the other of said pair of panels; and a plurality of substantially planar ties positioned transverse to and between the pair of opposing foam panels, each tie including a web portion separating a pair of opposed flange members encapsulated within respective opposing foam panels along a respective lateral panel axis; said engaging means enabling one of said block forms to be engaged with a plurality of similarly constructed block forms in both a side-by-side arrangement and a vertically stacked arrangement regardless of the orientation of said block forms the top longitudinal edges of one block form being engageable with both the top and bottom longitudinal edges of another similarly constructed block form and the bottom longitudinal edges of one block form being engageable with both the top and bottom longitudinal edges of another similarly constructed block form.
- 2. The apparatus of claim 1 wherein each opposing foam panel includes two substantially planar rectangular segments in angular relation to each other, each segment having at least one pair of opposing edges.
- 3. The apparatus of claim 1 wherein each opposing flange member is substantially planar and of sufficient strength to function as an anchoring stud.
- 4. The apparatus of claim 3 wherein each opposing flange member can be functionally encased within a respective opposing foam panel.
- 5. The apparatus of claim 4 wherein the opposing foam panels have a longitudinal axis and the opposing flange members have a longitudinal axis substantially equal in length to the transverse axis of the respective foam panel.
- 6. The apparatus of claim 1 wherein the web portion includes a pair of bridge members formed therein spaced parallel from each other and transverse to the opposing flange members.
- 7. The apparatus of claim 6 wherein each bridge member includes at least one rebar-retaining seat positioned therealong extending outwardly therefrom.
- 8. The apparatus of claim 7 wherein each bridge member includes at least one rebar-retaining seat positioned therealong extending inwardly therefrom.
- 9. The apparatus of claim 8 wherein the rebar-retaining seats are sufficiently large to retainably receive a plurality of rebar rods therewithin.
- 10. The apparatus of claim 6 wherein the opposing bridge members, in conjunction with each other, provide uniformly distributed structural support about the central lateral axis of the tie.
- 11. The apparatus of claim 10 wherein the opposing bridge members individually provide uniformly distributed structural support about their respective longitudinal axis when the tie is laterally cut in half.
- 12. The apparatus of claim 6 wherein each bridge member includes at least one re-bar retaining seat positioned therealong extending outwardly therefrom and at least one re-bar retaining seat positioned therealong extending inwardly therefrom.
- 13. A foam block concrete form comprising:a pair of opposing foam panels spaced apart in a substantially parallel relationship, each panel including a pair of horizontally opposed edges and inner and outer surfaces; a plurality of ties extending between and connecting the foam panels; and two rows of alternating teeth and sockets associated with each horizontally opposed edge of each panel, one row being positioned adjacent the outer surface of said panel and one row being positioned adjacent the inner surface of said panel and one row being offset from the other row such that when said pair of opposed panels are disposed relative to each other to form said block form the teeth associated with the row of alternating teeth and sockets positioned adjacent the outer surface of one of said pair of panels are horizontally aligned with the sockets associated with the row of alternating teeth and sockets positioned adjacent the outer surface of the other of said pair of panels forming said block form, and the teeth associated with the row of alternating teeth and sockets positioned adjacent the inner surface of one of said pair of panels are horizontally aligned with the sockets associated with the row of alternating teeth and sockets positioned adjacent the inner surface of the other of said pair of panels forming said block form; said two rows of alternating teeth and sockets associated with each horizontally opposed edge of each panel forming said block form and their horizontal positioning relative to each other enabling one of said block forms to be engaged with a plurality of similarly constructed block forms in a vertically stacked arrangement regardless of the orientation of said block forms, the top horizontal edges of one block form being engageable with both the top and bottom horizontal edges of another similarly constructed block form and the bottom horizontal edges of one block form being engageable with the top and bottom horizontal edges of another similarly constructed block form.
