Abstract:
A method and system for installing an insulated concrete wall includes insulation panels placed in an upright manner. Generally T-shaped wall studs are placed next to the insulation panels such that the front section of the wall stud is on the outside of the insulation panels and an anchoring section of the wall stud extends beyond the insulation panels into the gap into which concrete will later be poured. Concrete pouring forms are placed so as to render the gap into which concrete will be poured a desired thickness. The wall stud may also include slots for receiving cross-ties that secure the concrete pouring forms in proper position and retaining nubs that prevent the insulation panels from floating when concrete is poured. Concrete is then poured into the gap, surrounding the anchoring section the T-shaped wall stud.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation-in-part of U.S. Ser. No. 10/002,828 filed with the United States Patent and Trademark Office on Nov. 30, 2001, now U.S. Pat. No. 6,625,947, entitled INSULATED CONCRETE WALL SYSTEM AND METHOD OF MAKING SAME. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to a method and system for forming insulated concrete walls. More particularly, though not exclusively, the present invention relates to a method and system for securing insulation panels to a poured concrete basement wall while still providing a visible wall stud that may be used for finishing and other purposes such as hanging drywall. 
   2. Background of the Invention 
   Rising utility costs have increased the demand for concrete walls, such as those in most basements, that are insulated. Basement walls made from insulated concrete blocks, with the insulation actually contained in the concrete blocks, are extremely expensive and time consuming to install. Poured concrete walls are much less costly and take less time to install. Insulation has typically then been added or fastened to one or both faces of the concrete. Adding insulation after a concrete wall has hardened is an expensive and time consuming process. 
   Conventional uninsulated reinforced concrete walls are poured into forms that are typically constructed of heavy plywood panels clamped and nailed into place with cross-ties between parallel panels to prevent them from spreading apart under the hydraulic forces generated by the concrete. The plywood is initially treated so it can be stripped away after the concrete is set. 
   It has been shown that rigid foam plastic panels are strong enough to substitute for plywood, thus providing an insulated wall. For example, in U.S. Pat. No. 6,240,692 issued Jun. 5, 2001 to Yost, a series of rigid foam panels are used in place of the plywood forms. The foam panels of Yost are left in place permanently, thus providing the poured concrete wall with insulation on both sides. Yost also discloses a plurality of wall studs encased in each panel, each stud having a trust structure for increased strength. 
   Similarly, a pair of insulative panels are used in place of the plywood forms in U.S. Pat. No. 5,040,344 issued Aug. 20, 1991 to Durand. Durand discloses reinforcing each of the panels with horizontal stiffeners and using removable shores to maintain the panels in a vertical position during concrete pouring. 
   All of these systems require specialty components that are time consuming to install and drastically increase the costs of insulating poured concrete walls. Further, many of these systems also have their studs embedded in the foam. Embedding the studs in the foam requires the foam be specially made to fit the studs. This prevents the builder of the concrete wall from selecting the thickness of insulation to be used on site. This also makes it difficult to find the studs if additional finishing of the walls is to be done. There is therefore a need for an insulation system that is quick and easy to install, variable, relatively inexpensive, and that has wall studs visible beyond the insulation panels. 
   Because many of these insulation systems also use foam panels in place of plywood or aluminum forms, the insulation panels must be on both sides of the concrete wall. Often, insulation is only desired on the inside portion of the concrete walls. There is therefore a need for an insulation system that may be used only where and when desired. 
   It is therefore a primary feature of the present invention to overcome the problems in the prior art. 
   It is a further feature of the present invention to provide an insulated concrete wall system that is relatively low cost and easy to use. 
   Another feature of the present invention is to provide an insulated concrete wall system that allows insulation panels to be placed on one or both sides of a poured concrete wall. 
   A still further feature of the present invention is the provision of an insulated concrete wall system in which wall studs are secured in the poured concrete wall upon hardening of the concrete. 
   Another feature of the present invention is the provision of an insulated concrete wall system in which the wall studs are visible for easy finishing of the wall. 
   A further feature of the present invention is the provision of an insulated concrete wall system in which any size of foam insulation or fiberglass hardboard insulation may be used without the need for special grooves to be cut in the insulation material. 
   A still further feature of the present invention is the provision of an insulated concrete wall system in which the wall studs retain the foam panels to prevent them from floating during concrete pouring. 
   These, as well as other features, objects, and advantages of the present invention, will become apparent from the following specification and claims. 
   BRIEF SUMMARY OF THE INVENTION 
   The present invention generally comprises an insulated concrete wall system and method for installing same. The system of the present invention includes insulation panels, walls studs and forms placed so as to form a channel into which concrete will be poured. Insulation panels and forms are well known in the art and commercially available. The channel&#39;s thickness is designed to correspond to the desired thickness of the wall. 
