Abstract:
The present invention uses insulating concrete forms (ICF) in the construction of residential buildings. An entire wall panel is formed from polystyrene panels that may be cut by a hot wire machine. If necessary, hat channel shaped metal may be inserted into hat channel slots. Columns of polystyrene are removed so that concrete posts may be poured therein after the wall panel has been secured into place with rebar being located therein. Rebar and concrete also are formed along the top of the wall panel. Electrical and plumbing connection pathways are provided in the wall panel at the time of cutting with hot wire. Each wall panel is separately designed and cut by hot wire while still at the factory, but are all connected together to form an ICF residence. Openings are provided for doors and windows and are buck framed. Hat channels are inserted as necessary for strength and/or connection thereto.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a system and method of building a residential structure and, more particularly, to a residential structure having insulated concrete forms (hereinafter referred to as “ICF”) that are used in forming the walls, which walls are attached to a concrete slab and to a roof. 
         [0003]    2. Background of the Prior Art 
         [0004]    As this country was being settled, early pioneers built homes from whatever was available. In the areas having a lot of trees, the homes were normally made out of logs. In other areas that were rocky, homes were made out of rock. As the plains area of the country was settled, homes were made out of sod. In arid regions, homes were made out of stucco or were even dug into the sides of hills or cliffs. 
         [0005]    As time passed and this country was settled, the building of residential structures evolved to the use of wood frames. Sometimes precut stone or brick would also be used, but normally in conjunction with a wood framing. One of the problems with a wood framed house, with or without stone, is that it was expensive to heat in the winter and hard to cool in the summer. As the cost of energy has continued to rise, this has been a continuing concern for the homeowners and, hence, a concern for the home builders. 
         [0006]    About forty to fifty years ago, a trend started to use foam for insulation purposes in residential buildings. Some times expanded foam was sprayed inside the walls or under the roofs of residential buildings to provide additional insulation. Later, panels were inserted to provide insulation. As the trend to use foam continued, insulating concrete forms (referred to as “ICF”) started to be used in residential structures. Many different types of methods have evolved for building ICF residential buildings. However, fundamental problems still revolve around the methods being used to build ICF residential structures. 
         [0007]    The first major problem is the prior systems require a lot of labor in the shaping, cutting or modifying the foam blocks for the particular structure. A second problem is that after cutting, shaping or modifying the foam structure, the foam structure loses much of its insulating value. Third, the insulating foam does not have the structural integrity so enough concrete must be used therewith to give the strength necessary for the structure. 
         [0008]    An example of one of the prior ICF structures can be found in U.S. Pat. No. 6,401,413 issued to Niemann which shows an insulated concrete form wall building system. A pair of elongated expanded polystyrene side walls are located adjacent to each other with vertical ribs. Concrete is poured between the vertical ribs of the respective walls to form a composite polystyrene and concrete wall structure. 
         [0009]    Another type of ICF walls is shown in U.S. Pat. No. 5,697,189 issued to Miller, et al and has fiber reinforced concrete faces, but expanded polystyrene in the middle thereof. Vertical structure concrete ribs are located between the insulating panels to provide structural support. 
         [0010]    While the above were only two examples of patented systems that are already in existence, there are many others showing different types of ICF structures used in commercial and residential buildings. While each has its own advantages and pit falls, the major problem is the expense involved in building the structures. If the expense is held down, normally the buildings do not have the structural integrity. 
       SUMMARY OF THE INVENTION 
       [0011]    It is an object of the present invention to provide an ICF residential structure. 
         [0012]    It is another object of the present invention to provide a method of building an ICF residential structure using precut, ready to use, expanded foam panels. 
         [0013]    It is yet another object of the present invention to use precut polystyrene panels to form walls on a foundation of a residential structure, which wall columns may then be poured with concrete to give structure strength. 
         [0014]    It is yet another object of the present invention to design each panel of polystyrene that may be cut in the factory and delivered to the job site for construction into the building of an ICF residential structure with a minimum amount of labor being required at the job site. 
         [0015]    It is still another object of the present invention to provide reinforcement in the concrete columns of an ICF residential structure in the form of rebar or other suitable reinforcing material. 
