Abstract:
A system of building modules that may readily be assembled into wall structures that, when filled with concrete forms an insulated, roughly-finished wall structure ready to receive both exterior and interior wall treatments. The building modules may readily be assembled by relatively untrained personnel and forms walls typically having an overall R-value in the range of approximately 30. The novel building modules eliminate the need for setting traditional concrete forms and of finishing a bare concrete wall. The modules are provided in various lengths, the lengths typically being multiples of 16 inches.

Description:
FIELD OF THE INVENTION  
       [0001]    The invention pertains to forms for forming concrete-filled walls and, more particularly, to modular, preinsulated forms readily assembled and adapted to receive concrete therein. The modular forms create a concrete-filled wall having a rough finish on both an interior and exterior surface, thereby allowing ready finishing of these surfaces. 
       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. 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 for it to be necessary 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]    Many attempts have been made to overcome one or more of the aforementioned deficiencies in the concrete wall formations processes of the prior art. For example, U.S. Pat. No. 1,892,605 for WALL CONSTRUCTION, issued Dec. 27, 1932 to Paul Betzler provides a series of interlocking components to facilitate constructing a hollow wall structure. The hollow wall may, optionally, be filled with concrete, the interlocking block wall constituting a lost form. 
         [0007]    U.S. Pat. No. 3,410,044 for FOAMED PLASTIC BASED CONSTRUCTION ELEMENTS, issued Nov. 12, 1968 to Gerhard W. Moog provides construction elements that may be stacked and then, optionally, be filled with concrete. Interlocking blocks are optionally provided by MOOG. 
         [0008]    U.S. Pat. No. 3,552,076 for CONCRETE FORM, issued Jan. 5, 1971 to Werner K. H. Gregori, discloses a self-supporting concrete form of low-density foamed polymer. Once in place, concrete may be poured into the hollow central space in the form. The forms become part of the finished concrete wall. 
         [0009]    U.S. Pat. No. 4,075,808 for BUILDING CONSTRUCTION SYSTEM USING MORTAR-LESS MODULAR BUILDING BLOCK ELEMENTS, issued Feb. 28, 1978 to Sanford Pearlman teaches another set of interlocking form block useful for laying up a modular from for filling with concrete. 
         [0010]    U.S. Pat. No. 4,924,641 for POLYMER BUILDING WALL FORM CONSTRUCTION, issued May 15, 1990 to James H. Gibbar, Jr. 
         [0011]    U.S. Pat. No. 5,038,541 for POLYMER BUILDING WALL FORM CONSTRUCTION, issued Aug. 13, 1991 to James H. Gibbar, Jr. provides a form system wherein prefabricated polymer forms are assembled together and spaced apart by integrally connecting polymer blocks, spacers or spool means. The forms may then be erected on a foundation. 
         [0012]    U.S. Pat. No. 5,107,648 for INSULATED WALL CONSTRUCTION, issued Apr. 28, 1992 to Edward F. Roby teaches an insulated form system wherein the thickness of the wall may be varied. 
         [0013]    U.S. Pat. No. 5,323,578 for PREFABRICATED FORMWORK, issued Jun. 28, 1994 to Claude Chagnon et al. provides a prefabricated, collapsible formwork assembly. 
         [0014]    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 discloses plastic prefabricated form system. 
         [0015]    U.S. Pat. No. 5,570,550 for INSULATED WALL CONSTRUCTION, issued Nov. 5, 1996 to Edward F. Roby teaches another insulated form system wherein the thickness of the wall may be varied. 
         [0016]    U.S. Pat. No. 5,625,989 for METHOD AND APPARATUS FOR FORMING OF A POURED CONCRETE WALL, issued May 6, 1977 to Thomas R. Brubaker et al. discloses a form system wherein two identically configured panel members each define slots adapted to receive interconnecting flanges of connecting members. 
         [0017]    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 teaches an interconnectable system of panels useful for casting a concrete wall. 
         [0018]    U.S. Pat. No. 6,170,220 for INSULATED CONCRETE FORM, issued Jan. 9, 2001 to James Daniel Moore, Jr. shows an insulated concrete form system having at least one longitudinally-extending side panel and at least one web member partially disposed in the side panel. 
         [0019]    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. discloses a form system of polymer sheets (e.g., polyurethane or expanded polystyrene) that may be fabricated on site to provide concrete forms. 
         [0020]    U.S. Pat. No. 6,263,628 for LOAD BEARING BUILDING COMPONENT AND WALL ASSEMBLY METHOD, issued Jul. 24, 2001 to John Griffin G. E. Steel Company provides a panelized from system that may be erected and then filled with concrete. 
         [0021]    U.S. Pat. No. 6,321,498 for FORMWORK FOR BUILDING WALLS, issued Nov. 27, 2001 to Salvatore Trovato teaches a formwork consisting of a plurality of pairs of facing panels connected together to form an inside space to receive concrete. 
