Building construction using structural insulating core

The present invention relates to a structural insulating foam core wall that is versatile to be used as an independent framed wall, combination of an independent wall and Insulated Concrete Form (ICF) wall, in conjunction as part of a precast wall or as part of forming system to form a concrete beams and column structure, and modular units with concrete beams and columns. The structural insulating core wall, can also be used as individual foam spacer blocks, with or without brackets and horizontal bracing channels. Various types of flanges extensions are added to form different support channel flanges. The interlocking foam spacers and support channels which can be glued or screwed together to form structural insulating panels (SIPS), independent walls or as part of a precast wall with columns and beams integrated within the wall panels.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to an improved wall system where a structural insulating core wall is used as an independent framed wall, or in combination of an independent wall and a Insulated Concrete Form (ICF) wall, in conjunction as part of a precast wall or as part of forming system to form a concrete beam and column structure, various types of connectors and flange extensions, and modular units with concrete beams and columns. Various types of flanges of the wall forming mold separates the wall forming structure from the wall surfaces and can also be used as a concrete form support. Different types of insulation and methods of installation are discussed and therefore more prior art is discussed as well as a more in depth discussion on the background of the invention is mentioned.

BACKGROUND OF THE INVENTION

There are several methods to support multiple floors or a roof structure of a building, that is, by using a load bearing wall or by using a beam which is supported by posts on both sides of the beam. Should a wall require any windows a beam above the window and columns are installed on both sides of the window. A high-rise or larger type buildings, uses columns and beams to support the additional floors and roof loads above. On the other hand, smaller buildings also use walls to support the weight of additional floors or roof load above. These load bearing walls uses can be made of solid masonry, concrete or as a framed wall using wood or metal framing members typically spaced 16-24 inches apart. A non-load bearing wall can also be made using wood or metal framing members, the wall only supports itself not a roof or floor load above. The non-load bearing wall can also be built the same way, however the structural capacity of the framing members are less and therefore the material costs are less expensive.

The construction of a wall varies based on the type of materials that are used. For example a solid concrete or masonry wall does not need to be laterally supported, because the wall is connected horizontally from say one masonry block to another masonry block. On the other hand, a post and beam type construction needs to be horizontally braced somewhere within that building otherwise the building would collapse if the wind or an earthquake would cause the building to move horizontally. Usually that is done by adding diagonal braces that criss-cross between the columns or by adding a solid wall somewhere within the building structure. When a smaller wood or metal framed wall has a similar problem, that is, the framing members need to be supported between each other using by applying plywood over the framing members. The plywood acts a shear wall, by not allowing the framing members to fall down like “domino's”.

Typically the higher the wall, the thicker the wall becomes. This occurs because if a tall wall is not laterally supported (braced by another structure) then the wall will bend. For example, a masonry wall can have a pilaster added, that is, a column attached to the wall and made of the same material.

Typically wood or metal framed wall construction must be secured to a foundation or concrete slab either by anchor bolts embedded within a concrete wall and or attaching tie down supports which are secured to the metal or wood studs and then anchored into the foundation or foundation.

Concrete construction has changed over the years since the days of the Roman Empire where concrete was initially used. From the early concrete building structures, concrete wall construction has developed into today's construction uses ICF's (insulated concrete forms) to build concrete walls. Now as energy has become more expensive, these ICF's have reduced the amount of concrete within the wall by adding more insulation thereby creating columns and beams within the ICF's. These ICF's have a very rigid system with no flexibility on where to install the beams or columns.

Structural insulated panels or SIP's have a foam core with exterior skins usually plywood glued to the foam. Sometimes metal or wood is installed within the foam core and the wood or metal is connected between the panels for additional support. SIP's have a very limited load bearing capacity due to the structural limitation in the design of the panels. The use of SIP's have been limited to one or two story building and have never been used in conjunction with precast or poured-in-place concrete walls.

Rigid insulation boards have been installed on metal channels for years and more recently rigid insulation has been glued onto metal channels as a thermal barrier. Insulating blocks have embedded channels within insulation blocks also embedding the metal channels within the rigid insulation. Some insulated concrete forms (ICF's) have embedded plastic connectors within their rigid insulation blocks also separating the rigid foam from the plastic connectors. Structural insulating panels (SIP's) have no thermal break when wood or metal is added at the connections of adjacent panels. None of the systems has an interior and sheathing insulation combined as well as creating a thermal break within a wall forming structure.

Thin faced precast concrete wall panels have been using light gauge metal framing for the structural backing for a few years now. When the concrete is poured face up, insulation supports the concrete until it has cured, while pouring the concrete face down in a forming bed, the light gauge metal framing is suspended over the forming bed and the metal channel is typically embedded into the concrete facing and usually no thermal break is accomplished. These systems do not combine the wall and sheathing insulation, plus have that thermal break as well as the flexibility to install columns and beams within the structure.

Thin cementitious material has been applied over foam, however usually to make a block, and the entire block is entirely encased with the cementitious material. Sometimes a wall panel has also been fully encased with the cementitious material and recently an ICF block has been partially encased with the cementitious material. Cementitious materials have not applied to wall panels where the cementitious materials have had the thermal break between the interior and exterior surfaces.

Modular buildings have been very limited in their design and functionality of their superstructure. Modular construction has been typically limited to wood framed building and some have been developed using steel as a column and beam substructure. Concrete has had limited exposure in modular buildings, as well as the use of a structural insulating core to form concrete beams and columns within the exterior walls and common walls between modular buildings.

Today, more and more steel or concrete post and beam buildings are being built. Construction techniques for building walls have been changing significantly including metal channel framing and stay-in-place insulated forms where concrete is installed within these forms.

DESCRIPTION OF PRIOR ART

There have been various attempts on creating a form mold to pour a concrete column or beam within a wall. Some patents uses metal channels to help reduce the pressure produced by using a rigid foam material to form concrete beam or columns. Another type of patents uses foam blocks with vertical and horizontal chambers to form concrete columns and beams. Another type of panel is a composite panel that uses fiber concrete boards the panel surfaces as well as interior bracing within the panel with rigid foam at the interior. Another type of panel is when the foam molds create a continuous chamber to pour a solid concrete wall.

Various types of material are used in different capacity that can vary the way panels are made and formed. A triangular channel is used in wall panels, however their configuration, use and function is totally different. A rigid insulation is installed within the flanges of the rigid support structure, isolating the support from the concrete as well as allowing for additional fasteners to be installed later. Rigid and/or loose foam insulation is used in construction; however the insulation is not used in the same method to build a wall. Insulated concrete forms have been used in construction; however some types of ICF (Insulated Concrete Forms) are not capable of installing concrete columns or beams within the ICF walls as they were only intended to be used as full width concrete walls and other ICF's have no flexibility in column spacing. Structural insulated panels (SIP's) with their foam core and plywood exterior have a very limited use. Thin cast precast walls poured both face up or face down into a light gauged metal framed wall have typically no thermal break with the metal channel framing and the thin precast concrete wall facing. New products like Aerated Autoclaved Concrete or FoamGlas are both rigid boards as well as insulation boards that can be used in a variety of ways.

A. Concrete Column & Beam Using Metal Channels

Panels are formed here using rigid boards and or rigid insulation along with metal channels to form concrete columns or beams. The light gauge framing adds support means for installing drywall or other surface building materials.

In U.S. Pat. No. 6,041,561 & U.S. Pat. No. 6,401,417 by LeBlang shows how a concrete column and beam can be installed within a wall using metal channels and rigid insulation/hard board or as a column and beam within a wall and or as a separate beam using a rigid board between the channels to enlarge the beams or columns.

In U.S. Pat. No. 6,256,960 by Babcock (filed Apr. 12, 1999) is a modular SIP wall panel with a metal channel at one edge and overlapping inner and outer skins attached to the metal channel. One metal channel and the interior foam wall core form a pocket into which concrete can be poured to form a concrete column. A metal plate covers the top of the SIP panel for connection to a roof structure. The concrete columns are only one channel wide and therefore the column size or structural capacity is very limited.

In US 2007/0044392 by LeBlang was granted, however decided not to execute the patent.

B. Foam Block with Holes.

The next several existing patents uses tubes or rigid foam with vertical holes to form concrete columns. If light gauge steel is used, the metal is on the exterior of the form and not permanently attached to the foam.

In U.S. Pat. No. 4,338,759 by Swerdow (filed Jul. 28, 1980) and U.S. Pat. No. 4,357,783 by Shubow use a plurality of spaced, thin walled tubes are placed between two rows of channels into which concrete is then poured into the walled tubes to make an array of concrete columns within a wall. A beam is installed between the two rows of channels and is support by a metal channel with holes for the columns. The double wall construction is expensive solution to form a concrete column and a method to support the sides of the beam on top of the wall.

In U.S. Pat. No. 5,839,249 by Roberts (filed Nov. 16, 1996) & U.S. Pat. No. 6,164,035 by Roberts (filed Nov. 23, 1998) uses a foam block with vertical holes in it which is large enough to insert a metal vertical support as well as pour a vertical concrete column after the wall has been erected. A U shaped foam block sets on top of the wall and has holes which connect to the concrete columns. Also electrical outlets are shown where the foam has been removed and conduits are installed in the wall. In U.S. Pat. No. 6,588,168 (filed Apr. 17, 2001) by Walters also uses the U shaped foam block for construction a beam on top of a foam wall. The vertical foam void shows a metal channel in one hole and a vertically poured concrete column in other holes. The vertical holes are uniform in size and therefore fixing the size of the concrete columns. Since the concrete beam is a mold, the size is also limited to change without ordering different molds for different size beams.

Another type of foam panel is U.S. Pat. No. 6,523,312 by Budge (filed Feb. 25, 2003) that uses a foam panel with an array of vertically large holes as the mold chamber for a concrete column and a hollow section on top to form a concrete beam. The foam is embedded into a concrete footing to stabilize the wall prior to pouring concrete. The wall panel uses interlocking foam to secure one panel to another and no light gauge framing is used to support the panel.

In U.S. Pat. No. 6,131,365 (filed Oct. 2, 1998) by Crockett has a wall unit system consisting of interior foam ridges at the interior and a foam board on the exterior. A steel base plate is installed and the bottom and a hold-down hook at the top of panel with vertical straight plates between panels. A “tie down space” is in the middle of the wall for installing steel reinforcing to create a concrete column and a horizontal concrete beam is installed at the top of the wall. The insulated structural material in the middle of the wall is foamed plastic, foamed concrete etc. Nothing is shown or mentioned on how to hold the wall together when filling the wall with insulated structural material. The interior concrete column and beam does not show any prior art plus the interior insulated structural material also does not pertain to the pending patent.

In U.S. Pat. No. 6,119,432 (filed Sep. 3, 1999) by Niemann forms a panel by cutting the polystyrene foam into a concrete beam on top and bottom of panel. In addition the foam is cut into a rib pattern then glued back to create vertical holes within the foam into which concrete is then poured into the columns and beams. The patent does disclose recessed furring strips on the exterior of the wall. The patent discloses glue as the only means of holding the two sides of the panel together. The pressure of the wet concrete will push the two sides apart and the furring channel will probably be required to hold the panel together. The ribbed foam panels limits the size, spacing and structural integrity of the concrete beams as well as the array of concrete columns.

In U.S. Pat. No. 7,028,440 (filed Nov. 29, 2003) by Brisson uses foam blocks with vertical holes to form concrete columns and uses a horizontal recess at the top of the panels to form a beam pocket. The foam panels are made using a tongue and groove type connections between panels and the panels are glued together. Since the holes for the concrete are only support by foam, the size is limited as the concrete will deform as well as break the foam panels. Again the beam pocket is also fragile as there is not support to stop the wet concrete from deforming the beam.

In US 2007/0199266 (filed Feb. 27, 2006) by Geilen is a foam block with a hole at the interior for a concrete column and a foam cavity for a beam. At the exterior of the panel, vertical recessed wood or metal furring strips are installed at the column cavities of the panel and function as a wall forming structure. The interior portion of the foam panel is a tongue and groove construction interlocking adjacent panels together. A horizontal void in the interior foam forms a beam pocket at the top of the wall and the recess strips support the sides of beam pocket. The recessed furring strips at the corners, shown in conjunction with the concrete columns, cannot support to hold the wet concrete within the panel. The panel does not appear strong enough to support the wet concrete at the columns and especially at the wall corners. The columns are limited in size based on the size of the wall and require specially made forms to create different sizes.

In US 2008/0066408 (filed Sep. 14, 2006) by Hileman is a rigid foam block that has six vertical chambers and a horizontal mold at the top and bottom of each the foam block. When the rigid blocks are installed together they will form a wall with an array of small vertical and horizontal chambers into which concrete is then poured. The rigid foam block limits the concrete column and beam spacing for a wall.

C. Composite Panel

A composite panel are panels not formed with neither light gauge framing or rigid foam block type construction.

In U.S. Pat. No. 6,041,562 (filed Feb. 17, 1998) by Martella is a panel formed by polymer-modified fiber reinforced concrete material at the inner and outer surfaces of the panel along with panel spacers separating the inner and outer surfaces. A synthetic plastic foam is filled between the inner and outer wall surfaces. The panel spacers form chambers where concrete columns and beams can be poured. The size of the columns and beams is limited to the strength of the glue holding the panel together. In fact Martella even mentions that temporary bracing would be required.

These patents are not the typical ICF blocks that come in a variety of patent claims. These solid concrete walls are made uses varies techniques and some do combine some light gauge framing.

In US 2006/0251851 (filed Feb. 24, 2006) by Bowman uses various combinations of metal channels, that are embedded into rigid foam to create numerous configurations for a continuous concrete poured wall as well as a precast wall and flooring system. The embedded metal channels connect both sides of the wall form together. The only beams that are formed are within exterior surface of the precast wall or flooring system. No other columns or beams are developed by this patent.

In U.S. Pat. No. 6,681,539 (filed Oct. 24, 2001) by Yost uses metal channels on the exterior of foam panels and connect both sides of the panel together by wire and attaching them by retaining clips on the exterior on the wall. The space between the panel halves is a continuous concrete wall. The insulated form does not contain a column or beam with the wall.