         [0016]    It is yet another object of the present invention to provide pathways in the ICF structure through which electrical wiring and plumbing lines may be installed to the inside or outside of a residential structure. 
         [0017]    In the present invention, the slab for a residential structure is poured to the desired specifications. Each wall panel is designed and precut at the factory to the desired specification. When the precut panels are delivered to the job site, any undesired foam is removed and any metal strengthening such as hat channels may be inserted. 
         [0018]    The precut panels are then arranged vertically on the foundation and securely held in position by a wall alignment system. Once rebar is in place, concrete is poured in the appropriate columns forming the wall. A wood buck is placed around the windows and doors. For the door jams, rebar is driven into the adjacent concrete column while the concrete is still wet to hold and support the door jam when the concrete dries. 
         [0019]    After the concrete has hardened, the wall alignment system is removed, windows and doors bucked and a 2×12 board is attached to J screws extending out of the top of the concrete on each of the walls. 
         [0020]    Depending upon the inside finish out plan for the residence, suitable connections can be provided through hat channels to support the inside finish. Typically, thy wall would be used on the inside of the house. The dry wall would be secured in position by screws extending into the hat channels. 
         [0021]    On the outside of the residential structure, any desired type of outside finish can be used. If stucco is used, it can be applied directly to the foam. If a brick facade or some other type of facade is desired, it may be necessary to have external hat channels to which the facade may be attached. The same would be true for fiber cement siding. 
         [0022]    If the external structure is brick, anchors for the brick would still be provided by attachments to the hat channels, but a ledge to support the brick would be necessary on the foundation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]      FIG. 1  is a pictorial perspective of the walls of a residential structure embodying the present invention, which walls are located on a foundation of the residence with the roof, windows and doors being shown in broken lines. 
           [0024]      FIG. 1A  is an inside perspective view of a typical expanded foam panel that may be used in the present invention. 
           [0025]      FIG. 1B  is an outside prospective view from  FIG. 1A . 
           [0026]      FIG. 2  is an opposing perspective view from  FIG. 1A , but showing the female end of an expanded foam panel and with inside hat channel slots being horizontal. 
           [0027]      FIG. 3  is a top view of a four column panel also illustrating an external electrical opening and cross passage. 
           [0028]      FIG. 4  is a front view of  FIG. 3 . 
           [0029]      FIG. 5A  is a perspective view of a corner block having a single column. 
           [0030]      FIG. 5B  is a perspective view of a corner block having three columns. 
           [0031]      FIG. 5C  is an opposing perspective view from  FIG. 5B . 
           [0032]      FIG. 6  is a perspective view of a panel that may be used above a window or door. 
           [0033]      FIG. 7  is a top view of a section of a wall utilizing the present invention. 
           [0034]      FIG. 8  is a cross-sectional view of  FIG. 7  taken along section lines  8 - 8 . 
           [0035]      FIG. 9  is a perspective view of a wall alignment frame. 
           [0036]      FIG. 10  is a perspective view of one section of the wall being held in position by the wall alignment frame prior to pouring of the concrete. 
           [0037]      FIG. 11  is a cross-sectional view of an upper portion of the wall after pouring and attachment of a 2×12 board thereto. 
           [0038]      FIG. 12  is an elevated view of a section of the wall using the present invention having a window therein. 
           [0039]      FIG. 13  is a sectional view of  FIG. 12  along sectional lines  13 - 13 . 
           [0040]      FIG. 14  is a front partial perspective view of a section of a wall utilizing the present invention in which a door is located. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0041]    Referring now to  FIG. 1  of the drawings, a frame  20  for a residential structure is located on a foundation  22  and has a roof structure  21  attached thereto. The foundation  22  is typically made of reinforced concrete. The frame  20  has a series of wall panels making up the frame  20 , each of the wall panels  24  being separately designed for the particular residence. The frame  20  has windows  23  and doors  25  therein as would be found in most residences. The top of the frame  20  is capped off by a 2×12 board  26  that is held in position by J bolts  28 . The frame  20  and the panels  24  making up the frame will be discussed in further detail hereinbelow. 
