Abstract:
A free-standing, hollow, prefabricated concrete form for forming a lost form, pre-finished concrete wall having an insulating layer on at least one major surface, typically an outer, earth facing surface thereof. The inside of the form has a rough finished surface. The form provides metal studs, typically on conventional sixteen inch centers, thereby enhancing the strength of the wall. The form allows placement of conduits for wiring, either electrical power or so-called low voltage circuits (e.g., telephone, TV cable, network wiring, audio cables, etc.) within the wall. Water supply and drain lines may also be placed within the wall prior to filling the forms with concrete. Multiple prefabricated sections may be joined to one another end-to-end to fabricate longer walls.

Description:
FIELD OF THE INVENTION 
       [0001]    The invention pertains to modular forms for forming free standing, concrete-filled walls and, more particularly, to modular, pre-insulated forms readily assembled and adapted to receive concrete therein. 
       BACKGROUND OF THE INVENTION 
       [0002]    The process of forming vertical walls from poured concrete has been known for centuries. The process, while theoretically simple, typically requires highly skilled laborers and expensive forms to accomplish. Forms may be either built for single use or may be formed from modular sections assembled to the required configuration. Upon curing of the concrete wall poured therein, the reusable forms are typically removed and stored for later use on another project. 
         [0003]    Insulated concrete walls are sometimes constructed using form assemblies having insulation disposed as a part of the form. The form becomes part of the concrete wall. This type of construction is typically referred to as lost form construction. 
         [0004]    Regardless of the type of form utilized to construct a poured concrete wall, two major problems remain. First, the construction or assembly of forms typically requires skilled labor and is time intensive. In addition, a large capital expense is typically required in obtaining reusable forms. There is further expense involved in removing forms from storage, transporting forms to a job site, removing forms once a concrete wall has sufficiently cured, and finally, shipping the forms back to storage. When forms are not properly constructed or set, finished walls may be out of square or plumb, be of the wrong dimension, and/or have bulges or other abnormalities. It is not uncommon have to destroy one or more of the poured walls, reset the forms, and re-pour the concrete. This results in further expense as well as delays in the construction project. 
         [0005]    The second problem is that poured concrete walls constructed using forms of the prior art are notoriously difficult to finish. 
       DISCUSSION OF THE RELATED ART 
       [0006]    Several attempts to provide lost form type forms for building concrete filled walls appear in the prior art. For example, U.S. Pat. No. 5,311,718 for FORM FOR USE IN FABRICATING WALL STRUCTURES AND A WALL STRUCTURE FABRICATION SYSTEM EMPLOYING SAID FORM, issued May 17, 1994 to Jan P. V. Trousilek teaches a modular form system utilizing prefabricated plastic forms. 
         [0007]    U.S. Pat. No. 5,323,578 for PREFABRICATED FORMWORK issued Jun. 28, 1994 to Claude Chagnon et al. shows a prefabricated, collapsible formwork having flexible connecting elements. 
         [0008]    U.S. Pat. No. 5,860,262 for PERMANENT PANELIZED MOLD APPARATUS AND METHOD FOR CASTING MONOLITHIC CONCRETE STRUCTURES IN SITU, issued Jan. 19, 1999 to Frank. K. Johnson provides a system of interlocking form sections for forming continuous concrete walls, the form sections becoming a permanent part of the finished wall. 
         [0009]    U.S. Pat. No. 6,178,711 for COMPACTLY-SHIPPED SITE-ASSEMBLED CONCRETE FORMS FOR PRODUCING VARIABLE-WIDTH INSULATED-SIDEWALL FASTENER-RECEIVING BUILDING WALLS, issued Jan. 30, 2001 to Andrew Laird et al., teaches yet another system for assembling forms on site to fabricate a lost form concrete wall having a cavity into which reinforcing steel, electrical and/or communications conduits, plumbing, etc. may be placed prior to filling the form with concrete. 
         [0010]    U.S. Pat. No. 6,263,628 for LOAD BEARING BUILDING COMPONENT AND WALL ASSEMBLY METHOD, issued Jul. 24, 2001 to John Griffin teaches another lost form system wherein regularly spaced apart studs help define a cavity into which concrete is poured. 