In U.S. Pat. No. 6,880,304 (filed Sep. 9, 2003) & U.S. Pat. No. 7,409,800 (filed Dec. 10, 2003) by Budge uses two sheets of rigid foam with grooves cut at the vertical edges of the rigid foam. A ½ channel is installed at each vertical groove and the ½ channels on both sides of the wall interlock, forming a continuous form to pour a concrete wall. This patent and U.S. Pat. No. 6,523,312 by Budge (described earlier) both have the same abstract, however the earlier described patent contained the column and beam of which does not reflect the patent pending.

In U.S. Pat. No. 7,254,925 (filed Jul. 21, 2003) by Steffanutti uses metal channels with a rigid board to form a freestanding column with a hole in it, in lieu of pouring a solid concrete column. The window and door construction shows ports for receiving concrete to form doors and windows plus a removable strip for forming a window.

Light gauge metal is configured in many different shapes and therefore a forming mold should be analyzed with many different shapes.

In U.S. Pat. No. 5,279,091 (filed Jun. 26, 1992) by Williams uses a triangular flange and a clip to install a demountable building panel of drywall.

F. Insulation Filled After Wall Installed

The patents below describe various types of insulation used when constructing a wall including wet foam, loose granular fill insulation and dry cellulose fiber insulation.

In U.S. Pat. No. 5,655,350 (filed Jul. 18, 1994) by Patton installs a fire stop by installing an insulated material through holes at the interior side of a wall. In U.S. Pat. No. 5,819,496 (filed Apr. 28, 1997) by Sperber installs loose filled insulation particles in a wall using a netting material and using cavities holes for filling the wall voids. In U.S. Pat. No. 6,662,516 (filed Nov. 16, 2001) by Vandehey strengthens existing walls by injecting cavity walls with adhesive foam through holes in the sides of the walls. The adhesive foam is installed in layers and allowed to dry between additional layers. In U.S. Pat. No. 5,365,716 (filed Aug. 2, 1993) by Munson installs dry cellulose fiber insulation into a stud cavity wall by installing a vapor barrier to studs and then filling the cavity wall using a pneumatically pressure hose into the sides of the cavity wall. All the above patents are typically installing the insulation from the side through holes after the wall has installed. Loose insulation has been installed from the top of masonry walls for a long time.

G. Foam Panel

In U.S. Pat. No. 5,943,775 (filed Jan. 7, 1998) and U.S. Pat. No. 6,167,624 (filed Nov. 3, 1999) and U.S. Pat. No. 6,681,539 (filed Oct. 24, 2001) by Lanahan uses a polymeric foam panel with metal channels installed within the foam. The panels are interlocked together by a tongue and groove connection using the foam as the connector. An electrical conduit is horizontally installed within the panel for electrical distribution. The metal channels are embedded within the foam. None of the Lanahan patents use their panels to form concrete columns or beams. Walpole in U.S. Pat. No. 7,395,999 embeds a metal channel in foam for support and uses a tongue & groove joint sealer between panels. In U.S. Pat. No. 5,722,198 (filed Oct. 7, 1994) and U.S. Pat. No. 6,044,603 (filed Feb. 27, 1998) by Bader discloses a panel & method to form a metal channel and foam panel where the flanges are embedded into the sides of the foam panels. In U.S. Pat. No. 5,279,088 (filed Jan. 17, 1992), U.S. Pat. No. 5,353,560 (filed Jun. 12, 1992) and U.S. Pat. No. 5,505,031 (filed May 4, 1994) by Heydon show a wall and panel structures using overlapping foam and metal channels in various configurations.

H. Foam Tape on Studs

Foam tape is shown on metal and wood channels to reduce the conductivity between different building materials.

In U.S. Pat. No. 6,125,608 (filed Apr. 7, 1998) by Charlson shows an insulation material applied to the flange of an interior support of a building wall construction. The claims are very broad since insulating materials have been applied over interior forming structures for many years. The foam tape uses an adhesive to secure the tape to the interior building wall supports.

Products like waferboard, fiberboard and the like are now being developed to play more of factor in building walls and floors. In addition many of the products have the same or more of an insulation factor than rigid insulation.

In U.S. Pat. No. 7,077,988 (filed Jul. 18, 2006) by Gosselin uses a corrugated wooden fiberboard panel to attach to a concrete block wall and explains the system to manufacture. In U.S. Pat. No. 6,541,097 (filed Apr. 11, 2001) by Lynch developed a ribbed board product to be used for decking. In U.S. Pat. No. 6,584,742 by Kilgier uses metal channels and strand board at the interior with inner and outer facing layers. Vertical and horizontal structural steel is used to help support the panels. The materials being produced today are getting more sophisticated for example U.S. Pat. No. 7,232,605 by Burgueno is a hybrid natural-fiber composite panel with cellular skeleton tubular openings. The hybrid natural-fiber panel also has a greater strength than other types of products. It also can be used in place of rigid insulation to create the same energy efficiency as rigid insulation.

J. Plastic or Related Panel Connectors

Connector type patents are typically full width poured concrete walls. The plastic connectors hold the panels together and are made of various configurations.

In U.S. Pat. No. 5,809,726 (filed Aug. 21, 1996), U.S. Pat. No. 6,026,620 (filed Sep. 22, 1998) and U.S. Pat. No. 6,134,861 (filed Aug. 9, 1999) by Spude uses a connector that has an H shaped flange at both ends of the connector and connected by an open ladder shaped web. The connector is not a ICF block type connector, but long and is used both vertically and horizontally within the wall. All the Spude patents refer to a full width poured concrete wall. Sometimes the connector is located at the exterior surface; another is embedded within the panel surface.

In U.S. Pat. No. 6,293,067 (filed Mar. 17, 1998) by Meendering uses the same H shaped flange at both ends of the connector; however the web configuration is different. Also in U.S. Pat. No. 5,992,114 (filed Apr. 13, 1998) & U.S. Pat. No. 6,250,033 (filed Jan. 19, 2000) by Zelinsky also uses the same H shaped flange at both ends of the connector, also uses a different web configuration. Also in U.S. Pat. No. 6,698,710 (filed Dec. 20, 2000) by VanderWerf also uses the same H shaped flange at both ends of the connector, also uses a different web configuration.

In U.S. Pat. No. 6,247,280 (filed Apr. 18, 2000) by Grinshpun has an inner and outer skin which has an interlocking means built-in the interior surface of the panel skins. The ends of a panel connector are V shaped and lock into the interior interlocking means of each of the building panels. The connector also can accommodate a rigid insulation board within the interior of the wall panel. The panel construction is used for a continuous concrete wall, and does not affect this patent application.

In U.S. Pat. No. 6,935,081 (filed Sep. 12, 2003) by Dunn embeds an H shaped configuration in both sides of the wall panel which is rigid insulation. The H shaped configuration also has a recessed area into which a “spreader” can be installed. The spreader is another H shaped member that can slide into the recess of each side of the wall panel. The spreader also would be considered a web configuration is some of the above described patents. These spreaders are shown to be extended above the panels and slide into the recess of the above panel. Since these spreaders are made of plastic, the spreaders are easily breakable especially when trying to align them with the recessed grooves above.

In U.S. Pat. No. 5,566,518 (filed Nov. 4, 1994) by Martin uses rigid insulation as the sides of the wall panel. The interior side of each wall panel is scallop to form a vertical columnar shape as well as a horizontal shaping beam. The side walls are connected by a snap-on plastic connector that fits over the edge of the side walls. When connected the rigid insulation along with the plastic connector really just form another type of ICF blocks except here the scallops adds more expensive and doesn't really serve any function.

In U.S. Pat. No. 7,185,467 (filed Oct. 6, 2003) by Marty, uses a GRC as the mold form to pour concrete columns and beams. No explanation is given on how the panels are separated except of the sides like by windows. These panels would be a very expensive to fabricate as well as to install at a construction site. The beams and columns have no relationship to the present invention.

In U.S. Pat. No. 6,952,905 (filed Feb. 3, 2003) by Nickel, uses connectors that have dovetail slots where bolts heads fit into and the bolt shafts fit into the stone panels. In U.S. Pat. No. 6,978,581 (filed Sep. 7, 1999) by Spakousky uses dovetail slots with connectors, however the connectors do not allow for additional fasteners to be installed after concrete is installed within the mold and the connectors have a divider with two chambers within the wall. In U.S. Pat. No. 7,415,805 (filed Aug. 26, 2008) by Nickerson uses slit slots or dovetail slots to support the anchors within a wall. Nickerson also uses a tie assembly with a shank, two clamps, a support, saddle and end caps; or a tapered plug to fit into the dovetail slots to secure the block faces.

In US 2007/0062134 (filed Sep. 22, 2005) by Chung uses vertically oriented Aerated concrete panel to form a wall and then fill with concrete to form a column or beam within the wall. The pending patent by Chung also has no relationship with the present invention.

K. Baffles within Walls

Typically baffles in building construction are used in attic roofs to allow for air to circulate through the eaves into the attic. Some baffles have been used within walls to increase the insulation factor where mechanical lines occur.

In U.S. Pat. No. 6,754,995 (filed Sep. 25, 2001) by Davis shows a baffle used between wall studs or roof rafters and are typically used to allow air to circulate within a wall or roof attic. The Davis patent describes many different types of baffle patents; however none of the baffles are being used to separate concrete from insulation within a wall nor are used as a brace for a wall stud.

L. Precast Concrete Thin Panel Poured Face Down

Precast concrete panels when poured face down have the metal framing installed when the concrete face is being poured and other patents the metal framing is installed after the concrete has cured. None of the patents have a framing system in conjunction with a rigid insulation core as well as a structural insulated panel (SIP).

Most of the precast panel poured face down have the metal framing embedded into the concrete like Schilger in U.S. Pat. No. 4,602,467, Bodnar in U.S. Pat. No. 4,909,007 & U.S. Pat. No. 6,708,459, Staresina in U.S. Pat. No. 4,930,278, Cavaness in U.S. Pat. No. 5,526,629, Ruiz in U.S. Pat. No. 6,151,858. In the 3 patents by Foderberg U.S. Pat. No. 6,817,151, U.S. Pat. No. 6,837,013& U.S. Pat. No. 7,028,439 the hat channel is secured to the metal channel and one is separated by a thermal break at the flange. The Nanaykkara U.S. Pat. No. 6,988,347 & U.S. Pat. No. 7,308,778 both are cast face down however in U.S. Pat. No. 7,308,778 has insulation between the two precast panels. In Rubio at U.S. Pat. No. 7,278,244 uses a bracket which is attached to the metal channel. In Cooney U.S. Pat. No. 5,138,813 has a bracket that is inserted and then fastened to the metal channels.

M. Precast Concrete Thin Panel Poured Face Up

The concrete panels poured face up have the metal channels embedded into concrete or poured concrete over rigid insulation with a connector attached. Precast concrete panels when poured face up, typically have the metal framing installed when the concrete face is being poured.

The patent by Mancini U.S. Pat. No. 5,758,463 and LeBlang U.S. Pat. No. 6,041,561 both showing the metal channels embedded into the concrete and patents by LeBlang U.S. Pat. Nos. 6,041,561 and Spencer 6,729,094 showed a connector attached to the metal channel and rigid insulation sheathing.

N. Precast Concrete Wall with Exposed Insulation

In Moore U.S. Pat. No. 6,438,918 & U.S. Pat. No. 6,481,178 use an ICF as a form and a precast concrete facing is attached to the ICF.

Structural insulated panels known as SIP's are typically made using rigid insulation in the middle with plywood on both sides and wood blocking or metal connectors are installed in the middle connecting the two panels together.

Porter has developed many SIP patents using metal components including U.S. Pat. No. 5,497,589, U.S. Pat. No. 5,628,158, U.S. Pat. No. 5,842,314, U.S. Pat. No. 6,269,608, U.S. Pat. No. 6,308,491, and U.S. Pat. No. 6,408,594 as well as Babcock U.S. Pat. No. 6,256,960, Brown U.S. Pat. No. 6,564,521 and Kligler U.S. Pat. No. 6,584,742 of which Babcock shows a metal channel between two panels to interlock adjacent panels. In U.S. Pat. No. 5,638,651 uses metal channels at interior but does not have a thermal break on the metal channels. Porter shows 5 more patents using wood and one more U.S. Pat. No. 5,950,389 using splines to interlock panels. Frost in U.S. Pat. No. 6,568,138 uses holes in base plate for predetermine metal stud spacing.

P. Column & Beam Between Two Modular Buildings

Prefabricated modular building units when place adjacent to each other form a double wall.

In Mougin U.S. Pat. No. 3,678,638 uses a steel mold to form specially configured beams between modular building units. The wall system does not interconnect to a flooring system and the concrete columns are not integrated into the wall construction without having to construct a wood form.

P. No Relationship to Invention—Appeared Significant

In U.S. Pat. No. 5,335,472 (filed Nov. 30, 1992) & U.S. Pat. No. 6,519,904 (filed Dec. 1, 2000) by Phillips initially developed a patent where a concrete wall is formed by pneumatically applying concrete to a foam panel with a wire mesh layer. A concrete column is pneumatically applied in the U.S. Pat. No. 5,335,472 and a vertically poured concrete column in the second patent using metal channels, a forming plate and pneumatically placed concrete wall as the concrete form. None of the Phillips patents relate to the pending patent.

Q. Panel Construction

In U.S. Pat. No. 5,638,651 filed Jun. 21, 1996 by Ford uses an interlocking panel system where two U channels interlocks with an OSB board and the metal channel to form a building panel. In U.S. Pat. No. 6,701,684 filed Jun. 26, 2002 by Stadler uses vertical back to back U metal channels in a foam panel and a cementous coating over the foam to form a wall. In U.S. Pat. No. 6,880,304 filed Sep. 9, 2003 by Budge, uses vertical slotted framed to support a foamed wall assembly.