   The generally T-shaped wall studs are placed adjacent to one end of an insulation panel before the next insulation panel is put in place. The front section of the T-shaped wall stud extends beyond the front surface of the insulation panels and will be visible on the completed wall. The anchor section of the T-shaped wall studs extends beyond the width of the insulation panels and into the channel itself. 
   The thickness of the channel is maintained by the use of cross-ties. Preferably, these cross-ties go through slots in the T-shaped wall studs. The wall studs also preferably include several retaining nubs which prevent the insulation panels from floating or otherwise moving during concrete pouring. At the corner of a wall, a corner bracket may be used to secure two insulation panels in proper position. The corner bracket includes two channels for receiving insulation panels. The ends of these channels may include a retaining portion to secure the insulation panels in place. 
   When concrete is poured to fill the channel, the concrete surrounds the anchor section of the T-shaped wall stud. Upon hardening, the concrete secures the T-shaped wall stud in place. Aluminum or wooden forms are used to support the insulation panels and T-shaped wall studs during concrete pouring and are removed after the concrete has hardened. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the insulated concrete wall system of the present invention as assembled. 
       FIG. 2  is a top view of one embodiment of the insulated concrete wall system of the present invention. 
       FIG. 3  is one example of the T-shaped wall stud of the present invention. 
       FIG. 4  is a second example of the T-shaped wall stud of the present invention. 
       FIG. 5  is a top view of the corner bracket, as installed, of the present invention. 
       FIG. 6  is a side view of the embodiment of the T-shaped wall stud shown in  FIG. 4 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The present invention will be described as it applies to its preferred embodiment. It is not intended that the present invention be limited to the described embodiment. It is intended that the invention cover all modifications and alternatives which may be included within the spirit and scope of the invention. 
   Now, referring to the drawings,  FIG. 1  illustrates the insulated concrete wall system  10  of the present invention. The insulated concrete wall system  10  generally includes a number of forms  12  and insulation panels  14  secured to the concrete wall by a plurality of wall studs  16 . The forms are well known in the art and made of wood, aluminum or other suitable materials. 
   Initially, insulation panels  14 , are placed upright along the edge of what is to be the concrete wall  22 . Each insulation panel or sheet of insulation material has a front surface, rear surface, top side, bottom side, first edge, and second edge. A T-shaped wall stud  16  is placed along either the first or second edge of the insulation panel  14 . Next, another insulation panel  14  is placed on the other side of the T-shaped wall studs  16 . This process is continued until one side of the wall is formed. 
   As is also shown in  FIG. 1 , the builder places forms  12  across from the sheets of insulation  14  to form a channel  20  into which concrete  22  is poured. The width of the channel  20  is designed to correspond to the desired width of the concrete wall  22 . Typically, building codes require concrete walls to be at least 8 inches thick. Additional forms  12  may be placed on the outside of the insulation panels  14  and wall stud  16  to provide support necessary to prevent the insulation panels  14  and wall studs  16  from moving when concrete  22  is poured. 
   When needed, corner brackets  18  may be used to secure two insulation panels  14  at right angles to one another. As is more clearly shown in  FIG. 5 , the corner bracket  18  includes a first channel  36  and a second channel  38  into which insulation panels  14  may be secured. Preferably, the corner bracket  18  may also include a retaining portion  40  to keep the insulation panels  14  in place. 
   As is shown in  FIG. 3 , the T-shaped wall studs  16  of the present invention generally include a front section  26  that is connected to an anchoring section  28 . The retaining portion  30  at the end of the anchor section  28  is also included. The retaining section  30  prevents the T-shaped wall stud  16  from being easily removed from the concrete wall  22 . Preferably, the T-shaped wall stud  16  is made by extruding a resilient plastic material. This helps to keep costs down and allows the wall stud  16  to be made to any desired length. A plurality of holes  42  can be added to allow the user to insert a variety of securing devices  46  such as nails, pins, etc. 
   Alternatively, the wall stud  16  may also include ribs  34  and slots  32  as is shown in  FIG. 4 . The slots  32  are designed to accommodate the cross-ties  24  that may be inserted through the T-shaped wall studs  16  during installation as is shown in  FIG. 1 . Preferably, the slots  32  are spaced vertically along one side of the front section  26 . The number and spacing of the slots  32  can vary depending on the user&#39;s preference. For example, as shown, the slots  32  can be of varying lengths to accommodate the variety of cross-tie patterns used by contractors. For example, a contractor may use a plurality of 4 inch long slots in a predetermined pattern to accommodate both an 8×8 pattern of cross-ties  24  a 6×12 pattern. Either way, the slots  32  are thereby designed to accommodate the cross-ties  24  without the need to create a customized piece. Moreover, because the slots  32  can accommodate both typical patterns, there is no need to have large holes or gaps in the wall stud&#39;s face. This allows a user to secure nails, screws or other securing items during drywalling, finishing or at any other time. Using cross-ties  24  ensures the concrete wall  22  will be of uniform thickness. It is preferred that the cross-ties  24  be of the break-away variety. 