- 14. A concrete block form comprising:a pair of opposing panels positioned and spaced apart in a substantially parallel relationship to each other, each panel having a pair of horizontally opposed longitudinally edges, a pair of vertical longitudinal edges, and inner and outer surfaces; engagement means formed along the horizontal and vertical pairs of longitudinal edges associated with each panel for removably attaching one concrete block form to other concrete block forms having similar and complimentary engaging means associated therewith when such concrete block forms are placed both side-by-side and vertically adjacent thereto; the engaging means associated with the horizontal pair of opposing longitudinal edges associated with each panel including two rows of alternating teeth and sockets along each edge, one row being offset from the other row, the teeth associated with one of the opposed horizontal longitudinal edges being vertically aligned with the sockets associated with the other horizontally opposed longitudinal edge, and the sockets associated with one of the opposed horizontal longitudinal edges being vertically aligned with the teeth associated with the other horizontally opposed longitudinal edge; the engaging means associated with the vertical pair of longitudinal edges including two columns of alternating teeth and sockets, one column being offset from the other column, the location of the teeth associated with one of the vertical longitudinal edges corresponding with the sockets associated with the other of the vertical longitudinal edges and the location of the sockets associated with one of the vertical longitudinal edges corresponding with the location of the teeth associated with the other of the vertical longitudinal edges; said pair of panels forming said concrete block form being disposed relative to each other such that the teeth associated with the row of alternating teeth and sockets located adjacent the outer surface of one of said pair of panels are horizontally aligned with the sockets associated with the row of alternating teeth and sockets located adjacent the outer surface of the other of said pair of panels, and the teeth associated with the row of alternating teeth and sockets located adjacent the inner surface of one of said pair of panels being horizontally aligned with the sockets associated with the row of alternating teeth and sockets located adjacent the inner surface of the other of said pair of panels; and a plurality of ties extending between said pair of opposed panels for holding said panels in said spaced apart substantially parallel relationship; said engaging means enabling one of said concrete block forms to be engaged with a plurality of similarly constructed concrete block forms in both a side-by-side arrangement and a vertically stacked arrangement regardless of the orientation of said concrete block forms, the top longitudinal edges of one concrete block form being engageable with both the top and bottom longitudinal edges of another similarly constructed block form and the bottom longitudinal edges of one concrete block form being engageable with both the top and bottom longitudinal edges of another similarly constructed concrete block form.
- 15. A foam block concrete form comprising:a pair of opposing panels positioned and spaced apart in substantially parallel relationship to each other, each panel having top and bottom horizontal longitudinal edges, first and second end portions, and inner and outer surfaces; a plurality of ties extending between said pair of opposed panels for holding said panels in said spaced apart substantially parallel relationship; first engaging means associated with the first and second end portions of each panel for removably attaching one pair of panels to a similarly constructed pair of panels in side-by-side relationship to each other; and second engaging means associated with the top and bottom longitudinal edges of each panel for stackably attaching one pair of panels to another similarly constructed pair of panels, said second engaging means including two rows of alternating teeth and sockets along each edge, one row being offset from the other row, the teeth associated with the top longitudinal edge being vertically aligned with the sockets associated with the bottom longitudinal edge; said pair of panels forming said block form being disposed relative to each other such that the teeth associated with the row of alternating teeth and sockets located adjacent the outer surface of one of said pair of panels are horizontally aligned with the sockets associated with the row of alternating teeth and sockets located adjacent the outer surface of the other of said pair of panels, and the teeth associated with the row of alternating teeth and sockets located adjacent the inner surface of one of said pair of panels being horizontally aligned with the sockets associated with the row of alternating teeth and sockets located adjacent the inner surface of the other of said pair of panels; and said second engaging means enabling one of said block forms to be vertically removably attached with a plurality of similarly constructed block forms regardless of the orientation of said block forms, the top longitudinal edges of one block form being engageable with both the top and bottom longitudinal edges of another similarly constructed block form, and the bottom longitudinal edges of one block form being engageable with both the top and bottom longitudinal edges of another similarly constructed block form.
- 16. The apparatus of claim 15 wherein each of said plurality of ties includes a web portion positioned between a pair of opposed flange members, each flange member being encapsulated within one of said respective pair of opposing panels.
- 17. The apparatus of claim 15 wherein said first and second engaging means are substantially identical in construction.
US Referenced Citations (60)