         [0022]    U.S. Pat. No. 6,363,683 for INSULATED CONCRETE FORM, issued Apr. 2, 2002 to James Daniel Moore, Jr. provides another insulated concrete form system having at least one longitudinally-extending side panel and at least one web member partially disposed in the side panel. 
         [0023]    U.S. Pat. No. 6,438,918 for LATCHING SYSTEM FOR COMPONENTS USED IN FORMING CONCRETE STRUCTURES, issued Aug. 27, 2002 to James Daniel Moore, Jr. et al provides latching mechanisms for frictionally holding connectors or the like in position within a concrete form assembly. 
         [0024]    U.S. Pat. No. 6,691,481 for CORNER FORM FOR MODULAR INSULATING CONCRETE FORM SYSTEM, issued Feb. 17, 2004 to Donald L. Schmidt provides a corner form module. 
         [0025]    Published United States Patent Application No. for INSULATED CONCRETE FORM SYSTEMS AND METHODS OF MAKING AND USING THE SAME, published Dec. 15, 2005 upon application by Kenneth Franklin discloses a from system wherein flat insulating panels are tied together by a plurality of tying members. 
         [0026]    Published United States Patent Application No. for ASSEMBLAGE CONCRETE FORMS AND METHOD FOR MANUFACTURING THEREOF, published May 3, 2007 upon application by Qinjiang Zhu discloses from form system where steel mesh plates and a plurality of joining pieces in cooperation with insulating sheets are assembled to construct a concrete form. 
         [0027]    None of the patents and published patent applications, taken singly, or in any combination are seen to teach or suggest the novel building module form units of the present invention. 
       SUMMARY OF THE INVENTION 
       [0028]    In accordance with the present invention there is provided a novel system of building modules that may readily be assembled into wall structures that, when filled with concrete, form a roughly-finished wall structure ready to receive both exterior and interior wall treatments. The modules may readily be assembled by relatively untrained personnel. Finished walls constructed using the novel building modules typically have an overall R-value in the range of approximately 30. The novel building modules eliminate the need for setting traditional concrete forms and for finishing bare concrete walls. 
         [0029]    In an alternate embodiment, the outer walls of the building modules may be shipped to a building site where they may be assembled using metal width bars in lieu of solid top and bottom members. This may reduce the bulk and weight of the building modules being delivered to a construction site. 
         [0030]    It is, therefore, an object of the invention to provide a building module that may be combined with other like building modules to create a pre-insulated, lost form concrete wall. 
         [0031]    It is another object of the invention to provide a building module that is readily assembled into a form for receiving concrete by relatively untrained personnel. 
         [0032]    It is an additional object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that is readily finishable on both an interior and an exterior surface. 
         [0033]    It is a further object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that, when finished, has an R-value of approximately 30. 
         [0034]    It is an additional object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that achieves a high R-values using a combination of insulating materials and air spaces while minimizing the amount of insulating material. 
         [0035]    It is a still further object of the invention to provide a building module in varied lengths, typical lengths being multiples of 16 inches. 
         [0036]    It is yet another object of the invention to provide a building module that utilizes metal spacing bars in lieu of solid top and bottom members. 
         [0037]    It is an additional object of the invention to provide a building module that my be shipped knocked down to a construction site and assembled thereat. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0038]    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: 
           [0039]      FIG. 1  is a top plan view of a building module in accordance with the invention; 
           [0040]      FIG. 2  is an end elevational view of the building module of  FIG. 1 ; 
           [0041]      FIG. 3  is a top plan view of a corner building module in accordance with the invention; 
           [0042]      FIG. 4  is a detailed view of a portion of end, elevational view of  FIG. 2  showing spline-receiving grooves; 
           [0043]      FIGS. 5   a - 5   d  are schematic elevational views showing the layout of a front, right side, back, and left side of a typical building constructed using the building modules of  FIGS. 1-3 ; 
           [0044]      FIG. 6  is cross-sectional view of a typical wall constructed using the building modules of  FIGS. 1-3 ; 
           [0045]      FIG. 7  is a perspective view of a spacing bar used to form building modules in an alternate embodiment of the invention; 
           [0046]      FIG. 8  is an exploded end view of a building module being formed using the spacing bar of  FIG. 7 ; and 