SUMMARY OF THE INVENTION

The structural insulating core walls forms have many different wall configurations and uses that consists of an independent framed wall, structural insulating panels, combination of an independent wall and Insulated Concrete Form (ICF) wall, in conjunction as part of a precast wall or as part of forming system to form a concrete beams and column structure, modular units with concrete beams and columns; plus individual foam spacer blocks, with or without brackets and horizontal bracing channels. In addition different types of connectors and flanges extensions are added to form different support channel flanges within the structural insulating core. Another type column is one that is wider than the width of the wall, but yet incorporated the wall forming mold as part of the column forming mold. This wider column size requires a larger framing support that protrudes from the wall mold. In addition an insulated flange framing component can be used as an independent wall framing components or in conjunction with a concrete poured wall or column.

The wall framing structure as shown in US 2007/0044392 extends into the footing and through the foundation and is part of the forming structure of that solid concrete wall. By continuing the forming structure from the footing through foundation and up through the column and beam mold and into the wall mold above faster and more efficient construction method occurs. When the spacer insulation or foam spacer between the forming structure is not installed, the concrete within the column mold can then flow into a horizontal if a beam, if it is installed within the wall mold, or into a solid wall like a concrete foundation

Not all structures are supported by concrete footings, foundation or concrete slab on grade construction, but are supported by caissons. Caissons are vertical columns below ground that support an above ground structure by friction or end bearing. The greater the length or increased diameter of a caisson, the greater the load or weight the caisson can carry. The caisson can be placed anywhere within a building, typically under a wall or where a column occurs above. A column mold within a wall mold should have the flexibility to change size and location to fit the structural load capacity the column is required to carry. In addition the concrete column within a wall should be able to also have the flexibility to have an array of columns within a wall. In the World Trade Center building in New York, the architect Yamasaki designed that building to have an array of columns on the exterior of the structure. The patent pending allows for variations in the structural spacing of columns and the size of beams to change the structural integrity of the forming structure to fit the need of architects and builders.

In U.S. Pat. No. 6,401,417 by LeBlang shows how a concrete column and beam can be installed within a wall using metal channels and rigid insulation/hardboard. The wall forming structure extends through the wall to above the beam. The support for the beam is rigid foam, however in the pending patent; the insulation material will support the beam until the concrete cures. The wall mold at the wall beam can vary within the wall without having to change the wall configuration. When a floor construction intersects the wall beam, the wall beam can change accordingly. For example ledger beam that supports the floor can be mounted directly on the wall form structure along with the joist hangers and anchor bolts to support the flooring system. The ledger board now is part of the forming mold and also is a horizontal bracing member to secure a stronger mold structure. The floor beam now also becomes a natural fire stop within the building construction. Since the joist hangers are installed prior to the concrete columns and beams are installed in the wall, the floors joists that are outside of the patent pending can be used as a scaffold for pouring concrete into the wall mold.

One method described earlier is to have the exterior width of the beam be the same width as the width of the form structure. There are times when the beam width has to be wider, and the patent pending gives that flexibility by extending the wall forming structure into the wider horizontal beam.

A previous patent pending application US 2007/0044392 by LeBlang, showed modular building units stacked adjacent to one another as well as on top of one another. When stacked adjacent to one another the space between the units is the exposed C channels and the interior finish of the modular units. A column forming structure is formed when a full depth spacer is connected between one module and another. The size of a concrete column will vary depending on the load capacity of the column. Several C channels will be spaced close to one another on each module and spacers will connect the modules together plus additional steel reinforcing can be added within the column to form the column between modules.

A concrete beam can be formed also using two adjacent modules. One-half of a beam is formed on one module and the other half of the beam is formed on the adjacent module. After the modules are secured together with the module spacer connectors, a horizontal rigid board can be stalled above the ceiling rim joists. Horizontal hat channels are attached to the vertical C channels and a rigid board is secured to the hat channels. The vertical and horizontal rigid boards form a horizontal beam. After all the modules for a particular floor of a building are installed, the concrete can now be poured into the multiple columns and beams within the building structure. The module forming structure within the module walls, extend above the top of the beam mold. The module above will rest onto the top of the concrete beam and against the vertical forming structure from the module below. The module forming structure from the module below can now be secured to the rim joist of the upper modules floor system. Additional steel reinforcing can be added through the holes of each module. Again after the modules are placed adjacent to each other, the module spacer connectors are now connecting each module. The horizontal rigid board forming the beam can also be built using rigid insulation material between the vertical forming structure of both modules plus an angle on the interior between the modules.

The beams and columns can be formed using completed modules or panelized sections which comprise the same components as a module unit. The previous patent pending application, showed a concrete beam within a wall structure which consisted an array of metal channels and rigid insulation. I did want to note that the size and or gauge of the metal channels can greatly be reduced, because the metal channels are not the support for constructing the wall, but rather a means of attaching the interior and exterior finish to the wall which in the method to form the wall column or beam. As mentioned earlier, the foundation and footing can be poured at the same time, therefore supporting the walls above (1stfloor) without using a wall brace or hurricane tie down. By installing concrete blocks below the metal supports, the wall can be plumb and straight prior to any concrete installed within the footing as well as the wall.

Another aspect of the pending patent is that either spacer insulation, foam spacer or foam material not only creates a thermal break between the structural support members in a wall, but also allows fasteners to secure drywall and siding into a concrete wall after the concrete has cured. The fasteners can penetrate the structural support members and a second layer of foam material allows the threads of the fastener to be secured to the structural support members without having to penetrate the concrete.

Another aspect of the pending patent is that the foam material created a bent flange channel and a double flange channel allowing the foam material to easily be secured to the wall forming structures.

Another aspect of the pending patent is that the spacer foam can be formed to include the area shown as the foam material creating the thermal break between the wall forming structures as well as an insulated wall. This structural insulating core of channels and foam spacer can be used as the center core of a concrete column and beam wall mold or as just a framed wall using the support channels and either spacer insulation or foam spacer for a conventional framed wall. The spacer insulation is formed using tongue and groove sides so as to easily slide into place between the channels. This interlocking foam core can glue together to form panels as well as to form structural insulated panels (SIP's) with the exterior and interior faces glue together to form one panel.

Another aspect of the invention is that exterior wall sheathing and interior rigid insulation in a wall are formed as one and together form an integrated material referred to a foam spacer. The integrated wall sheathing speeds construction since usually two different construction trades installs the wall sheathing and the interior insulation and the rigid insulations provides a measurement say 16″ or 24″ on center for a faster wall installation.

Another aspect of the invention is to form thin-cast precast walls using the structural insulating core and a forming bed when pouring the concrete over the top (face up) on to the structural insulating core. Additional columns and beams can be formed by removing sections of the foam spacer integrating the columns and beams into the thin-cast concrete face of the precast panel.

Another aspect of the invention is to form thin-cast precast walls using a connector attached to the insulating channels or to the structural insulating core and embedding the connector into the concrete bed. Concrete columns and beams are poured where the spacer foam is not located.

Another aspect of the pending patent is that by installing baffles at the ICF block form support braces, the baffle compartmentalizes the interior of a wall mold structure to form a vertical chamber to form a column. The space between the columns can now be filled with loose granular insulation along with a horizontal baffle at the bottom of a horizontal beam. Together the baffles form a column and beam structure into which concrete can be poured.

Another aspect of the pending patent is that the structural insulating core SIC along with the insulating concrete forms ICF's can form concrete beams and columns within a wall. In addition the ICF can be wider than the SIC wall thickness forming larger concrete beams and columns. The ICF's can also be used to form columns and beams where two adjacent building modules are placed adjacent to one another.

Another aspect of the pending patent is the formation of an insulated flange on a wall framing structure. The insulated flange can be used as an independent framing member or can be installed within a concrete column or continuous concrete wall. The insulated flange allows concrete to flow around the insulated flange allowing future penetrations into a concrete wall like screws or nails to easily be fastened into a concrete structure. In addition, a scaffolding connector could easily be attached to the interior forming structure as well as removing the scaffolding support connector as well as installing and removing any temporary bracing after the concrete is installed within the molds.

Another aspect of the pending patent is the formation of the bent flange and double flange channels. Both channels when embedded into concrete allow for additional fasteners to be installed into the concrete wall. A standard C or U channel can have flange extensions added to the basic channels to have the bent or double flange channel characteristics.

Another aspect of the pending patent allows the structural insulating core with the interlocking insulation and metal channels or wood blocking function together as a wall construction.

Another aspect of the pending patents it the formation of a structural insulating panel (SIP) when the structural insulating core and the rigid board and rigid insulating are all glued together.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A building construction using a structural insulated core as an independent wall or together with a rigid board and rigid insulation to form structural insulated panels or as concrete columns and beams using various wall molds to encase the wall forming structure and embed a hardenable material such as concrete within the wall forming structure or as blocks with or without short brackets. In addition, the structural insulating core along with insulating concrete forms ICF form column and beams within the wall molds. In addition, various types of connectors are used to form concrete column and beam molds. The various types of wall molds are formed using metal or plastic forming structures with reinforcing means, insulation and rigid boards.

After review of the existing and pending patents, one can recognize the differences in this patent application. InFIG. 1a wall mold10is shown in isometric view with two different configurations of column molds20. The wall mold10consists of a rigid board50and rigid insulation51are the inner and outer rigid boards that define the outer surfaces of the wall mold10. The interior of the column molds20&21are also shown in a plan view drawing inFIG. 2andFIG. 3. The width of the column molds20are determined by the thickness of the spacer insulation52located between the rigid board50and the rigid insulation51. On the other hand, the width of the column molds20is the distance between the spacer insulation52. InFIG. 2the support channel of the column forming structure is an H channel40shown at the middle of the column mold20extending outside of the wall mold10but yet an integral part of the column mold20securing both the rigid board50and the rigid insulation51to the wall mold10. InFIG. 3the H channel40is smaller than inFIG. 2which allows the rigid insulation51to be secured to the outer surface of flange40cof the H channel40. The opposite flange40c′ of H channel40is secured on the interior surface of the flange40c′ making it easier to fasten another material to the H channel40. Since no fastening means is shown connecting the spacer insulation52to either the rigid board50and rigid insulation51, the material has to be compatible so an adhesive (no shown) can connect the various materials together. The depth of the column molds20are determined by the structural strength of the adhesive and the bending stress of the rigid board50and rigid insulation51. On the other hand, the rigid board50, rigid insulation51and the spacer insulation52could all be formed of the same material and secured together with the H channel40. Steel reinforcing60can be added prior to the column molds20being filled with a hardenable material.

InFIGS. 4-6a wall mold11is shown in isometric view with two column molds20. The wall mold11consists of a rigid board50and rigid insulation51as the outer surfaces of wall mold11along with the spacer insulation52between the outer surfaces. The column forming structure within the column mold20shown inFIGS. 4 & 5consists of two support channels shown as U channels41. The flanges41bare secured to the rigid board50and the rigid insulation51along with the spacer insulation52. The spacer insulation52fits securely between the web41aof each U channel41. The space between the web41aof the U channel41define the depth of the column mold20. InFIG. 6the column mold20uses support channels shown as C channels42to function in a similar capacity as the U channels41inFIG. 5. The C channels42inFIG. 6have a lip42cto give the column mold20additional strength. As likeFIG. 5the web42athe C channels42define the width of the column mold20. The C channel42is shown with rigid foam53at the interior of the C channel42. The rigid foam53is secured within the C channel42by the two flanges42band the web42aand the lip42c. The rigid foam53eliminates any air infiltration that could occur within the C channel42. Since the wall mold11has the U channels41or the C channels42as part of the column mold20, the spacer insulation52can be installed as part of the wall mold11or the spacer insulation52can be installed after the wall mold11has been installed in a vertical position. When the spacer insulation52is a solid material the spacer insulation52can be fabricated as part of the wall mold11and prior to erecting the wall mold11. On the other hand if the spacer insulation52is not installed prior to the wall mold11being erected, a loose granular insulation material52acan be poured into the area occupied by the spacer insulation52through the top of the wall mold11. In addition, in lieu of a loose granular insulation52a, a dry cellulose fiber insulation52bor a liquid foam52ccan also be filled from the top of the wall mold11. Typically the spacer insulation52is a rigid foam type material, however new products are being developed like hybrid natural-fiber composite panel with cellular skeleton tubular openings which can function the same as a rigid foam material.

InFIGS. 7-9a wall mold12is shown in isometric view with two column molds20. The wall mold12consists of a rigid board50and rigid insulation51as the outer surfaces of wall mold12along with the spacer insulation52between the outer surfaces. The distance between the spacer insulations52define the width of column mold20. The plan view inFIG. 8shows a bent flange channel44as the column forming structure and is located in the middle of column mold20. The bent flange channel44has a web44awhich is the same width as the spacer insulation52. The bent flanges consist of two parts, that is44bis adjacent to the rigid insulation51and the remainder of the bent flange44dis bent again to be close to the web44a. The double bending of flange44b&44dallows a fastener37to secure the bent flange channel44at two spots that is the flange44band44d. Light gauge metal say 25 gauge is not very strong, and the double flanges44band44dallow two surfaces into which a fastener37can attach to and thereby increasing the strength a fastener37can attached to support the rigid board50as well as resist the force of wet concrete39pushing against the rigid board50. When the wall mold12is erected vertically the steel reinforcing60is added and the column mold20is filled with concrete39. Upon doing so the web44aand the bent flanges44b&44dcreate a cavity38which is more clearly seen inFIG. 10. Since the cavity38is not filled with concrete39as typically the small space between the web44aand the bent flange44dis not large enough to allow concrete39to flow into. When additional materials shown (in ghost) is applied to the rigid board50, the fastener (not shown) can then penetrate the rigid board50and into the bent flange channel44without having to penetrate into the concrete39within the column mold20. InFIG. 9another column mold20(shown in plan view) is formed the same as inFIG. 8, however a support channel shown as C channel42is the column forming structure and is located in the middle of the column mold20. The two flanges42bof the C channel42abut the rigid board50and the rigid insulation51. The flanges42beach have a lip42cwhich is at a right angle to each of the flanges42b. Between the lip42cand the web42aand adjacent to the flanges42ba foam material54can be installed using several methods which is also more clearly shown inFIG. 11. When the wall mold12is oriented vertically, concrete39is installed within the column mold20and the foam material54becomes encased in the concrete39. After the concrete39has cured within the column mold20, fasteners37can be installed through the C channel42and into the foam material54without touching the concrete39.