         [0011]    U.S. Pat. No. 6,321,498 for FORMWORK FOR BUILDING WALLS, issued Nov. 27, 2001 to Salvatore Trovato teaches another modular form system for creating a lost form, concrete filled, insulated wall. 
         [0012]    U.S. Pat. No. 6,363,683 for INSULATED CONCRETE FORM, issued Apr. 2, 2002 to James Daniel Moore, Jr. shows yet another modular form system for fabricating lost form, concrete filled, insulated walls. 
         [0013]    None of the patents and published patent applications, taken singly, or in any combination are seen to teach or suggest the novel free-standing form system for fabricating an insulated, concrete filled wall of the present invention. 
       SUMMARY OF THE INVENTION 
       [0014]    In accordance with the present invention there is provided a prefabricated concrete form for forming a lost form, pre-finished concrete wall. An insulating layer is preformed on an outside (i.e., earth facing) side of the form. The inside of the form has a rough finished surface that is treatable with any typical decorative finish commonly used in the industry with regard to interior wall finishing. The form provides metal studs, typically on conventional sixteen inch centers, thereby allowing treatment of the resulting concrete wall in a manner similar to a wood framed wall. 
         [0015]    The novel system allows placement of conduits for wiring either electrical power or so-called low voltage circuits (e.g., telephone, TV cable, network wiring, audio cables, etc.) within the wall. Water supply and drain lines may also be placed within the wall prior to filling the forms with concrete. 
         [0016]    It is, therefore, an object of the invention to provide a modular, free-standing lost form concrete form for creating a concrete-filled, free standing wall. 
         [0017]    It is another object of the invention to provide a modular, free-standing lost form concrete form that may readily be interconnected to form long, continuous wall sections. 
         [0018]    It is an additional object of the invention to provide a modular, free-standing lost form concrete form wherein conduits for electrical circuits and/or water supply and drain lines may be preinstalled within the form prior to filling the form with concrete. 
         [0019]    It is a further object of the invention to provide a modular, free-standing lost form concrete form having insulating board pre-placed on the outside of the form. 
         [0020]    It is a still further object of the invention to provide a modular, free-standing lost form concrete form having a magnesium oxide insulating board pre-placed on the outside of the form. 
         [0021]    It is another object of the invention to provide modular, free-standing lost form concrete form into which an opening to accommodate a door, window, or other portal may readily be placed. 
         [0022]    It is yet another object of the invention to provide a modular, free-standing lost form concrete form that has metal studs on a standard center-to-center spacing, for example, 16 inch centers, pre-placed within the form. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]    Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein: 
           [0024]      FIG. 1  is a front, perspective, schematic view of a section of the free-standing form in accordance with the invention; 
           [0025]      FIG. 2   a  is an end, perspective, schematic view of the free-standing form of  FIG. 1 ; 
           [0026]      FIG. 2   b  is a detailed portion of the view of  FIG. 2   a;    
           [0027]      FIG. 3  is a side, elevational, schematic view of two sections of the free-standing form of  FIG. 1  joined together end-to-end; 
           [0028]      FIG. 4  is a side, elevational, schematic view of the free-standing form of  FIG. 1  showing electrical wiring boxes and conduits in place; 
           [0029]      FIG. 5  is a side, elevational, schematic view of the free-standing form of  FIG. 1  showing embedded water supply lines; 
           [0030]      FIG. 6  is a side, elevational, schematic view of the free-standing form of  FIG. 1  showing an alternate embodiment having water supply and drain lines embedded in the free-standing form of  FIG. 1 ; and 
           [0031]      FIG. 7  is a side, elevational, schematic view of the free-standing form of  FIG. 1  showing framing modified to accommodate a window therein. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0032]    The present invention provides a modular, free-standing form system for forming concrete filled walls having a pre-insulated outer surface and a roughly finished inner surface. The forms are of the lost form variety wherein the form becomes a permanent part of the concrete filled wall. 