           [0047]      FIG. 9  is a top plan view of a corner building module constructed using the spacing bar of  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0048]    The present invention provides a system of modular building units that may be readily assembled and used to construct an insulated, roughly-finished concrete-filled wall. The modular building units are adapted to receive both exterior and interior wall surface treatments. 
         [0049]    In the United States as well as other localities, standardized dimensions for construction have emerged over the years. For example, sheet materials such as plywood, wallboard, particleboard, etc. are typically supplied in 4-foot widths and 4, 8, 10, or 12-foot lengths. Many building codes require that studs (i.e., upright vertical posts in a building framework or wall) typically be placed on 16-inch centers, a spacing that conveniently accommodates standard 4-foot wide panels. Other such standard measurements for window widths and heights, door widths and heights, etc. have also emerged. The building modules of the present invention are sized and configured to accommodate such standard dimensions. 
         [0050]    Referring first to  FIGS. 1 and 2 , there are shown top plan and side elevational schematic views, respectively of a typical building module in accordance with the present invention, generally at reference number  100 . Top and bottom members  104   a ,  104   b , along with vertical members  102   a ,  102   b  define and enclose a structure having the general form of a rectangular parallelepiped. 
         [0051]    Typically, pressure treated plywood is used to form vertical members  102   a ,  102   b  and top and bottom member  104   a ,  104   b , respectively. As used herein in, the term “pressure treated” is intended to encompass any wood treatment method or material wherein the wood is protected from rot, fungus, insect attack, or any other similar wood-degrading conditions. In the embodiment chosen for purposes of disclosure, a nominal thickness of ¾ inch has been found satisfactory for vertical members  102   a ,  102   b  and ½ inch nominal thickness for top and bottom members  104   a ,  104   b , respectively. It will be recognized by those of skill in the art that other materials, dimensions or treatments may be chosen to meet a particular operating circumstance or environment. Consequently, the invention is not considered limited to the particular materials, dimensions, or treatments chosen for purposes of disclosure. For example, polymers, metals, fiberglass, etc. may all be substituted for plywood chosen for purposes of disclosure. 
         [0052]    Top horizontal support strips  106   a ,  106   b  and bottom horizontal support strips  108   a ,  108   b  are fastened in respective top and bottom corners adjacent the points of intersection of respective top member  104   a  and vertical members  102   a  and  102   b  as well as bottom member  104   b  and vertical members  102   a  and  102   b . In the embodiment chosen for purposes of disclosure, a pressure treated 1×2 “nailer” strip has been found suitable for the application. In alternate embodiments ¾″ spacers may be substituted for horizontal support strips  106   a ,  106   b  and bottom horizontal support strips  108   a ,  108   b.    
         [0053]    Foam insulation sheets  110   a,    110   b  are attached to inward-facing surfaces of horizontal support strips  106   a ,  108   a  and  106   b ,  108   b , respectively. Insulation sheets  110   a,    110   b  are typically polyisocyanurate insulation. An exemplary insulation is Thermax® manufactured by Dow Building Solution division of Dow Chemical. Foam sheets  110   a,    110   b  may be attached to vertical members  102   a ,  102   b , respectively, using a suitable adhesive or any other suitable attachment method such as caulk, small nails or screws, or other similar fasteners believed to be known to those of skill in the art. 
         [0054]    Air spaces  112   a ,  112   b  are formed between respective surfaces of insulation sheets  110   a,    110   b,  and vertical members  102   a ,  102   b.    
         [0055]    Holes  114  and half-holes  116  are provided to receive rebar  614  ( FIG. 6 ) when building modules are assembled in the manner described in detail hereinbelow. 
         [0056]    Openings  118  are provided in top and bottom members  104   a ,  104   b , respectively, to allow pouring concrete into the central, interior space remaining within building modules  100 . The assembly and filling of multiple building modules  100  is described in detail hereinbelow. 
         [0057]    Optional end members  122   a ,  122   b  may be provided to seal an end of building module  100 ,  200  when a window or door opening (see  FIGS. 5   a - 5   d ) is to be left in the wall being constructed. 
         [0058]    It will be recognized by those of skill in the art that commercially available foam backed plywood may be used for form vertical members  102   a ,  102   b , thereby eliminating the step of applying foam insulation  106   a ,  106   b  to the vertical members  102   a ,  102   b  formed from non-foambacked plywood or other materials. 