         [0042]    Foam, whether polystyrene or some other type expanded foam, is typically delivered in blocks that are 8 ft.×8 ft.×16 ft. These blocks are cut into pieces with the largest piece being 4 ft.×1 ft.×8 ft. Since the 8 foot length represents the ceiling height, sometime that may vary and may be up to 9 ft in height. Typically if a 9 ft. ceiling is being provided for in the structure, the original block may be 9×8×16, or the original 8×8×16 ft. block has to be cut in a different manner. 
         [0043]    Regardless of the height or length, each panel is approximately one foot thick. That thickness represents the thickness of the wall for the residence being built. It has also been found that 1½ lb. density polystyrene is ideal for use in the present invention. 
         [0044]    Referring now to  FIGS. 1A and 1B  in combination, a five column panel  30  is shown. To form the five column panel  30 , a 4×1×8 ft. block is fed through a hot wire machine (not shown) at the factory. The hot wire machine (not shown) simultaneously cuts out the columns  32 ,  34 ,  36 ,  38  and  40  through hot wire slots  42 ,  44 ,  46 ,  48  and  50 , respectively. During the same pass in the hot wire machine, electrical and plumbing passage ways  52 ,  54 ,  56  and  58  are cut through hot wire slots  60 ,  62 ,  64  and  66 , respectively. 
         [0045]    Simultaneously with this first pass through the hot wire machine, hat channel slots  68  and  70  are cut. Hat channel slots  68  and  70  are cut by the same wires that cuts out columns  34  and  38  respectively. At this point at the factory, none of the foam form in columns  32 ,  34 ,  36 ,  38  and  40 , nor the circular foam portions in the electrical passage ways  52 ,  54 ,  56  and  58  are removed. 
         [0046]    Simultaneously with the cutting of the columns  32 ,  34 ,  36 ,  38  and  40 , electrical and plumbing passage ways  52 ,  54 ,  56  and  58 , and the hat channel slots  68  and  70 , the male end  72  and the female end  74  of the five column panel  30  are cut. With the same pass, hat channels  76  and  78  are cut into male end  72  and the female end  74 , respectively. 
         [0047]    Depending upon the interior finish that is desired in the residence, the five column panel  30  may have to be run through a hot wire machine again to cut additional hat channel slots  80 ,  82  and  84  on the inside of the five column panel  30 . 
         [0048]    Each of the columns  32 ,  34 ,  36 ,  38  and  40  are approximately six inches square, but with rounded corners. The foam between the columns is approximately 2 inches thick. 
         [0049]    After passing through the hot wire machine as described hereinabove, the five column panel  30  is again run through the hot wire machine after being rotated 90 degrees. During this next pass through the hot wire machine, the top end  85  of the five column panel  30  is cut out as shown in  FIGS. 1A and 1B . The purpose of this shape will be explained in more detail subsequently. 
         [0050]    Referring to  FIG. 2 , an opposing perspective view from  FIG. 1A  is shown so the particular shape of the female end  74  of the five column panel  30  can be seen. However, in the perspective view as shown in  FIG. 2 , the hat channel slots  80 ,  82  and  84  that were located vertically in  FIGS. 1A and 1B , are cut horizontally in  FIG. 2  and labeled as  86 ,  88  and  90 . 
         [0051]    Referring now to  FIGS. 3 and 4  in combination, a four column panel  92  is shown. The four column panel  92  has columns  94 ,  96 ,  98  and  100 , which are cut through hot wire slots  102 ,  104 ,  106  and  108 , respectively. Simultaneous with the same pass through the hot wire machine (not shown), the male end  110  and the female end  112  are also cut. Likewise, during the same pass through the hot wire machine, hat channel slots  114  and  116  are cut at the back of columns  96  and  98 . Electrical and plumbing passage ways  118 ,  120 , and  122  are also cut through hot wire slots  119 ,  121  and  123 , respectively. 
         [0052]    If vertical inside hat channel slots are to be used, inside hat channel slots  124 ,  126  and  128  are cut through hot wire slots  130 ,  132  and  134 . 