         [0033]    Referring first to  FIG. 1 , there is shown a front, perspective, schematic view of a section of the free-standing form in accordance with the invention, generally at reference number  100 . Free-standing form  100  has a length “l”  102 , a height “h”  104 , and a depth “d”  106 . In the embodiment chosen for purposes of disclosure, length “l”  102  is approximately 24 feet (7.3 m), height “h”  104  is approximately 10 feet (3 m), and depth “d”  106  is in the range of approximately 8-12 (0.2-0.3 m) inches. It will be recognized that free-standing form  100  may be implemented in many other sizes and, consequently, the invention is not considered limited to the dimensions chosen for purposes of disclosure. Rather, the invention covers free-standing forms in all practical dimensions. 
         [0034]    Free-standing form  100  has a rectangular base  101   a  formed from angle stock, typically treated steel angle stock or the equivalent. Long angle stock members  108  are joined to short angle stock members  110  at intersections thereof using self tapping screws  112 , not shown in  FIG. 1  and best seen in  FIGS. 2   a  and  2   b . While self tapping screws  112  have been chosen for purposes of disclosure, it will be recognized by those of skill in the art that other suitable fasteners or joining methods may be substituted therefor. In addition to fasteners, adhesives or spot welding may be used to join long angle stock members  108  to short angle stock members  110 . 
         [0035]    Top frame  101   b , substantially identical to the base  101   a  is formed from long angle sections  108  and short angle sections  110 , also held together by self tapping screws  112  or the like. 
         [0036]    Studs  114  are placed at predetermined intervals along both front and back long angle stock members  108  and are also attached to base  101   a  and top frame  101   b  by self tapping screws  112  or the like. Studs  114  are metal “C” studs well known to those of skill in the art and not further described herein. Studs  114  are typically placed at regular intervals on industry standard center-to-center spacing, for example 16 or 24 inch spacing behind stud material. 
         [0037]    The depth dimension “d”  106  is established by spacers  116  that tie studs  114  located at the front of free-standing form  100  corresponding studs  114  at the rear thereof. Spacers  116  are short lengths of “C” stud material identical to the material from which studs  114  are fabricated. 
         [0038]    Referring now also to  FIGS. 2   a  and  2   b , there are shown an end, perspective, schematic view of the free-standing form  100  and a detailed portion of the view of  FIG. 2   a , respectively. Spacers  116  may readily be seen in  FIGS. 2   a  and  2   b.    
         [0039]    A reinforcing steel bar, known as rebar  118 , is loosely secured to a top surface of spacer  116  by clamps  120 . Rebar is well known to those of skill in the art and is not further discussed herein. Further, rebar  118  forms no part of the present invention and is shown only to illustrate the intended use environment of free-standing form  100 . 
         [0040]    Clamps  120  are typically straps such as one hole conduit straps well known to those of skill in the art. Clamps  120  are typically attached to the upper surface of spacers  116  by a single self tapping screw  112 . It will be recognized that many alternate clamps or fastening methods may be substituted for clamps  120  for securing rebar  118  to spacers  116 . 
         [0041]    A sheet of insulating board  122  is shown attached to outer faces, not specifically identified, of studs  114  of both major surfaces of free-standing form  100 . In the embodiment chosen for purposes of disclosure, insulating board  122  is 12 mm (approximately 0.5 inch) thick magnesium oxide board such as Magnum® board provided by MBP Magnum Building Products of Tampa, Fla. USA. Magnesium oxide (MgO) board is chosen for its many desirable properties for below grade installation. MgO board is waterproof, mold and bacteria resistant, dimensionally stable, and is structurally durable. The insulating board  122  is attached to the MgO board. The MgO board is a minimum of 0.5 inch thick. While the MgO board has some insulating value, it is only R 1.2. The MgO board is fire rated, non-carcinogenic, insect proof (i.e., termites, carpenter ants), and silica free. 
         [0042]    Referring now to  FIG. 3 , there is shown a front, elevational, schematic view of a pair of free-standing forms  100  joined end-to-end to one another. When insulating board  122  is placed on a major surface of a free-standing form  100 , a gap  130  may be left to allow access to an interior region  128  within free-standing form  100 . Gap  130  allows access to end studs  114  so that two sections of free-standing form  100  may be joined end-to-end to one another. The gap is closed after joining forms. 