FIGS. 10-12are isometric views of several forming structures previously described.FIG. 10shows an enlarged view of the bent flange channel44previously shown inFIG. 8; however this isometric view shows holes36in the web44a. InFIG. 12is the same bent flange channel44inFIG. 10, except the flange44balso has holes36. The holes36in the44bflange are used to install foam material54into the holes36filling the cavity38and covering the flange44bwith foam material54. If the foam material54is installed in a factory, the foam material54will first fill the cavity38and then the residual is then removed with a hot knife (not shown) to form a smooth plane parallel to the flange44b. If the foam material54is installed at the construction site, the foam material54will be soft and when either the rigid board50or rigid insulation51is secured with fastener37, the foam material54will be of sufficient thickness to separate the rigid board50or rigid insulation51from the bent flange channel44as shown inFIG. 14. Another way to install the foam material54is through the gap45between the web44aand the bent flange44d. When installing the foam material54through the gap45, located between the bent flange44dand the web44a, the foam material54will first fill up the cavity38and then the excess will penetrate through the holes36. Depending when the foam material54is applied, the foam material54excess will be cut (by a hot knife not shown) to form as smooth plane parallel to the flange44b.FIG. 11shows the same holes36at the flange42bof the C channel42. The holes36are shown with the foam material54passing through the holes36. Depending on the amount of foam material54that has been installed through the holes36, the foam material54shown on the flange42bor44bwill form a bell shape54aor the foam material54when smoothed will form a solid rectangular shape54b. InFIG. 11the foam material54is shown on the web42awhich is typically used around windows and doors for securing them to the web of the column forming structure like42a.

TheFIGS. 13-14shows the wall molds13&16which consists of a rigid board50and rigid insulation51as the outer surfaces of the wall molds13&16along with the spacer insulation52between the outer surfaces. InFIG. 13the column forming structure shown in column mold20consists of four support channels shown inFIG. 11. For clarity purposes, the two C channels42that are located in the middle of the column mold20are shown with the foam material54at the flanges24bas shown inFIG. 11. The two C channels24shown at the spacer insulation52are also shown with the foam material54b, however the foam material54can be eliminated if the spacer insulation52is cut slightly differently. The distance between the two webs42bof the C channel42that encase the spacer insulation52is the total width of the column mold20. The depth of column mold20is the distance between the outside surfaces of the foam material54of both flanges42bmore clearly shown inFIG. 11. The number of C channels42will vary depending size and structural requirements of the concrete column35and the steel reinforcing60required.FIG. 14is similar toFIG. 13, except here the column forming structure consists of two support channels shown as bent flange channels44in the middle of the column mold20and two U channels41shown at the ends of column mold20. Like inFIG. 13, the foam material54is adjacent to the bent flange channel44as well as the rigid board50and the rigid insulation51. Any additional material (shown in ghost) may be attached with fasteners37after the concrete39has cured in either the column molds20because both the C channel42and the bent flange channel44have foam material54behind the flanges42bof their respective channels.

InFIG. 15is a plan view of wall mold14which consists of three wall panels65that is one wall panel65is in the middle and two wall panels65are located on side of the wall panel65. The width of wall panel65is from the centerline of one column mold20to the centerline of the other column mold20and the desired height of a building wall as shownFIG. 24. The three wall panels65all show rigid board50and rigid insulation51extending to the centerline of one column mold20to the centerline of the other column mold20as the inner and outer surfaces; however all three columns molds have a slightly different configurations within the wall mold14. The lower partial wall panel65shows one-half of column mold20wherein the support channels is shown as C channel42and the flange42bis overlapping the spacer insulation52. By having the flange42boverlap the spacer insulation, additional material like drywall (shown in ghost) can be attached with a fastener37to the C channel42. The spacer insulation52is shown as a rigid type insulation that is smaller than the web42aand fits between the lips42dof the C channel42. The other half of column mold20is shown in wall panel65where an H channel40is used. A portion of the flange40bextends into the spacer insulation52which now allows additional material (shown in ghost) to be installed with fasteners37. The column molds20is are formed by using the panel configuration at both the ends of wall panel65and the ends of the partial wall panels65. In other words, one-half of column mold20is form by the C channel42in wall panel65and the other one-half column mold20is formed with the C channel42of the partial wall panels65. The C channels42in both the wall panels65have their flanges42bfacing within the column mold20rather than engaging the spacer insulation52as shown in the other column mold20. In the other column mold20both the support channels shown as C channels42have foam material54shown at the interior of the C channel42allowing fasteners37to be installed within the column mold20after the wall panels65has been erected in a vertical position. The width of wall panel65varies depending on the number of spacer channels47installed within the wall mold14and are further described inFIG. 24. When the spacer insulation52has the spacer channels47added a wall panel65a structural insulating core111is formed between the inner and outer rigid boards or any of the previous wall molds.

InFIG. 16shows a vertical wall section A-A taken throughFIG. 15however any one of the previously mentioned wall molds could be used or in this case a concrete foundation39″″ is installed below the wall inFIG. 16and a concrete floor39′ is shown inFIG. 17. The wall sections are taken through the middle of the wall mold rather than at the column molds. The wall panel65inFIG. 16is shown with the spacer channel47extending from the concrete footing39″ through the concrete foundation39″″ into the wall mold14. InFIG. 24the wall molds are shown as large panels where a foundation can be incorporated into the wall panel. The upper section of the wall molds14as shown inFIGS. 16 & 17are shown with the rigid board50and rigid insulation51as the outer surfaces along with the spacer insulation52. If the wall section A-A were taken through the column mold20in bothFIGS. 16 & 17, concrete39would be shown rather than the spacer insulation52and reinforcing steel60would be installed within the column mold20. Below the concrete floor39′ is a foundation mold15that has hat channels70attached to the C channel42and a rigid board50and rigid insulation51are attached to the hat channel70. The foundation mold15is described more fully in US 2007/0044392 by LeBlang. Another hat channel70is shown with a foam material54attached on the interior side of the hat channel70. The foam material54seals the fastener37from any water penetrating through the concrete foundation39″″ as well as from the hat channel70. The foam material54shown on the interior of the hat channel70allows additional fasteners (not shown) to be attached to drywall (not shown) to be attached to the concrete foundation39″″. The column mold support shown as the C channel42is located within the column mold20, passes through a foundation mold15and then into a concrete footing39″. Therefore the wall panel65when installed into a vertical position, will consist of the wall mold14plus a foundation mold15and the C channel42, however only the C channel42extends through the wall mold14and the foundation mold15then into the concrete footing39″. The wall mold14is also showing a reverse hat channel71which is used to secure the rigid insulation51or as a horizontal or vertical electrical chase. In addition wood blocking72is installed on wall mold14for decorative trim base (not shown) can be installed after drywall (shown in ghost) is installed. The wood blocking72is also used as a horizontal connection between adjacent wall panels65as well as the reverse hat channel71and the hat channels70used in the foundation mold15.

FIG. 17shows the wall panel65and the same wall mold as shown inFIG. 15, except here the support channel shown as C channel42and spacer channel47are longer and extend into a concrete floor39′. The rigid board50is shown extending to the bottom of the concrete floor39′ defining the edge of the concrete floor39′. As mentioned inFIG. 16if the wall section A-A where take through the column mold20the steel reinforcing60would extend from the column mold20into the concrete floor39′.

FIG. 18is similar toFIG. 14, in that the wall mold17consists of a rigid board50and rigid insulation51as the outer surfaces of column mold20and the U channels41form the other sides of column mold20. The flanges40bof the H channel40are shown in the middle of the rigid board50and rigid insulation51as well as between the H channels40. The rigid board50and rigid insulation51can each be attached to the H channel40by screws122. Depending on the size of the column mold20, additional H channels40along with additional rigid board50and rigid insulation51′ can be installed between the H channels40forming a longer column mold20.

FIG. 19shows a wall mold18which consists of a rigid board50and rigid insulation51as the outer surfaces along with the spacer insulation52between plus a column mold20. The column mold structure in column mold20is shown with a U channel41with its flanges41bencasing the end of the spacer insulation52and wood blocking72is attached to the web42aof the C channel42. The wood blocking72is used to attach a door or window (shown in ghost) to the wood blocking72. Additional steel reinforcing60is added prior placing the wall mold18vertically and then pouring of concrete39into the column mold20. Many of the previously described column mold structures can be used to attach wood blocking72to form a door or window at the concrete column35.

FIG. 20shows two wall panels65intersecting at a corner forming an column mold20that is L shaped. The wall panel65in wall mold19consists of a rigid board50and rigid insulation51as the outer surfaces of wall panel65and an array of C channels42with the foam material54applied on the flanges42bof the C channels. A door (shown in ghost) has the foam material54shown on the interior side of web42aof the C channel42so the door (shown in ghost) can be attached to the wall panel65after the concrete39has cured. No wood blocking72is needed to secure the door (shown in ghost) as shown inFIG. 19since the foam material54allows a fastener37to be installed directly into the web42awithout having to penetrate the concrete39as shown inFIG. 19. The wall mold19′ consists of a rigid board50and rigid insulation51as the outer surfaces of wall panel65and the column forming structure consists of an array of bent flange channels44with foam material54binstalled at the flanges44b, as described inFIG. 14, plus the spacer insulation52installed within the wall mold19′. The column mold20is partially formed in wall mold19, and partially formed in wall mold19′. When the wall mold19&19′ are installed vertically and connected together, column mold20is formed. Additional steel reinforcing60is installed within the column mold20and concrete39is installed when the walls are erected in a vertical position creating an L shaped column. Typically the column mold20would be used when two walls molds intersect at 90 degrees or at any angle. The elongated column mold20at the corner of a building has the integrity of a solid concrete wall or shear wall (more commonly used like diagonal bracing for wind shear), but in not a solid concrete wall since the spacer insulation52separates each concrete column35within a building structure. The only connection between each column mold20is a concrete beam discussed inFIG. 21and other drawings.

FIG. 21is an isometric view andFIG. 23is a wall section both drawings show two wall panels65that is wall panel65is installed above another wall panel65. Both wall panels65consist of a rigid board50and rigid insulation51along with the spacer insulation52between the outer surfaces. The wall panel65is shown with a column mold20and horizontal beam mold90intersecting at the top of wall panel65. In wall panel65, the spacer insulation52is shown stopping at the bottom of the beam mold90. The wall panel support channel shown as an H channel40forms column mold20then passes through the beam mold90then extending above the wall panel65. The extension above the lower wall panel65is shown in ghost in the wall panel65and when wall panel65is resting above the lower wall panel65, fasteners (not shown) connect the rigid board50and rigid insulation51to the H channels40of wall panel65. Horizontal steel reinforcing60can be installed through the holes36in the H channel40at the beam mold90and at the spacer channel47of the beam mold90. The wall panel65is shown with U channels41as supports for the column mold20and is used as an spacer channel47in the middle of the spacer insulation52. The U channels are shown shorter at wall panel65above in order to allow for the column mold supports of H channels40to be secured with fasteners37through the rigid board50and rigid insulation51thereby connecting the two wall panels65together. The column mold20can be filled with concrete39prior to wall panels65being installed. The beam mold90can be filled with concrete39at the same time as the column mold20or the beam mold90can be filled with concrete39when the column mold20is filled with concrete39. In wall panel65, a wood ledger73is attached directly to the H channels40within the column mold20and the spacer channel47. Anchor bolts74are attached directly to the wood ledger73and placed within the beam mold90. The metal joist hanger75is attached to the wood ledger73. A similar light gauge metal joist and metal ledger joist (not shown) can also be in lieu of the wood ledger. Another added feature, is to install wood blocking72at a floor line or where horizontal support is required between panels as shown in wall panel65.

FIG. 23shows A wall section of the beam mold90of the two wall panels65shown inFIG. 21. The wall section is shown at the beam mold90wherein the spacer channels47are shown as H channels40extend above the spacer insulation52into beam mold90as well as the H channel40from the column mold20. The rigid board50extends on the outside of the two wall panels65. The spacer insulation52as described previously is not shown the lower wall panel65instead loose granular insulation52aas shown inFIG. 4is installed between the rigid insulation51and the rigid board50to the bottom of beam mold90. The wood ledger73, anchor bolt74and metal joist hanger75are used in the beam mold90as discussed inFIG. 22. On the other hand,FIG. 22shows an extension of the wall panel65fromFIG. 23, however the panel mold65is formed differently, that is loose granular insulation52aas shown inFIG. 4is installed between the rigid insulation and the rigid board50to the bottom of the beam mold90. A horizontal baffle board91is shown at the bottom of the beam mold90and is used when loose granular insulation52ais used in lieu of the spacer insulation52to support the weight of concrete39within the beam mold90. Wood blocking72can be installed at the top of the wall panel65to connect to the wood roof joists (shown in ghost). An anchor bolt74connects the wood blocking directly into the concrete39within the beam mold90.