         [0053]    The fundamental difference between the four column panel  92  as shown in  FIGS. 3 and 4  and the five column panel  30  as shown in  FIGS. 1A and 1B  is the horizontal length. Obviously, the horizontal length may have to vary depending upon where the panel is to be used in the residential structure. Also, illustrated in  FIG. 3  is the connection to an outside receptacle which goes into opening  136  connected by a cross passage  138  to electrical passage way  122 . By insertion of suitable electrical wire (not shown) through electrical passage way  122 , cross passage  138  to opening  136 , an electrical receptacle can be provided with power on the outside of the residence. 
         [0054]    Referring now to  FIG. 5A , a vertical corner block  140  is shown, which vertical corner block  140  is again made out of expanded foam and is typically 8 ft. in length. When passing the vertical corner block through the hot wire machine, the female end  142  and the male end  144  are formed therein. Simultaneously, the column  146  is cut simultaneous with hat channel slots  148 ,  150 ,  152 ,  154 ,  156  and  158 . The additional hat channel slots are for strength and for connection to the corner of the residential structure. The vertical corner block  140  as shown in  FIG. 5A  only has one column, namely, column  146 . 
         [0055]      FIGS. 5B and 5C  shows opposing perspective views for three column vertical corner blocks  160 . While it is preferred to use a three column vertical corner block  160 , sometimes it may only be possible to use a single column vertical corner block as shown in  FIG. 5A . The three column vertical corner block  160  has columns  162 ,  164  and  166 . However, in  FIG. 5C , the three column vertical corner block  160  has been flipped to the opposite end from the view as shown in  5 B. The female end  168  and the male end  170  are clearly shown in the three column vertical corner block  160 . The use of the hot wire machine to cut the columns  162 ,  164  and  166 , the female end  168 , the male end  170  and the various hat channel slots in the three column vertical corner block  160  are the same as previously described hereinabove for prior figures. 
         [0056]    Referring to the frame  20  of the residence being constructed as shown in  FIG. 1 , window openings  172  are located within the frame  120 . Above the window  172  as shown in  FIG. 1  is located an upper window panel  174 . 
         [0057]    Referring to  FIG. 6 , a perspective view as shown of upper window panel  174 . The upper window panel  174  is basically the same as the four column panel  92  except it is shorter. That is so the upper window panel  174  can fit above the window opening  172 . Other similar upper window panels will be used throughout the frame  20  for other window openings. 
         [0058]    Referring now to  FIGS. 7 and 8  in combination, a typical wall section for the frame  20  of a residence is shown and indicated with reference numeral  176 . The wall section  176  is in place on a suitable foundation such as foundation  22 . Foam columns  178 ,  180 ,  182 ,  184  and  186  remain within the wall section  176 . It has been found for single story residences, only every other foam column needs to be removed and filled with concrete. Therefore, every other foam column  178 ,  180 ,  182 ,  184  and  186  have not been removed in the wall section  176 . If the structure being built was a two story structure and this was the lower level, then all of the foam columns would be removed and filled with concrete. 
         [0059]    In the other columns not containing foam as shown in  FIGS. 7 and 8 , rebar  188 ,  190 ,  192 ,  194  and  196  extends from the foundation  122  (see  FIG. 1 ) up to the top end cut  85  (see  FIGS. 1A and 1B ) and rebar  188 ,  190 ,  192 ,  194  and  196  are tied to cross rebar  198  and  200 . On approximate 4 ft. centers J bolts  202 ,  204  and  206  are also tied to cross rebar  198  and  200 . The J bolts  202 ,  204  and  206  extend above the top of wall section  176  by approximately 3 inches. 
         [0060]    When concrete is poured into the wall section  176  as will be subsequently described, concrete columns  208 ,  210 ,  212 ,  214  and  216  are formed around rebar  188 ,  190 ,  192 ,  194  and  196 , respectively to form concrete reinforced columns. Across the top a concrete plate  218  is poured and formed in the top end cut  85  (see  FIGS. 1A and 1B ). 