         [0043]    Joining bolts  124  with washers  132  and nuts  134  may be used to abut end studs  114  of adjoining sections. It will be recognized by those of skill in the art that other devices and/or techniques may be used to join sections of free-standing form  100  to one another. Such devices and/or techniques are believed to be known and are not further discussed herein. The invention includes any and all such devices and/or techniques and is, therefore, not considered limited to joining bolts  124 , washers  132 , and nuts  134  chosen for purposes of disclosure. 
         [0044]    Referring now also to  FIG. 4 , there is shown a front, elevational, schematic view of free-standing form  100  having electrical boxes  136  embedded therein. Electrical boxes  136  are connected to conduits  138  that are placed within free-standing form  100  to allow in-the-wall wiring in the final concrete-filled wall section made from free-standing form  100 . While individual conduits  138 , each connected to a single box  136  are shown, it will be recognized that alternate wiring arrangements may be placed inside free-standing form  100  prior to the filling thereof with concrete. Boxes  136  are schematic and are intended to represent any electrical box whether for power or low voltage/communications applications. 
         [0045]    Referring now also to  FIG. 5 , there is shown a front, elevational, schematic view of a free-standing form  100  having liquid (e.g., water) supply lines  140  or similar plumbing embedded therein. Like conduits  138  ( FIG. 4 ), that are placed within free-standing form  100 , water supply lines  140  are routed to the top of free-standing form  100  for connection to hot and cold water supplies, not shown, or the like. It will be recognized that  FIG. 5  is schematic and that water supply lines  140  may represent any in-the-wall plumbing such as a compressed air line, an oxygen line, a vacuum line, or any other supply or suction line. 
         [0046]    Referring now also to  FIG. 6 , there is shown a front, elevational, schematic view of a free-standing form  100  having both water supply lines  140  or similar plumbing, as well as a drain connection  142  embedded therein. In this embodiment, both water supply lines  140  and drain connection  142  are run horizontally across an interior region of free-standing form  100 . It will be recognized that drain line  142  is preferably installed with an appropriate slope. Both supply lines  140  and drain connection  142  may be connected to mating water supply lines  140  and/or drain line  142  at the interface between adjacent sections of free-standing forms  100 . 
         [0047]    Referring now also to  FIG. 7 , there is shown a front, elevational, schematic view of a free-standing form  100  having an opening  144  in the framing to allow installation of a window, not shown. Framing elements, possibly formed from the same material as studs  114  discussed hereinabove, are used to define opening  144  into which a pre-hung window or the like can be placed upon completion of the concrete filled wall defined by free-standing form  100 . It will be noted that any opening formed through free-standing form  100  must be sealed from front to back to seal the concrete pour, not shown, within free-standing form  100 . While an opening  144  for a window has been chosen for purposes of disclosure, it will be recognized that openings suitable for doors or other portals may likewise be placed in free-standing form  100 . Consequently, the invention is not considered limited to openings for windows but rather includes any opening through the wall formed by filling free-standing form  100  with concrete. 
         [0048]    In use, one or more free-standing forms  100  are fabricated as described hereinabove. If two or more free-standing forms  100  are required to form the length of wall desired, adjacent forms must be secured to one another end-to-end. Any plumbing or electrical components that must connect at the edges of free-standing form  100  sections must be made. 
         [0049]    Rebar must be inserted and secured within free-standing forms(s)  100 . For safety and aesthetics, exposed ends of free-standing form(s)  100  should be covered. Typically, the horizontal rebar is already installed in the walls. It is necessary to join the pre-installed rebar only where the wall sections come together. 
         [0050]    Finally, once free-standing form(s)  100  are fully prepared and braced as required, concrete, not shown, may be poured into the hollow, interior spaces  128  within free-standing forms  100 . Once the concrete is cured, the resulting wall may be backfilled using backfilling materials and techniques well known to those of skill in the art. Interior finishing may be accomplished utilizing studs  114  or the insulating board  122  forming the interior surface of the wall. 
         [0051]    When required, electrical circuits and/or plumbing may be completed using conduits  138  and/or water supply and drain lines  140 ,  142 , respectively. Interior finishing of MgO walls is accomplished utilizing conventional materials and methods. All that is required prior to final finishing is taping and spackling the few joints where the wall sections join. 
         [0052]    Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention. 
         [0053]    Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.