   The ribs  34  provide a securing and stabilizing function. In use, the ribs  34  help to keep the insulation panels  14  in place. Additionally, the ribs  34  stabilize the wall by providing a channel along which water can flow. When the wall stud  16  of the present invention is used and the concrete  22  has hardened, it will eventually develop minute cracks. These cracks are most likely to develop along the weakest portions of the wall. The concrete  22  is at its thinnest where the wall stud  16  is located. Thereby, the cracking can be controlled allowing for thermal expansion. When a small crack does develop, water may seep in. If the water has no place to go, it could seep into the insulation, causing mold, warping and spots on any finished walls. However, the ribs  34  create vertical channels traveling the length of the wall stud  16 . These channels allow any incoming water to flow down below grade to the footing where it can be allowed to drain into sump pumps, tile, etc. 
   Also shown in  FIG. 2 , strips  44  of bentonite may be added as desired. Typically, the strips  44  of bentonite have a sticky backing, allowing for easy installation. Bentonite increases the walls ability to manage any incoming water. As is shown in  FIGS. 2 and 6 , the wall stud  16  may also include nubs  35  which are designed to prevent the insulation panels  14  from upward movement when the concrete  22  is poured into the gap  20 . Preferably, the nubs  35  are located on the anchor section  28 . The nubs  35  may be of any desired shape and be located on either or both the front section  26  or the anchor section  28  of the wall stud  16 . 
   As can also be seen in  FIG. 2 , a portion of the anchor section  28  of the wall stud  16  is secured within the concrete  22  of the wall. The desired width of the insulation panels  14  may be changed by the builder at any time. The anchor section  28  of the wall stud  16  is of a length that allows for many different thicknesses of insulation panels  14  to be used. For example, if four inches of insulation is used instead of two inches, two inches less of the anchoring section  28  will be secured in the concrete  22  of the wall. In order to secure the insulation panels  14  in place, a pin, nail or other securement device  46  can be used. A plurality of holes  42  are preferably provided in the anchor section  28  of the wall stud  16 . Preferably, the holes  42  can be staggered to provide a hole  42  for the different thicknesses of insulation panels  14  that are commonly in use. In this manner, the present invention can be used with 1, 2, 3, or 4 inch varieties of foam insulation. An additional benefit in the holes is realized when the concrete  22  is poured. Any holes  42  that are not used are filled by concrete  22 . This further secures the wall stud  16  within the concrete  22 . 
   Rebar is typically required and must be added to the interior of the concrete wall. Supporting the rebar during the pouring process may be accomplished through the use of plastic supports  48 . Each plastic support  48  includes a vertical portion that rests against the insulation panels  14 . The horizontal portion begins at the corner. The corner is placed around a hole  42  through which a nail or pin  46  is placed. The staggered holes  42  allow the rebar to be placed at desired horizontal locations. Additional supports  48  may be used to place rebar as need to meet any horizontal spacing. The horizontal spacing of rebar may be dictated by code, city or governmental regulations or an engineer&#39;s/owner&#39;s requirements. The curved or receptively shaped end portion of the plastic support  48  is shaped to accommodate a typical piece of rebar. Thus, rebar can be positioned during assembly of the wall form. 
   Once all of the insulation panels  14 , wall studs  16 , forms  12  and other materials are in proper position, concrete  22  is poured into the gap  20 . After the concrete  22  has hardened or set, the forms  12  are removed. This leaves an insulated concrete wall wherein the wall studs  16  are clearly visible. Additionally, because the wall studs  16  are on the outside of the insulation panels  14 , drywall may be easily secured to the wall studs  16 . Therefore, finishing a wall insulated according to the system of the present invention is expedited. Further, because the wall studs  16  are on the outside of the insulation panels  14 , a small gap will exist between any installed drywall and the insulation panels  14 . This increases the R-value of the wall constructed according to the system  10  of the present invention. Higher R-values are desirable as homes constructed with high R-value walls have lower overall heating and cooling costs. 
   Further, because the wall studs  16  are on the outside of the insulation panels  14 , no special connection between the insulation panels  14  and wall studs  16  is required. This allows the builder to purchase any type of insulation panel  14  from any vendor at the lowest possible costs. 
   A general description of the present invention as well as a preferred embodiment to the present invention has been set forth above. Those skilled in the art to which the present invention pertains will recognize and be able to practice additional variations in the methods and systems described which fall within the teachings of this invention. Accordingly, all such modifications and additions are deemed to be within the scope of the invention which is to be limited only by the claims appended hereto.