         [0059]    Each building module  100  has an overall length “L”  120  typically chosen to be a multiple of 16 inches, for example, 16″, 32″, 48″, 64″, 80″, 96″, etc. It will be recognized that other lengths may be provided as needed to construct a particular wall configuration. 
         [0060]    While a 16″ fundamental length has been chosen for purposes of disclosure, it will be recognized that other fundamental module lengths compatible with building codes, practices, or traditions in regions other than the United States may be substituted therefore. Consequently, the invention is not limited to the particular dimensions chosen for purposes of disclosure. 
         [0061]    Referring now also to  FIG. 3 , there is shown top plan view of a building module  200  adapted for forming corners in cooperation with building module  100 . Vertical members  202   a  and  202   d  are disposed in a mutually orthogonal relationship, meeting at outside corner  204 . Likewise, vertical members  202   b  and  202   c  are mutually orthogonal and meet at an inside corner  206 . 
         [0062]    A substantially square member  208  is provided to help join vertical members  202   a  and  202   d . Dimensions of square member  208  are chosen to be compatible with the interior construction of building module  200 . 
         [0063]    Top horizontal support strips  210   a ,  210   b ,  210   c ,  210   d  and corresponding bottom horizontal support strips, not shown, are fastened in respective top and bottom corners  204 ,  206  to respective vertical members  202   a ,  202   b ,  202   c ,  202   d . In the embodiment chosen for purposes of disclosure, pressure treated 1×2 “nailer” strips have been found suitable for the application. Spacers may be substituted for horizontal support strips  210   a ,  210   b ,  210   c ,  210   d . ¾″ diameter spacers have been found suitable for the application although other similar spacers may be substituted therefore. 
         [0064]    Foam insulation sheets  212   a ,  212   b ,  212   c ,  212   d  are attached to inward-facing surfaces of horizontal support strips  210   a ,  210   b ,  210   c ,  210   d  and corresponding bottom horizontal support strips, not shown, respectively. 
         [0065]    Air spaces  214   a ,  214   b ,  214   c ,  214   d  are formed between respective inner surfaces of insulation sheets  212   a ,  212   b ,  212   c ,  212   d , and vertical members  202   a ,  202   b ,  202   c ,  202   d.    
         [0066]    Holes  216  and half-holes  218  are provided to receive rebar  614  ( FIG. 6 ) when building modules are assembled in the manner described in detail hereinbelow. 
         [0067]    Openings  220   a ,  220   b ,  220   c ,  220   d  are provided in top member  222  and a corresponding bottom member, not shown, to allow pouring concrete into the central space remaining within building modules  200 . The assembly and filling of multiple building modules  100 ,  200  is described in detail hereinbelow. 
         [0068]    Building modules  100 ,  200  are adapted for interconnection, both top-to-bottom and end-to-end. Because, while building modules  100 ,  200  are structural elements in their own right, they rely upon a concrete core for final structural integrity. However, until filled, they must be viewed as concrete forms. Consequently, it is important that block-to-block sealing be maintained to avoid concrete blow out during the concrete pouring process. To accomplish this necessary sealing, each building module  100 ,  200  may be equipped with grooves to accommodate a spline or a tongue-and-groove arrangement. 
         [0069]    Referring now to  FIG. 4 , there is shown an enlarged portion of a side elevational view of a corner region of building module  100 ,  200 . Grooves  402  and  406  are formed in the end surfaces of top member  104   a  and vertical member  102   b , respectively. When the illustrated surface is abutted with a second building module  100 , not shown, grooves  402  and  406  align with corresponding grooves, not shown, in the second building module  100 ,  200 . Splines, not shown, are then received in corresponding grooves  402  and  406  thereby creating a seam capable of preventing concrete blowout during the pouring process as described in detail hereinbelow. 
         [0070]    Likewise, grooves  404  and  408  are provided in the top surface of top member  104   a  and along the top edge of vertical member  102   b , respectively, to allow sealing the building module  100 ,  200  to a corresponding building module, not shown, placed above the illustrated building module  100 ,  200 . Grooves  404 ,  408  also receive splines, not shown, during assembly to prevent concrete blowout along horizontal seams between adjacent building modules  100 ,  200 . 
         [0071]    It will be recognized that inter-module sealing may not be necessary in certain operating environments. Therefore, such structures as grooves, tongues, and splines may be eliminated. 