FIG. 24shows a panel diagram of a building elevation using many of the previously described column and beam molds as well as the wall panels. When constructing a building using wall panels, each wall panel requires a different number even though the wall panels are a variation of the previously described wall panels65. The wall panels shown in this drawing can be as narrow as 4′-0″ wide shown as W1to intermediate panel widths shown as W2to full width length walls shown as W3. The height H1of any of the W1, W2or W3wall panels could be from the footing39″, including the concrete foundation39″″ to the beam mold90at the second floor. Wall panels are sometimes manufactured from column centerlines or from large window jambs depending on the size of the windows. The wall panel W4is shown in the middle of column mold20to the end of the wall mold32and extending from the footing39″, including the foundation39″′ to the roof referring to height H3. On the other hand, smaller sections like a foundation wall panel W5is easier to handle without using a crane (not shown) to install the foundation wall panel W5. Another example would be wall panel W6as part of an L column mold20or a window header mold W5W which incorporated a concrete beam39″′ at the roof line as well as above the door/window WD1. The interlocking panel connection shown inFIG. 21is shown at the beam molds90. On the other hand, the wall panel W2could be two stories high by making the panel heights H1and H2as all one panel height. This particular building showed the concrete columns35close together, therefore there are not many spacer channels47. The column mold20is shown wider as it depends on the spacing between window/door WD1& WD2as well as any floor or roof beams that would affect the size of the column mold20. For example, the column mold20is shown inFIG. 20as an L shape is used on the right side of the building along with the window detail shown in the same drawing. Another column mold20is shown on the left corner of the building that is also L shaped, however the size and number of column support members is less than on the right side. A column mold20is shown next to a window WD2and is a wider column mold. Since a concrete beam39″′ is located between the building floors above, a window header like a concrete beam39″′ is not required.

FIG. 25shows three wall panels65similar to the wall panels shown inFIG. 15, however the column molds20are wider than the wall panels65between the column molds20. Column mold20shows the same column mold structure of a C channel42in one wall panel65and an H channel40in the other wall panel65as shown inFIG. 15. A larger C channel48is shown protruding perpendicular to both the wall panels65and are connected to the flange42bof the C channel42and to the flange48bof the other larger C channel48. The opposite side of the column mold20shows the flange48bof the larger C channel48connecting to the flange40bof the H channel40. The web48aof the large C channel48is shown with a foam material54; however the foam material54is not really necessary unless drywall (not shown) is installed over the larger C channel48. Reinforcing steel60is installed within the column mold20and a steel stirrup61passes around the reinforcing steel60. After the wall panels65are vertically into place, a rigid board50is installed at the opposite flange48bof each of the large C channels48of the wall panels65. The other column mold20shows another larger C channel48where the web48ais attached to the web42of the C channel42. The large C channel48can be attached to the wall panels65prior to the erection the wall panels or can be attached after the wall panels65have been erected. The rigid board50is installed between the webs48aand connected to the flanges48bafter the reinforcing steel60and steel stirrups61have been installed.

FIG. 26is a wall section B-B taken through wall panel65inFIG. 25. The wall section B-B is similar to the wall section A-A shown inFIG. 23, except here the beam mold90is wider and overhangs the wall panel65. A beam support channel49is shown dashed in the plan view ofFIG. 25and is supported by the larger C channel48of the column molds20. Horizontal reinforcing steel60is installed in the beam mold90and steel stirrups61are installed around the reinforcing steel60. A rigid board50is placed on the flange49bof the beam support channel49and on the rigid insulation51of the wall panels65. Concrete39can now be installed within the beam mold90after the wall panel65is installed vertical to the height of the beam support channel49. A steel and rigid flooring system described in a previous patent pending by LeBlang is shown resting on the concrete beam39″′. The spacer channel47shown as C channel42extends through the beam mold90and past the rigid floor system mentioned earlier and similar to channels extending into the wall above as shown inFIG. 21. The concrete39can be poured over the rigid floor system as well as between the C channels42. After the rigid floor system is complete another wall panel65can be placed above the wall panel65and attached at the rigid board50and at the wood blocking72.

InFIG. 27andFIG. 28show two interior wall sections where a non-load bearing wall channel shows a C channel42is used to support a beam molds90. Another C channel42is used to frame the beam mold90by using C channels42to form the beam mold90. A rigid board50is installed at the interior of the90leaving the C channels42exposed for utility access around the concrete beam39″′. The C channel42extends above the concrete beam39″′ in order for a flooring system shown inFIG. 26to be securely fastened to the interior wall C channel42. InFIG. 28the wall section shows a concrete beam39″′, which is narrower and being supported by the C channel42. An array of hat channels70is secured to the C channels42and a rigid board50is secured to the hat channel70. The wall panel65inFIG. 28shows another interior beam mold90, which is shown with spacer insulation52between the C channel42and the spacer insulation52is used to support the concrete39within the beam mold90.

FIG. 29is an isometric view of one of the many ICF's (Insulating Concrete Forms) that are presently used in the construction industry. There are many different patents concerning various types of connectors used to form an ICF andFIG. 29&FIG. 30shows one of those connectors64. The connectors64connect the rigid foam block faces88located on both sides of an ICF block mold96forming a cavity98between the rigid foam block faces88. The ICF block molds96are placed adjacent and above each other forming a wall mold97. The connectors64come in a variety of shapes and are installed in a variety of ways, however all these connectors have holes within the connectors and/or spaces between the connectors to allow concrete39to flow horizontally between the connectors64forming a concrete wall between the rigid foam block faces88as well as to the top of the ICF block molds96. In lieu of filling the entire cavity98with concrete39in a typical ICF, this pending application shows a horizontal baffle91and a vertical baffle92installed within the cavity98forming a column mold20and beam mold90. A vertical baffle92is installed adjacent to the connectors64and located on both sides of the column mold20. The baffles92can be made of solid foam, plastic or metal so the baffle edge92afits snuggly against the rigid foam block faces88and against the connectors64. Fasteners (not shown) connect the connectors64to the baffles92. As described inFIG. 4where the spacer insulation52was not used, a loose granular insulation material52acan be poured into the cavity98through the top of the wall mold97. In addition, in lieu of a loose granular insulation52a, a dry cellulose fiber insulation52bor a liquid foam52ccan also be filled from the top of the wall mold97. On the other hand, a more passive insulating wall would be adding sand or gravel (not shown) within the ICF cavity98. After the cavity98is filled with either of the insulation materials52a,52bor52c, a horizontal baffle91can be installed over the insulation materials52a,52bor52cand on top of the exposed connector64. The width of the column mold20is determined by the size of the connector64between the rigid foam block faces88and the length is corresponds to the number of connectors64one desires to have in the middle to form the column mold20. The width of the beam mold90is determined by the size of the connector64between the rigid foam block faces88and the height is determined by the location of the horizontal baffle91within the wall mold97.FIG. 30also shows the connector64extending below the rigid foam block faces88and extending into a concrete footing39″. Since individual ICF block molds96are not well connected horizontally between each other, an angle76is shown connecting the connector64as well as supported by a concrete block spacer89until the concrete39is poured into the concrete footing39″. The angle76shown inFIG. 30allow the connectors64to be connected together to form a wall panel65by connecting the ICF block molds96.

FIG. 31shows and isometric drawing of H channels40′ &40with a coupling63connecting the two H channels40together. The coupling63can be used on any of the support channels, but more specifically shown is the H channel40′ &40. The coupling63is shown connecting to the webs40a′ &40ato the web63a, as well as the flanges40b′ &40bbeing connected to the flanges63bof the coupling63. When a column forming structure or interior channel as described earlier is not long enough for a wall panel, a coupling63can be used to connect two channels together.

InFIG. 32shows a cross section of a C channel42with a different insulating foam100wrapped around the flange42bof the C channel42, and shown inFIGS. 10 & 11as well as in some of the previous wall mold applications. The insulating foam100has a thickness t which is constant as it wraps around the flange42b. The C channel42also has a lip42cat the end of the flange42b. The insulating foam100extends the length of the flange42bshown as100a, then around the lip42cover the back side of the flange42bshown as100a′ and stops at the web42a. The lip42cand the friction of the flange42ballows the insulating foam100to adhere to the C channel42. The insulating foam100is shown inFIG. 33after a hot knife (not shown) has cut the groove into the insulating foam100for the C channel42configuration.

FIG. 34shows a double flange channel105, which is another type of support channel to form column molds20and beam molds90that consist of a web105aand two bent flanges105b′ &105b′″, one at each end of the web105a. The bent flanges show an outer flange105b′, a turning flange105b″, and a returning flange105b″′; which are connected to the web105aof the bent channel105. The bent flanges allows a fastener (not shown) to be connected to two flanges, the outer flange105b′ and the inner flange105b″′. These double flanges105b′ &105b″′ gives the fastener37(not shown) twice the strength to support the rigid board50or rigid insulation51from the pressure of the concrete39shown in any of the previously mention Figures. Also shown inFIG. 34is insulating foam100that is wrapped around the bent flange105b. The insulating foam100extends the length of the flange105b″′ shown as100a, then around the turning flange105″ over the back side of the returning flange105b′ shown as100a′ and stops at the web105a. The friction between the outer flange105b′ and the returning flange105b″′ is sufficient to hold the insulating foam100into place. The insulating foam100as shown inFIG. 35can also be used on U channels or on H channels previously described.

FIG. 36shows a cross-section of the insulating foam100installed on a hat channel86. The foam material54can be installed using the same method as described inFIG. 11, that is applying holes36on the face70aof the hat channel70and then applying the foam material54into the holes36and then further removing the residual with a hot knife (not shown). The foam material54shown here has a thermal break at the flat edge of the foam material54as shown installed in similarFIGS. 13,14&16.

The isometric drawing ofFIG. 37shows insulating foam100placed on the flange42bof the C channel42. A punch press or a roll punch110can make a hole36into the insulating foam100and then force the insulating foam100through the hole36in the flange42bthereby attaching the insulating foam100to the C channel42. The insulating foam100that passes through the hole36is enough to secure the insulating foam100to the flange42bof the C channel42.

FIGS. 38,39&40is a structural insulating core111that consists of foam spacers55and support channels within the foam spacers55with rigid board50and rigid insulation51installed over the structural insulating core111. The foam spacers55wrap around the flanges105b′ &105b″′ of the support channels and the webs105ainterlock between adjacent foam spacers55. In addition, the flanges105b′ of the support channels fit into grooves shape55bof foam spacer55and where the support channels are located within a column mold20or the spacer channels47within the foam spacers55. More specifically the support channel of the column mold20forming structure is a double flange channel105and the interconnection between the foam spacers55and the insulating foam100.FIG. 38is showing the wall mold81consisting of the rigid board50and the rigid insulation51as the outer surfaces of wall mold81. The structural insulating core111forming structure at the column mold20consists of three double flange channels105, however only one double flange channels105on the right side of the column mold20has the insulating foam100. The insulating foam100is wrapped around the flange105b′ of the double flange channel105and the isometric shows the insulating foam100is also attached to the double flange channel105above the foam spacers55. The insulating foam100is shown attached to the outer flange105b′ and more clearly shown inFIG. 40. The foam spacer55is configured to have a tongue shape shown as55aand a groove shape shown as55b. The tongue shape55aextends to the web105aof the double flange channel105and has a depth of the inner flange105b″′. The width of the foam spacer55extends from the outer edge of the insulating foam100on both sides of the double flange channel105. The other side of the foam spacer55shows a double flange channel105between the foam spacers55. The foam spacer55is shown abutting the double flange channel105and shown as55bas the groove side of the foam spacer55. The foam spacer55fits adjacent to the web105aof the double flange channel105and extends to the turning flange105b″ to the edge of the projection55pof the adjoining foam spacer55. The groove shape55bis configured so that the outer flange105b′ fits into a slot55swithin the projection55pof the foam spacer55. The adjacent foam spacer55is shown with the tongue shape55afitting securely against the web105aof the double flange channel105. The plan section ofFIG. 40shows the foam spacer55more clearly and shows the column mold20. Where the column mold20occurs, the insulating foam100is required the full height of a concrete column35. On the other hand, where foam spacer55is required at the opposite end of the column mold20, a groove shape55bis required to begin an array of foam spacer55and double flange channels105within the wall mold81. InFIGS. 38 & 40also show the double flange channel105being used as an spacer channel47like similarly shown inFIG. 15. The combination of the double flange channel105and the foam spacer55is another combination of the structural insulating core111. The column molds20(only one shown) and beam mold90can be any size depending on the structural requirements of the column and beam. The wall mold81can consist of several wall panels65between each column mold20and the beam mold90within the wall panels65connects to the column molds20. Where a beam mold90occurs, the insulating foam100is installed on the double flange channel105.

FIG. 41is an isometric view structural insulating core111showing the double flange channel105being attached to a standard base plate120used in light gauge metal framing. A base plate120is attached to the floor175, and the double flange channel105is connected to the base plate120. The base plate120, however is different because the base plate120has a groove121cut in the flange120band another groove121in the double flange channel105at the returning flange105b″ and these grooves121are cut16′ &24″ OC in the base plate120in order to easily attached them together without measuring. Also the base plate120is larger than width of the web105aof the double flange channel105. The groove121is in the middle of the returning flange105b″ and corresponds to the groove121in the double flange channel105and the groove121in the foam spacer corresponding to the base plate120. By having a larger base plate120, the spacer insulation creates a thermal break between the flanges105b′ and105b′″ of the double flange channel105. Now only the grooves121come in contact with the turning flange120b″ of the base plate120. In addition, diagonal bracing78is shown installed on the surface of the foam spacer55connecting the array of double flange channels105.

FIG. 42shows another structural insulating core is similar toFIG. 38except inFIG. 42the support channels are shown as C channels42with insulating foam100secured around the flange42and the lip42cwhen the C channels extend into the beam mold90supported by rigid board50and rigid insulation51. The insulating foam100slides around the lip42cmaking the insulating foam100easier to install around the C channel42. The insulating foam100is installed typically only where the beam mold90passes the C channel42within the wall mold82. In addition the foam spacer55has a different tongue shape55aand groove shape55bconfiguration since the C channel42is used inFIG. 42. The foam spacer can be changed to fit any size or shape of support channels.

FIG. 43shows a plan view of the wall mold82shown inFIG. 42. The insulation foam100is shown at the center C channel42. The C channel42on the left side of the column mold20shows the foam spacer55over lapping the C channel42at the flange42bat the groove shape55bwith a projection55pextending the length of the flange42b. A foam material54at the interior of the column mold20is connected at the flange42bof the C channel42. The left C channel42at the column mold20can be reversed as shown at the right C channel42of the column mold20. The right C channel42of the column mold20is shown with foam material54at the flanges42b. The foam material54can be incorporated as part of the foam spacer55as shown as the projection55pof the groove shape55b. The projection55pand the groove shape55bof the foam spacer55encases the outside face of the web55aand the flanges42bof the C channel42and the projection55pextends to the lip42c. The base plate120without the groves121shown inFIG. 41or the angles99inFIG. 44can be installed over the projections55pof the foam spacers into any of the support channels previously shown, creating a thermal break between them.