         [0061]    Referring now to  FIGS. 9 and 10  in combination, a wall section  220  is being constructed on foundation  222  using the present invention. In the wall section  220 , the inside hat channels  224  are arranged horizontally based on the preference of this builder. The hat channels used to support inside finishing materials or outside finishing materials can be either vertical or horizontal depending upon the preference of the builder or end user. 
         [0062]    To hold the wall section  220  vertical while the concrete is being poured, a wall alignment frame  226  (see  FIG. 9 ) is located on top of wall section  220 . Straps  228  are connected between the wall alignment frame  226  and anchors  230  with the straps  228  being adjusted to make sure the wall section  220  is absolutely vertical. Thereafter, the concrete is poured in the top end cut  85  (see  FIGS. 1A and 1B ) to form a wall section similar to the one in  FIGS. 7 and 8 . 
         [0063]    Referring to  FIG. 11 , a top part of the wall section  220  is cross sectioned at a J bolt after the wall section  220  has been completed. The J bolt  232  as shown in  FIG. 11  is wired to cross rebar  234  and  236 . The bottom of the J bolt  232  receives the cross rebar  236  therein in the bottom of the J. The upper cross rebar  234  is held in position and wired to the J bolt  232  and a cross bar  238 . The cross bar  238  holds the upper cross rebar  234  at the ideal height within the top end cut  85 . When the wall section  220  is completed as shown in  FIG. 11 , a 2×12 board  240  is bolted into position and held there by nut  242  and washer  244 . 
         [0064]    Referring now to the wall alignment frame  226  as shown in  FIG. 9 , the horizontal channels  246  and  248  are spaced apart by 12 inches so that a wall section will fit exactly therein so that it can be held in position. Cross channels  250  hold the horizontal panels  246  and  248  in position. Slots  252  provide a place for the straps  228  to connect to the wall alignment frame  226  as shown in  FIG. 10 . 
         [0065]    Referring to  FIGS. 12 and 13  in combination, a wall section  254  is shown that includes a window  256 . The wall section  254  has the 2×12 board  240  across the top thereof. The window opening  256  has a window buck  258  therearound, which window buck  258  is normally made of wood. As can be seen in  FIG. 13 , only some of the columns are concrete columns  260 . The other columns are foam columns  262 . 
         [0066]    Referring now to  FIG. 14 , a wall section  264  is shown that has a doorway  266  therein. The wall section  264  has the 2×12 board  240  at the top thereof. The doorway  266  has a door buck  268  therearound along with a door jam  270  at the bottom thereof. When the wall section  264  is poured and while the concrete therein is still wet, door rebar  272  is driven into the wet concrete and used to hold the door buck  268  in position. Thereafter, when the concrete hardens, the door rebar  272  will securely hold the door buck  268 . 
         [0067]    Once the frame  20  has been completed on the foundation  22  as shown in  FIG. 1 , a roof  21  may be constructed in the normal matter. Wiring is provided through the electrical passage ways and may be inserted prior to the building of the roof  21 , or afterwards if that is a preference of the builder. To save crawling in attic space, it may be preferred to insert the wiring prior to building the roof  21 . 
         [0068]    The external part of the frame  20  can be completed in any manner desired by the builder such as stucco, brick facade, hardy board or some other type of external structure. If stucco is used, external hat channels are not required. However, if other type of external finish is used that requires attachment to the frame  20 , external hat channels will be required. Internally, the frame  20  can be finished in any manner desired. Assuming sheet rock is the preferred internal finish, the sheet rock can be connected through hat channels to the frame  20  once the roof  21  has been installed and the structure has a dry interior. 
         [0069]    By building a residence using the present invention, it will cost approximately the same as a conventionally built house. Under conventionally built houses, approximately fifty percent of the cost is spent in materials and fifty percent is spent in labor. For a residence built according to the present invention, approximately 75% of the cost will be in materials and 25% will be in labor. Overall, the cost of building a house by either conventional methods or by the present invention will be approximately the same. However, once a house is built by the present invention, the amount of energy required to heat or cool the house will be a small fraction of what would be required if the house had been built by conventional means.