         [0072]    It will be recognized that in alternate embodiments, building modules  100 ,  200  could be provided with a tongue-and-groove sealing system replacing the groove and spline system chosen for purposes of disclosure. Consequently, the invention is not considered limited to the groove and spline system chosen for purposes of disclosure but includes tongue-and-groove sealing systems as well. 
         [0073]    As previously stated, building modules  100 ,  200  are adapted to be assembled into a desired wall configuration. Referring now to  FIGS. 5   a - 5   d,  there are shown front, right-side, rear, and left-side elevational views, respectively of a small building illustrating the use of the novel building modules  100 ,  200  in accordance with the invention. The terms front, right side, etc. are, of course, arbitrary. 
         [0074]    In  FIG. 5   a,  a door  502  and a window  504  are shown. In  FIG. 5   b,  an “overhead” or garage door  506  may be placed. In  FIG. 5   c,  two windows  508 ,  510  are shown. In  FIG. 5   d,  a single window  512  is shown. The presence and/or placements of door  502 , windows  504 ,  508 ,  510  and  512 , and overhead door  506  is arbitrary and only used to illustrate the flexibility of using building modules  100 ,  200  in varying lengths. 
         [0075]    Referring now to  FIG. 6 , there is shown a cross sectional, elevational view of a typical wall built in accordance with the building modules and method of the present invention, generally at reference number  600 . 
         [0076]    Building modules  100 ,  200  are designed for ease of use by persons of minimum skill. The procedure for erecting a building is first, an appropriate footer  602  is placed in accordance with local building codes or accepted practices using conventional techniques. 
         [0077]    Next, U-shaped starting channels  604  are secured to footer  602 , typically using bolts  606  embedded in footer  602  and secured with nuts  608  to the footer  602 . U-shaped channels  604  are typically placed at all seams of building modules  100 ,  200  and at least every 4 feet along the footer  602 . U-shaped channels  604  are bolted or otherwise fastened to footer  602  using techniques believed to be well known to those of skill in the art. Consequently, such techniques are not further discussed herein. 
         [0078]    Once U-shaped channels  604  are in place, building modules  100 ,  200  are placed within U-shaped channels  604  in a pattern such as one of the patterns of  FIGS. 5   a - 5   d.    
         [0079]    As each building module  100 ,  200  is abutted to its neighbor, a spline, not shown is inserted in grooves  402 ,  406  ( FIG. 4 ) as discussed hereinabove. Corner building modules  200  ( FIG. 3 ) are used to form corners. 
         [0080]    When a first course of building modules  100 ,  200  is complete, a spline, not shown, is inserted into grove  408 . As each building module  100 ,  200  is placed above a lower course, the spline, not shown, forms a guide to align the next course of building modules  100 ,  200 . 
         [0081]    When all courses of building modules  100 ,  200  are laid up, rebar  614  may be placed vertically through-holes  114 ,  116 ,  216  and  218 . 
         [0082]    Vertical alignment braces  616  are attached to the surface facing the interior of the building being constructed using building modules  100 ,  200 . Typically 2×2 material disposed on 16″ centers is used. The vertical alignment braces  616  become the “studs” for later attaching an interior finish layer  620  to the wall  600  being constructed. 
         [0083]    Prior to pouring concrete, the laid-up assembly of building modules  100 ,  200  is braced to keep the form securely plumb during the pouring and curing of the concrete. While no bracing is shown in  FIG. 6 , methods and materials for aligning and bracing concrete forms are believed to be well known to those of skill in the construction trades. Consequently, such material and methods are not further discussed herein. 
         [0084]    Once the rebar  614  is positioned and the wall is adequately braced, concrete  618  is poured into the interior cavities of building modules  100 ,  200  through openings  118 ,  200   a ,  220   b ,  220   c , and  220   d.    
         [0085]    After the concrete  618  cures, an exterior finish, typically at least some combination of building paper, Tyvek® wrap, foam insulation board, etc.  610  is covered by siding  612 . In alternate construction, a masonry veneer finish (e.g., brick, stone, etc.), not shown, may be applied to the exterior face of the wall in lieu of siding  612 . 
         [0086]    Interior wall finish is typically accomplished by placing foam insulation, not shown, between the studs formed by vertical alignment braces  616 . Dry wall  620  may then be applied and finished using conventional finishing techniques. 
         [0087]    It is estimated that the R-value of the wall of  FIG. 6  is approximately 30. The R-value contribution of each of the wall components is shown in Table 1. 
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
             