FIG. 44shows an isometric drawing of the structural insulating core111without the rigid board and rigid insulation as previous discussed inFIG. 42consisting of two C channels42and three foam spacers55that are wider than the C channels42. The foam spacer55between the C channels42abuts the web42aat the tongue shape55aof the foam spacer55and the foam spacer55abuts the lip42cat the C channel42on the left. The opposite end of the foam spacer55has the groove shape55bwhere the web42aof the C channel42fits into. Since the foam spacers55are wider than the C channels42the excess foam spacer on both sides of the C channel42forms a projection55pthat overlaps both flanges42b. The tongue and groove configuration shows how the foam spacers can easily fit together between the C channels42. The projections55pof the foam spacers55can easily be screwed or glued to the C channels42. The webs42acan easily be glued to the foam spacers55creating a stronger structural insulating core111.FIG. 46also shows the foam spacers55and C channels42in a separated position prior to securing the foam spacers55together creating a structural insulating core111. InFIG. 46the C channel42can be wood blocking72, however the tongue space55ais not required in the foam spacer55. The structural insulating core111can be used as an independent wall; an interior core for of the columns and beam molds previously described; and as a forming structure in a precast wall which is described inFIG. 53-56. A screw122and double headed fastener123are shown secured through the foam spacer55at the projection55por into the insulating foam100to connect precast concrete walls to the structural insulating core111shown inFIG. 53-56. A double headed screw was shown in LeBlang U.S. Pat. No. 6,041,561 to secure a precast concrete wall to metal channels. Not mentioned in the patent by LeBlang, is a screw122can be used to attach the insulating foam100to the C channel42. Attaching the screw122and/or the double headed fastener123to the structural insulating core111provides as thermal break with the C channels42as well as providing a means of securing a structural insulating core111to concrete as shown inFIG. 53. When the structural insulating core111is installed within a wall mold82as shown inFIG. 42, and the rigid board50and rigid insulation51are all glued together, the wall mold82would then be considered a structural insulated panel (SIP). Usually a SIP has a foam core with wood blocking and a rigid board50made of plywood on both sides of a foam core. By making the interior of a SIP with a structural insulating core111SIP's would be able to support a greater structural load for both a wall or a roof load since everything is glued together. Also shown are drainage channels151that protrude from the structural insulating core111to create an air space should it be required when some exterior surface finish materials (not shown) are applied over the structural insulating core111. In addition a recessed groove133is shown on the exterior face of the structural insulating core111to allow water drainage between the structural insulating core111and various stucco applications. Since the structural insulating core111is a solid wall, two methods are shown to secure the structural insulating core111to a floor175. Base plate angle99is shown attached to the C channel42at the flange42band the floor175; however a groove121is cut into the structural insulating core111at the base plate angle99. Another method is to install the base plate angle99on the surface of the structural insulating core111and connect to the flange42bof the C channel42using a fastener37and thereby having a thermal break between the C channel42and the base plate angle99. A trough132is shown in the middle of the structural insulating core111and is aligned with the holes36of the C channel42for use as an electrical chase within the structural insulating core111. In some cases the trough132is required to be metal channel (not shown) for compliance with some electrical codes. In addition, the trough132can be used to install a horizontal bracing channel150shown in use inFIG. 47connecting the C channels42within the structural insulating core111. Usually the holes36within the C channels42are spaced 24″ apart so the trough132could be installed to align with the holes36therefore making the foam spacers55be shorter pieces rather than the full height of the wall. The horizontal bracing channel150is shown within the trough132passing through the holes36within the C channels42and into the adjoining spacer insulation55. The C channels42and the horizontal bracing channel150can also be shorter in length and used as brackets to secure four adjacent spacer insulations55together. The foam spacers55or a smaller foam spacers55swhich are shown with a tongue55tthat fits into the trough132in the foam spacers55also shown inFIG. 61. When the four small foam spacers55sintersect the tongues55tof two small foam spacers55sfit into the troughs132of the two small foam spacers55sbelow; plus the horizontal bracing channel connects the two small foam spacers55stogether as well as the C channel42because the horizontal bracing channel150has a hole36in the web42alocking the C channel42with the tongue shape55aand the groove shape55btogether. The smaller foam spacers55scan be installed together without support channels since the tongue shapes55aand the groove shapes55binterlock between smaller foam spacers55sas well as the horizontal bracing channel150within the troughs132plus the tongues55tfitting into the troughs132together form a structural insulating foam core wall.

FIG. 45shows a plan view ofFIG. 44except here two reverse lip channels79are used between three foam spacers55. The reverse lip channel79is similar to the C channel42inFIG. 7, except the lip79cis bent in the opposite direction as the lip42c. The tongue shape55aa fits against the web79aof the reverse lip channels79and the groove shape55bfits against the adjacent reverse lip channel79at the web79aand the projection55pof the foam spacer55fits against the flanges79band abuts the lip79c. Since the structural insulating core111has a snug fit between the reverse lip channels79and the foam spacers55, the wall panel65can be glued together. The reverse lip channel79and the C channel42have the same physical characteristics since the lip79c&42cfunction in the same way giving the reverse lip channel79the same strength as the C channel42. In addition, the reverse lip channel79can also be use in place of the horizontal bracing channel150where ever it has been used.

FIG. 47is similar toFIG. 44except the three foam spacers55of the structural insulating core111is less than the thickness of the foam spacers55inFIG. 44. The foam spacers55extends beyond the webs42aof the adjoining C channels42enough to create a thermal break and cover the C channels42with the same projection55p. The open portion of the C channel42has a lip42cwhere the tongue shape55afits between and a horizontal bracing channel150(typically used to connect adjacent C channels within the building industry) plus the opposite end of the foam spacer55also fits between the webs42aof the adjacent C channel42. Since the foam spacer55overlaps the C channel42at the projection55pand fits between the webs42a, the foam spacer55is also a wall insulation as well as a wall sheathing material all made together as one material.FIG. 48is a plan view of the wall panel65showing the tongue shape55aand groove shape55band the projection55pof the foam spacer55between the C channels42as shown also inFIG. 47. InFIG. 48the C channel42can be wood blocking, however the tongue space55ais not required in the foam spacer55and the horizontal bracing channel150is not required.

FIG. 49shows an isometric view of various modular units170that are stacked on top of each other and adjacent to one another, but are joined together at the common walls172of each modular unit170where concrete columns and beams are formed within the common walls172of the various modular units170as a common wall mold173more clearly shown inFIGS. 50,51&52.

The modules170are three-dimensional structures consisting of a wall174, a floor175and a ceiling. The modules are built in a manufacturing plant, and finished on the interior, thereby leaving the structural system exposed on the exterior of the module where modules170abut one another. Other walls shown as exterior walls171of a module are finished with an exterior finished material directly from the manufacturing plant. Modules are shipped by truck and hoisted by crane to its specified location within the building. As one module is installed, additional horizontal or vertical steel reinforcement60is added between one module170and the other module170at the columns molds20and concrete beam mold90. As module170is installed adjacent to another module170, form common wall molds173are created between modules, into which concrete39is poured to form a concrete column and beam within the common wall172. Some modules might have exterior walls171that face the exterior of the module170, which can be finished with a variety of building materials and built using various wall forming structures previously described, which when poured with concrete39become part of the module170. The various column forming structures previously described can extend above, below or adjacent to another column or wall molds to become part of an adjacent module.

InFIG. 50, the modular wall section shows two adjacent modules170installed. The floor175is constructed using an array of metal floor joists176bthat extend into the structural insulating core111also shown inFIG. 51. Many different types or flooring systems construction are available on the market, however in the floor mold112shown inFIG. 50is a patent pending by LeBlang US 2008/0062308 which consists of metal floor joists176b, rigid board50, form filler104insulation and concrete39. Where the floor mold112connects to the structural insulating core111below the floor175are secured to the C channels42to the end of the metal floor joists176b. Drywall177and a ceiling rim joist176care attached to the structural insulating core111, concrete39then is poured over the floor mold112to the outer flange42bof the C channel42thereby encasing the C channel42in concrete39to the level of the concrete floor39′. The interior walls (not shown) are installed over the floor175and electrical, plumbing and heating are installed but not shown as a part of thisFIG. 51. An array of ceiling joists176dare installed with or without drywall177attached and secured to the ceiling joists176d. A connector179is placed on the top of the adjoining structural insulating core's111connecting each module170together. A beam mold90is formed when the two adjacent modules170are installed together, the connector179are installed between the modules170and concrete39is installed between the structural insulating core111of each module. Instead of pouring concrete39on the floor mold112, concrete39can be poured after the modules are set in place and the concrete39within the floor mold112will also flow into the beam mold90.

FIG. 52is a plan view showing the two adjacent modules170installed next to each other. The structural insulating core111is shown with the C channel42as well as additional C channels42shown at the column mold20. A connector179connects the C channel42of the adjacent modules170. Drywall177is shown as the interior finish of the modules170. Additional reinforcing steel60is added into the column mold20and beam mold90between the adjacent modules170. Concrete39is poured into the column mold20and then into the beam mold90connecting the modules170together.

FIG. 53shows an isometric view of a wall panel65where the concrete39is poured on top of the structural insulating core111of the precast mold180. Any of the previous described structural insulating cores111with either the spacer insulations, foam spacers55or supporting channel configurations can be used to form a precast mold180. The previously described wall molds were first erected vertically then the hardenable material was poured into the wall molds, that is into the column and beam molds, while here the precast molds are laid horizontally and then the hardenable material is installed into the molds. The structural insulating core111shown here is similar toFIG. 42, however the rigid board50is not required and concrete39is used instead as the exterior wall material. The rigid insulation51shown inFIG. 42can be used as the bottom of the precast mold180or a forming bed typical used in precast construction can be used. The C channels42of the structural insulating core111is shown extending into a beam mold90at the ends of the wall panel65. The insulating foam100fits over the C channel42at the bottom of the beam mold90so drywall (not shown) or other materials can be attached after the concrete39has cured. Screws122or double headed fasteners (not shown) are attached through the structural insulating core111into the C channel42. In addition a recessed groove131is installed to additionally secure the structural insulating core111to the concrete39. Also to add additional strength to the wall panel65, a rib124is installed parallel to the C channel42and another rib124is installed perpendicular to the C channel42in the structural insulating core111. The ribs124add additional strength to the concrete39allowing the C channels42to be spaced further apart. The precast mold180is complete when the wall panel65side boards (not shown) are installed. Additional steel reinforcing (not shown) is installed in the beam molds90and the column mold20and concrete39is poured over and into the precast mold180when the precast mold180is in a horizontal position. Since the concrete39passes through the holes36(not shown) in the C channel42of the beam mold90, the C channel42is secured to the structural insulating core111. In addition, ribs124and grooves121are also installed on the structural insulating core111to add additional bonding strength to the concrete39bonding to the structural insulating core111. When the ribs124and recessed grooves131are added to the structural insulating core111, the screws that are secured to the C channel42might not be required to secure the concrete39to the structural insulating core111.FIG. 54is an enlarged view of the beam mold90. Many of the other previously described wall molds can also be used to form the precast mold180.

FIG. 55is showing an isometric view of the same precast mold180as shown inFIG. 53except the precast mold180is shown face down. The precast mold180is turned upside down so that the precast mold180is now placed onto a forming bed184and the structural insulating core111is suspended over the forming bed184so the flange42bis set to the depth of the concrete39of the precast mold180. Any of the previous described structural insulating cores111with either the spacer insulations, foam spacers55or supporting channel configurations can be used to form a precast mold180. The previously described wall molds were first erected vertically then the hardenable material was poured into the wall molds, that is into the column and beam molds, while here the precast molds are laved horizontally and then the hardenable material is installed into the molds. InFIG. 56the C channel42are shown having foam material54at the flange42b. The foam material54is not really necessary since the C channel42is encased in concrete. Holes36are cut into the structural insulating core111at the criss-crossing ribs124to ensure concrete39flows into the ribs124. Another way to form the precast mold180is to install the insulating foam100on each of the C channels42along with the screws122and install an angle77connecting each C channel42to the desire shape of the precast mold180. Now set the precast mold180over the forming bed184and pour the concrete39into the forming bed184, beam mold90and into the column mold20. After the concrete has become firm, then add the remaining foam spacer55to complete the structural insulating core111. The edge forming boards of the precast mold180are shown in (ghost).

FIG. 57shows an isometric drawing of a large foam block190. The foam block190has a tongue mold191and a groove mold192on each side of the foam block190. The previous drawings shown have many different types of channels within the various wall molds, wall panels as well as the various column and beam molds, therefore the foam spacer55and structural insulating cores111all have a different configuration at the channels.FIG. 57shows the foam spacer55inFIGS. 44 & 46. The foam block is cut into smaller shapes by using a wire that when heated electric current in the hot wire cuts the foam material into many different shapes including foam spacers. By cutting the tongue shape55aseveral foam spacers are being cut with the hot wire at the same time. The length of the foam blocks is cut at the groove shapes55b, however the tongue shaped including the projections55pis being cut at the same time. The process continues cutting the tongue and groove shapes until the foam block is fully cut. The foam block is now required to be turned 90 degrees so the foam block can be cut to the desire thickness of the spacer block and then rotated and turned 90 degrees to cut the height of the foam spacers. The foam spacer can also be cut to form and electric chase between blocks making the length cut to include the electric chase.

FIG. 58shows a plan view of a structural insulating core with an alternated shape for the foam spacer55. The foam spacer55shows a protruding tongue55aand a projection55pon the same side of the foam spacer55. The tongue shape55ais the same as inFIG. 44where the tongue shape55afits between the42cof the C channels42and abuts the web42awhen installed in place. InFIG. 58the projection55pextends past the web42aand is longer than the flange42bof the C channel42. The additional length of the projection55pis shown as an extension55eof the foam spacer55is the equal to the length of the flange42bplus the length of the recess194where the foam spacer55abuts is longer than the flange42bof the C channel42thereby overlapping the adjacent foam spacer55. What is shown inFIG. 58is that the foam spacer55can be cut into any configuration and still be installed next to an adjacent C channel42using the same configured foam spacer55. The support member in the structural insulating core can be formed with wood blocking72or the C channel42. If the wood blocking72(as shown by an X) is used, the tongue shape no longer extends to the web42abut abuts the wood blocking72and the projection55pstill rests in the recess194of the groove shape55bof the adjacent foam spacer55. Inner and outer boards can be installed over the structural insulating core to foam a structural insulated panel (SIP. In addition, a cementitious coating195can be installed on any of the foam spacers55prior to being installed in the C channels42.

FIGS. 59 & 60show a similar isometric view as shown inFIG. 53except the C channels42in the structural insulating core111or concrete columns35are located differently, however still forming a similar precast mold180where the concrete39is poured on top of the structural insulating core111. The foam spacer55is connected between each of the C channels42forming the structural insulating core111. Concrete columns35or concrete beams39″′ can be formed anywhere within the precast mold180by removing the foam spacer55at a column mold20or beam mold90location. The column mold20inFIG. 59is shown in the middle of the foam spacer55while the column mold20inFIG. 60is formed between foam spacers55. One half of the column mold20is formed at one foam spacer55and the other half is formed at the adjacent foam spacer55. The foam spacer55overlaps the C channel42and interlocks with the adjacent foam spacer55. When the spacer insulations55are connected together the column mold20is formed with the C channel42located in the middle of the column mold20. When the concrete39is installed over the foam spacer, the foam spacer55remains attached to the C channels42and become a part of the precast mold180.

The precast mold180in bothFIGS. 59 & 60can be turned upside down as shown inFIG. 55using holes36that can be installed in the foam spacer55in order to place concrete39within the precast mold180.

FIG. 61is an isometric drawing showing a concrete beam39″′ and a concrete column35formed by using ICF block molds96and the structural insulation core111. The foam spacer55of the structural insulating core111as shown inFIG. 61is the same width as the ICF block mold96and the C channel42is the same width as the cavity98within the ICF block mold96. InFIG. 61, the ICF block mold96is shown attached to the C channel42forming a column mold20between the structural insulating core111and an adjacent structural insulating core111(not shown) on both sides of the column mold20of the ICF block mold96. In addition, an ICF block mold96is installed on top of the structural insulating core111to form an beam mold90into which a concrete39(not shown) can be poured. InFIG. 29a concrete beam39″′ is formed using the ICF mold96and baffles92. InFIG. 61the structural insulating core111acts as the baffle when the spacer foam55is installed below the ICF block mold96when a concrete beam39″′ and a concrete column35is formed. In addition, the bracing plate152shown inFIG. 44can be horizontal as shown above the window opening inFIG. 61. The bracing plate152is shown above the window opening219to form a structural support above the window opening219. The bracing plate152can be installed on both sides of the foam spacer55. In addition, inFIG. 20an “L” shaped column was previously described using C channels42plus rigid boards50and rigid insulation51. The ICF block molds96can form an “L” shaped column when the structural insulating core111or previously described wall configuration is adjacent to ICF block mold96. A smaller foam spacer55sas shown inFIG. 44is shown removed below the concrete beam39″′. The horizontal bracing channel150is shown passing the trough132on top of the foam spacer55and into the concrete column35therefore allowing the horizontal bracing channels150to be connected by reinforcing ties that are typically used to connected steel reinforcing steel60located within the concrete beam39′″ and concrete column35. Also shown is an ICF connector extension64′ shown inFIG. 67.

FIG. 62throughFIG. 66shows various configurations of the ICF block molds96attached to the structural insulating core111. InFIG. 62is a wall section showing the beam mold90is placed above to the structural insulating core111. The C channel42with holes36extending into the beam mold90and attached with a fastener37through the rigid foam block faces88of the ICF block mold96. When concrete39is poured into the beam mold90, the C channel42will be secured into the concrete39. In addition the reverse hat channel71as shown inFIG. 16can be installed as part of the structural insulating core111, when the foam spacer55width is large enough to accommodate the depth of the reverse hat channel71. The reverse hat channel71can also connect two ICF block molds96as shown inFIG. 67. The reverse hat channel71would be installed between the typical connector64of an ICF block mold96and therefore would be installed between one ICF block mold96and an adjacent ICF block mold96(not shown) connect the connectors64of the respective ICF block molds96.

FIG. 63shows beam mold90using an ICF block mold that has a connector64that is deeper than the depth of the structural insulating core111. The C channel42extends above the foam spacer55of the structural insulating core111. On both sides of the C channel42is a brace channel135. The flanges135aare attached to the flanges42aof the C channel42in the structural insulating core111. The opposite flange135aof the brace channel135is shown extending beyond the beam mold90. Another brace channel135is shown at the interior side of the beam mold90. A foam material54can be installed at the webs135bof the brace channels135for installing drywall (not shown) onto the beam mold90after the concrete39(not shown) is poured within the beam mold90.

InFIG. 64the beam mold90is shown with a tapered and deeper shape of the ICF block mold96above the structural insulating core111. Typically this shape of ICF block molds96are used as brick ledges or wider beam molds available from many existing manufacturers. Shown in ghost is the ICF block mold96protruding on both sides of the structural insulating core111. A smaller foam spacer55s, as shown inFIG. 44, is shown above a concrete beam39″′. A horizontal bracing channel150is above the smaller foam spacer insulation55sand an anchor bolt74connecting the horizontal bracing channel150to the reinforcing steel60in the concrete beam39′″ through the vertical hole36vin the smaller foam spacer insulation55s.

FIGS. 65 and 66both show plan views of the two structural insulating cores111between an ICF block molds96which form a column mold20. In bothFIGS. 65 & 66, the ICF block mold96extends over both flanges42aof the C channels42on both sides of the column mold20in the structural insulating core111to firmly secure the ICF block mold96to the C channels42. Fasteners37are connected to through the rigid foam block faces88into the C channel42. The foam spacer abuts the web42of the C channels42in the different configurations. InFIG. 65the ICF block mold96on the left extends past the flange42band the foam spacer55has a recess194where the rigid foam block faces88fit into. Therefore, the projections55pas is shown inFIG. 58has been removed. InFIG. 66the projections55p(not shown) have also been removed as shown inFIG. 58, and the foam spacer55is shown with the same configuration as the foam spacer55on the left side of the column mold20. The horizontal bracing channel150is shown passing through the column mold20. InFIG. 58the projection55pextends past the web42aand is longer than the flange42bof the C channel42. The additional length of the projection55pis shown as an extension55eof the foam spacer55is the equal to the length of the flange42bplus the length of the recess194where the foam spacer55abuts is longer than the flange42bof the C channel42thereby overlapping the adjacent foam spacer55.

FIG. 67is a wall section of the ICF block mold96shown at the ICF column mold20. The reverse hat channel71as also described inFIG. 62can extend around the concrete39(not shown) within the column mold20. The reverse hat channel71passes between rigid foam block face88of the ICF block molds96where two ICF block molds96intersect and the flange71cof the reverse hat channel71connect to the connectors64of each ICF block molds96. The connectors64attaches to the rigid foam block faces88of the ICF block mold96.FIG. 67shows an ICF connector extension64′ that attaches to connector64within the ICF block mold96. The ICF connector extension64′ has a tapered edge64″ at the bottom of the ICF connector extension64′ to be installed directly into the bottom of a concrete footing39″ or resting on top of a concrete block spacer89prior to concrete39(not shown) being installed within the concrete footing39″. The ICF connector extension64′ can be used with the C channel42that can also be inserted in the concrete footing39″. A horizontal bracing channel150is shown passing through the column mold20from a structural insulated core111.

FIG. 68is a plan view of column mold20that is larger than the previous column molds and is also connected between the foam spacers111. The column mold20has criss-crossing connectors64a&64bthat are embedded within the column mold20. The column mold20is secured by fasteners37to the webs42bof the C channels42. The structural insulating core111overlaps the C channels42at the flanges42ainterlocking the structural insulating core111to the column mold20. A horizontal bracing channel150is shown passing through the column mold20.

FIG. 69is a plan view of a column mold20comprising of a rigid board50and a one piece mold212that is U shaped having two sides212aand a back212b. The sides212aof the one piece mold212fits between the structural insulating cores111and is connected to the C channel42within the structural insulating cores111. Another C channel42within the one piece mold212is installed at the sides212aand back212bwithin the one piece column mold212for additional strength. Additional flange extensions as shown inFIGS. 73 & 74can be added to the C channel42within the one piece mold212for easy installation of additional wall materials like drywall (not shown). The one piece mold212can be a rigid material like polystyrene or aerated autoclave concrete. The same material shown in the one piece mold212is shown as a rigid board50installed over the structural insulating cores111as well as another rigid board50is shown as forming the fourth side of the one piece mold212. The one piece mold and the rigid board50can all be connected to the C channels42within the structural insulating core111by fasteners37(not shown). A horizontal bracing channel150is shown passing through the one piece mold212between the structural insulating cores111on both sides of the one piece mold212and connected to the vertical reinforcing steel60.

FIG. 62andFIG. 70are similar in that they both have a beam mold90that is above the structural insulating core111. InFIG. 62the beam mold90is above the structural insulating core111, and inFIG. 70the beam mold is a one piece mold212. The one piece mold212can be formed as a single mold where the interior has been removed thus forming the two sides212aand the bottom212b. The C channel42within the structural insulating core111extends through the bottom212bof the one piece mold212securing the C channel42into the one piece mold212. The one piece mold212can be of a rigid insulation, aerated autoclaved concrete or a rigid board material. Depending on the material used to form the one piece mold212, the same material can also be used for the structural insulating core111. A connector64as shown inFIGS. 70 & 72Ais shown as an additional support between the two sides212aof the beam mold90as well as a groove121shown in the connector web64d.

FIGS. 69 & 71are similar because the same rigid board50is attached to the structural insulating core111and the beam mold90. Not all rigid boards have similar insulating properties, and therefore must be distinguished to be of different materials.FIG. 71is a wall section showing the structural insulating core111with the rigid board50attached. The rigid board50can either be glued to the structural insulating core111or attached with fasteners (not shown) to the C channels42. The beam mold90can be formed as one piece mold212having 2 sides212aand a bottom212b. The one piece mold212can be of the same material as the rigid board50. A base plate120can be installed over the structural insulating core111so an anchor bolt74can be installed through the web120ainto the beam mold90. Concrete39and reinforcing steel60are installed within the beam mold90. A twist connector220can be used to support the 2 sides212aof the beam mold90. The twist connector220is shown in more detail inFIGS. 72B & 72C. The smaller spacer insulation55sis shown below the beam mold90with a vertical hole36vand an anchor bolt74that attaches the horizontal bracing channel150to the reinforcing steel60within the beam mold90.

FIG. 72Ashows an enlarged plan section of connector64installed within a rigid board50or the connector64shown inFIGS. 70 & 71. Typically most ICF block molds96as shown inFIG. 61have the connector64embedded within the rigid foam block faces88and are molded within the rigid foam block faces88during the manufacturing process. On the other hand some rigid foam block faces88can only be cut after the product has cured and therefore the rigid foam block faces88are cut or sliced like bread into thin rigid foam block faces88like aerated autoclave concrete and other rigid products. After the rigid foam block faces88are cut into slabs, the rigid foam block faces88need to be cut or routed to form a dove tail shape or an inverted V shape64ainto which a connector end64bcan be slid into the inverted V shape Ma into each of the rigid foam block faces88as shown inFIG. 62or as shown in the sides of210ainFIG. 70. The inverted V shape Ma can be of any shape as long as there is sufficient friction on the connector end64bfrom being pulled from the inverted V shape Ma within the rigid foam block faces88. Also shown inFIG. 72Ais an extended leg64cof the connector64. The extended leg Mc is shown to add additional resistance and strength to the holding capacity of the connector64. The connector web64dcan be a short bracket as shown inFIG. 70Aor a like a full height web44aof the bent flange channel44inFIG. 7. The connector web64dcan have holes36or grooves121to install reinforcing steel60within the one piece beam mold210. The length of the connector64will vary depending if the rigid foam block faces88are placed in a vertical or horizontal position. InFIG. 7the rigid board50or rigid insulation51can be interchanged to be the rigid foam block faces88. In addition, the connector64can be of rigid plastic as well as metal as described earlier. The connector64as described has a cavity38similar to the cavity38of the bent flange channel44inFIG. 10. The inverted V shape Ma conforms to the two sides64e, the extend leg Mc and the connector end64bof the connector64.

FIG. 72BandFIG. 72Cshow the twist connector220in an inserting positionFIG. 72Band the fixed position72C. As stated earlier the twist connector220is shown installed in the beam mold90inFIG. 71, however any of the rigid foam block faces88as described earlier can also be used. The side wall210ais also shown inFIGS. 72B & 72Cwith a dovetail joint213shown within each half of the side wall210a. The dovetail joint213is similar to the invert V shaped Ma shown inFIG. 72A; however the dovetail joint213has a wide opening at the interior side shown as L1and a wider opening within the middle of the side wall210ashown as L2. The twist connector220shown inFIGS. 72B & 72Chas two connector heads220aconnected by a connector shaft220b. The connector heads220aare shown having a narrow width L1′ with a longer length of L2′.FIG. 72Bshows the connector head220ashown in a vertical position; where the smaller connector head L1′ is inserted through the interior side L1of the dovetail joint213. The connector head220ais then turned or twisted 90 degrees within the dovetail joint213, so that the long length L2′ of the twist connector220is turned the full width L2of the dovetail joint213. When the twist connector220is turned 90 degrees within the dovetail joint213, the twist connector220is locked into position within the side wall211a. The twist connector shaft220bis rectilinear in shape and when the twist connector220is in the locked position, the twist connector shaft has a rebar depression220cso steel reinforcing (not shown) can be installed in the rebar depressions220cas shown inFIG. 71.

FIG. 73andFIG. 74shows various flange extensions added to the U channel41and the C channel42previously shown as bent channel44inFIG. 10, as a double flange channel105inFIG. 40and reverse lip channel79inFIG. 45. InFIG. 73the flange extension200is shown attached to the U channel41at200a, then bent at200baround the flange41bof the U channel41and continues at an angle to the web41aforming a cavity38. Another flange extension201is similar to flange extension200except a portion of the flange extension at201a′ has two extra bends in form a flange depression201a″ when drywall (shown is ghost) is applied of the flange extension201a′. The flange extension202is attached to the U channel41at202a, then bent at202baround the flange41b, however a gap202b′ is formed between the flange41band the continuation of the flange extension202at202c. The gap202b′ is formed so as to install a foam spacer55not shown between the flange41band the flange extension202c.

InFIG. 74has a flange extension203that is installed by friction rather than a fastener37as shown inFIG. 73. The flange extension203has one leg203athat rests against the lip42cand the other leg203brests against the web42aof the C channel42. The leg203bis at an angle to the web42bsimilar to the flange extension200. When the leg203afits against the lip42cand other leg203brest against the web42a, friction against the leg203bto the web42bholds the loose flange extension203in place. The flange extension204is shown as a rectangular tubular shape, however the flange extension204can be a “C” so as not to allow concrete to flow into the flange extension204as shown as a spacer inFIG. 14. The flange extensions200,201,202&203can be short brackets or full length depending on the height of the wall as shown inFIG. 24and can be manufactured of plastic or metal. The flange extensions200,201,201&203are attached to the U channel41or C channels42when embedded into any of the previous described concrete molds in order to have a cavity38into which drywall (not shown) can be installed into the concrete molds.

FIG. 75shows a full height wall panel45consisting of a base plate120at the top of bottom of the wall panel45with an array of C channels42spaced between the foam spacers55. Enlarged detail is shown inFIG. 76, and a wall section inFIG. 77plus a plan window section shown inFIG. 78. An enlarged cross-sectional view of the wall panel45is shown inFIG. 44, also shown as the structural insulating core111consisting of the foam spacer55and the C channels42. The groove121in the foam spacer55is shown inFIG. 41is also shown inFIG. 75at the top and bottom of the wall panel45for the base plate120to fit through. The diagonal bracing78as shown inFIG. 41can be used vertically; horizontally or diagonally to connect the C channels42within the rigid wall panel45. The diagonal bracing78is installed over the foam spacer55with fasteners37into the flange42bof the C channel42. A reverse hat channel71as shown inFIG. 62is also shown attached to the C channels42.FIG. 76shows the bracing plate152attached to the C channel42above the window opening219. Also shown is a base plate angle99at the top of the wall in lieu of using the base plate120also shown inFIG. 44.FIG. 78shows a plan view of the C channel42, another C channel42that has a cripple stiffener145that attaches to the second C channel42which is typically used in light gauge framing. Additional insulation is shown around the window opening219. The support member in the structural insulating core can be formed with wood blocking72or the C channel42.

Three-dimensional structures consisting of modules170with a wall174, a floor175and a ceiling are discussed inFIGS. 49-52.FIGS. 79-81is similar toFIGS. 50-52in that they both form a column20and a beam mold90using two adjacent modules170′ &170as part of the column mold20and the beam mold90.FIGS. 50-52used the structural insulating core111and a rigid board to form the ICF block mold96.FIG. 81shows a plan view where modules170′ and170form a column mold20. Each module170′ &170have a structural insulating core111and a C channel42forming the sides of the column mold20. An ICF block mold96consists of a connector that is attached to the two rigid foam block faces88of the ICF block mold96. The rigid foam block face88of the ICF block mold96at module170′ is attached at the flange42bof the C channel42in each of the structural insulating cores111of module170′. The other rigid foam block face88of the ICF block mold96at module170is attached at the flange42bof the C channel42in each of the structural insulating cores111of module170. Therefore the column mold20is formed when the rigid foam block face88of module170′ and the rigid foam block face88of module170are attached to the respective structural insulating cores111of each of the modules170′ &170.

FIG. 80shows a vertical wall section of module170where the ceiling joists176dand the metal floor joists176bintersect the C channels42of the structural insulating core111. The concrete floor39′ is shown forming a concrete beam39″′ between the rim joist176cand the C channel42for retrieving and stacking of the various modules170.

FIGS. 79-81shows how modules170′ &170fit together when stacked on top of one another. When each of the modules170′ &170are stacked on top of one another a gap35is between the structural insulating core111of module170′ and module170. The C channels42of the structural insulating cores111of module170′ &170extend above the structural insulating cores111of each module. The rigid foam block face88of the ICF block mold96fits on top of the structural insulating core111of module170′ and the rigid foam block face88and fits on top of the structural insulating core111of module170along the entire length of the column mold20, that is the distance between one column mold20and the next column mold20. A connector64attaches to the rigid foam block faces88aand can be secured into the C channel42that protrudes into the beam mold90. Steel reinforcing can be installed within the beam mold90and the column mold20prior to concrete39installed. In addition, concrete39can be installed in the gap35between the structural insulating cores111of the modules170′ &170to provide a higher fire rated wall assembly between modules.

FIG. 82is similar toFIG. 59except the C channels42in the structural insulating core111have been removed. The spacer insulation52used inFIG. 82is an aerated autoclave concrete which is manufactured differently and is harder than polystyrene. Both materials are considered a insulating type product, however autoclave concrete is harder and can be exposed to the exterior when protected from the weather by painting. Aerated autoclave concrete can be manufactured in different densities and therefore the exterior surface or rigid board50is a denser aerated autoclave concrete and spacer insulation52is more porous and has a greater insulating value or the entire wall panel65can be the foam spacer55which is the denser insulation. The column mold20inFIG. 25shows a larger C channel48protruding out from the wall panel65, however inFIG. 82rigid board50extends above the spacer insulation52allowing the column mold20to be deeper than the spacer insulation52of the wall mold181. The connector64inFIG. 70or the twist connector220inFIG. 71can be used to support the rigid board50on both sides of the column mold20. A T shaped joint213, shown in ghost inFIG. 72B, is also shown inFIGS. 82 & 84. A typical precast lift connector221is shown embedded into the spacer insulation52and another lift connector221is shown having a depression221daround the lift connector221shown inFIG. 83. Since aerated autoclave concrete is soft prior to being installed in an autoclave at the manufacturing plant, the lift connector221can be embedded into the aerated concrete prior to autoclaving and the connector and a depression can also be installed in the wet aerated concrete. After the aerated concrete has been autoclaved, it is harden and the panels can be moved using the lift connector221. In addition, the connectors (not shown) can be used to hold the aerated autoclaved concrete or the foam spacer55to the concrete39within the column molds20or the beam molds90. In addition, the beam mold90inFIG. 26shows a protruding beam, however inFIG. 82the rigid board50is shown extending above the spacer insulation52, forming the beam mold90. The spacer insulations52and rigid board50can be glued together or can be screwed together depending on the densities if the spacer insulations52.

FIG. 85shows the front elevation of a wall panel65andFIG. 86shows the rear of the same wall panel65. An isometric view of the rear view of a similar wall panel65is shown inFIG. 82. Since a wall panel65can be at least 10 feet wide by 35 feet tall, smaller aerated autoclave concrete sections of the foam spacer55or foam insulation52with rigid board50can be used to form the beam molds90and column molds20are formed to complete the wall mold181. InFIGS. 53,59&60concrete39is poured over the various wall molds, however when the concrete39is eliminated and the foam spacer55is exposed, ribs124are required at the joints between the foam spacer55wall sections. The front elevation shown inFIG. 85has various architectural reliefs shown inFIG. 44as a protruding drainage channel151or a recessed groove133. The architectural reliefs can be installed in the aerated concrete prior to autoclaving when the aerated concrete is soft and can be cut by wire or pressed into the desired shape or can be cut after autoclaving by cutting with a saw or by hot wire cutting.

FIG. 87is similar to the beam molds shown inFIGS. 62 & 70. The structural insulating core111at the wall, supports the beam mold90which is formed by the rigid foam block faces88that are attached to the C channel42of the structural insulating core111. Another structural insulating core111shown at an angle above the beam mold90is a roof mold230. Concrete39is installed in the beam mold90along with a hold down strap232that is embedded into the beam mold90. An angle base plate231is placed on top of the concrete39and the hold down strap232and the angle base plate are attached to the C channel42within the structural insulating core111in the roof structure. The support member in the structural insulating core can be formed with wood blocking72or the C channel42. The structural insulating core111at the roof can be extended by adding roof extension foam spacer55ethat is in the shape of a roof eave.

FIG. 88is similar toFIG. 87except the beam mold90is located at the top of the structural insulating core111and within the structural insulating core111at the roof above the structural insulating core111in the wall. The C channel42in of the structural insulating core111at the wall, is attached to the C channel42in the structural insulating core111at the roof. InFIG. 88the eave foam spacer55eis attached to the C channel42in order to form the beam mold90as well as a filler insulating234that fills the void between structural insulating core111at the roof and the structural insulating core111at the wall. After concrete39is installed in the beam mold90a filler insulation234can be installed above the beam mold90.

The roof structural insulating core111inFIG. 88is similar to the spacer insulation55shown inFIGS. 47 & 48. InFIG. 48the spacer insulation55is braced by the horizontal bracing channel150.FIG. 89is a plan view of a wall panel161where the spacer insulation is the full depth of the C channels42and the spacer insulation55fits against the webs42aand against above the lips42cand the other side of the foam spacers55rests against the web42band the projection55prests above the flanges42b. An additional rigid board50is installed at the exposed flanges42bso the concrete beam39″′ can be formed above the wall as shown in any of the other drawings.

FIG. 90is a roof section or a wall section of the structural insulating core111shown inFIG. 88and is the same profile at the plan view shown inFIG. 89except the C channels42are shown deeper, since the structural capacity of the C channels42would typically have a greater strength. InFIG. 90the wall panel65shows the foam spacer55to be the full depth of the C channels42and the foam spacers55fits against the webs42aand against the lip42cand rests on the foam material54. The other side of the foam spacer55rests against the web42aof the adjacent C channel42and above the flanges42b.FIG. 89also shows that the projection55pis longer similar toFIG. 58where the extension55eis shown and is shown extending longer than the width of the flange42bforming a greater thermal break in the foam spacer55and the C channel42. The support member in the structural insulating core can be formed with wood blocking72or the C channel42.

FIG. 91is the same section asFIG. 90; however the bottoms of the foam spacers55are shown deeper than the C channels42. The additional depth of the spacer insulations55forms an addition air space235between the C channels42and a finished ceiling (not shown). In addition, the foam spacers55are shown sliding into position in the wall panel65. Since the foam spacers55not have a projection55pon the underside of the foam spacers55, the foam spacer55has slide into position after the C channels42have been installed instead of installing the C channels42at the same time as the foam spacers55.

CONCLUSION AND SCOPE OF INVENTION

A new method of construct a concrete post and beam structure using the wall forming structure plus the interior and exterior rigid board and the spacer insulation configurations as the mold to form concrete columns and beams in or protruding from a wall. The concrete columns and beams are made using the light gauge metal building components or plastic composites as the forming structure within the wall mold. The rigid board or rigid insulation for the wall surfaces and spacer insulation supports the beam within the wall.

To form a concrete column within a framed wall, the channels are spaced the length of the column width to support the concrete. If the column is required to be too long, additional channels are installed to connect the exterior and interior sheathing on both sides of the flanges of the channels. The column width is determined by the width of the web of the channel. The larger the column size required the wider of the wall and the larger the channel size within the wall.

The wall forming structures within the wall molds are not structural supports to support additional floors or to support a beam, but are used to attach the exterior and interior rigid boards to the wall forming structure in order to form a column or beam mold. Concrete columns and beams are poured when the wall are erected in a vertical position as a single wall or as a modular building as well as in a horizontal position as a precast wall. The drawings have shown many wall forming structures like an elongated column or “L” shaped columns.

Different types of wall forming supports are shown. Some wall supports make the interior spacer channels easier to insert into an adjoining wall support and other wall supports have a foam material that surrounds the flange of the wall supports while others are just wood supports. Other wall supports have an air space at the interior of the support channel to allow for fasteners to penetrate the forming supports to later connect drywall or an exterior building material. The foam material at the forming support flanges give the thermal break as well as a water stop (should the wall be installed below grade) between the forming supports and the exterior or interior wall surface. Another type of wall forming supports are flange extensions that are added to channel supports, that allow for additional material to be added after concrete is installed within a concrete wall, beam or column. Other wall forming supports are connector that slide or twist the connectors into place securing both sides of the concrete mold into place.

The tongue and groove interlocking of the foam spacer allows a wall to be formed easier and is a better method to stop heat or cold transfer through a wall. The interlocking foam spacer can be used as a typical exterior wall with or without the concrete column or beam within the wall. The interlocking foam spacer can used with any of the support channels plus can be connecting vertically between panels. The foam spacer can easily be slide into place without having to measure between channels for a faster and easier connection.

The foam insulation can be used as a insulator between the precast concrete and the metal supports. The fasteners can be connected either through the foam insulation or the foam spacer on the outer surface of the support structure. The support channels with the fastener through the foam spacer can be installed so the fastener is embedded into the concrete bed (like a typical precaster).

Another method would be to have the wall built with the mold supports and interior spacer channels and then install the fasteners through the foam spacer and then pour the concrete over the wall foam spacer forming a precast wall.

The structural insulating core can be used as an independent wall, screwed or glued to together to form a SIP or together to form a larger SIP to form concrete columns and beams.

The structural insulating core can be used along with an ICF to form concrete columns and beams within a wall.

It is understood that the invention is not to be limited to the exact details of operation or structures shown and describing in the specification and drawings, since obvious modifications and equivalents will be readily apparent to those skilled in the art. The flexibility of the described invention is very versatile and can be used in many different types of building applications.