             
               
                   
                 Siding with building paper, 
                 2 
               
               
                   
                 etc. 
               
               
                   
                 Outer plywood 
                 1 
               
               
                   
                 ¾″ Air gap 
                 1 
               
               
                   
                 ½″ foam 
                 7 
               
               
                   
                 Concrete 
                 1 
               
               
                   
                 ½″ foam 
                 7 
               
               
                   
                 ¾″ air gap 
                 1 
               
               
                   
                 Inner plywood 
                 1 
               
               
                   
                 1″ foam 
                 8 
               
               
                   
                 ½″ air gap 
                 1 
               
               
                   
                 ½″ drywall 
                 1 
               
               
                   
                 Total 
                 31 
               
               
                   
                   
               
             
          
         
       
     
         [0088]    The use of novel building modules  100 ,  200  to construct concrete-filled walls is also environmentally advantageous. A smaller quantity of insulating foam is required to achieve a predetermined “R” value than in conventional wall construction. This results in less pollution from the foam manufacturing process and a smaller amount of scrap foam eventually reaching landfills or other disposal sites. 
         [0089]    As shown in  FIG. 1 , building module  100  has a top surface  104   a  and a bottom surface  104   b  (not shown in  FIG. 1 ) formed from a solid material such as plywood. Typically, building modules  100  are constructed at a central manufacturing facility and shipped to a building site where they are used to construct wall structures as described in detail hereinabove. The building modules  100  and  200  ( FIG. 3 ) so formed occupy a significant volume and weight for shipping purposes. 
         [0090]    Referring now to  FIG. 7 , there is shown a perspective view of a spacing bar  700  for use in assembling building modules in an alternate embodiment of the invention. By replacing solid top and bottom surfaces  104   a ,  104   b , respectively, with spacing bars  700 , the building modules  100 ,  200  may be shipped to a construction site in a knocked-down (KD) form and assembled at the construction site. Significant reduction of shipping expense may be achieved using this approach. Also, it is anticipated that the cost of spacing bars  700  is lest than solid top and bottom members  104   a ,  104   b , respectively. 
         [0091]    Spacing bars  700  are formed from sheet material formed into a U-shape having and elongated, central surface  702  and a pair of end surfaces  704 ,  706  perpendicular thereto. A plurality of inwardly projecting spikes  708  may be formed in central surface  702  proximate each of end surfaces  704 ,  706 . A hole  114  is formed proximate the midpoint of central surface  702 . Optionally, holes  710  may be provided in one or both of end surfaces  704 ,  706 . 
         [0092]    Referring now also to  FIG. 8 , there is shown an exploded, schematic end view of a building module  100  being formed using vertical members  102   a ,  102   b  and spacing bars  700 . As may be seen, inwardly projecting spikes  708  are spaced so as to properly space apart vertical members  102   a ,  102   b . Spikes  708   a  closest to respective end surfaces  706 ,  708  are spaced away therefrom so as to capture and outer (i.e., inwardly-facing) surface of horizontal support strips  106   a ,  106   b  at the top and bottom, respectively of vertical members  102   a ,  102   b.    
         [0093]    Inner spikes  708   b  are disposed so as to engage an edge of foam sheets  110   a ,  110   b.    
         [0094]    Building modules  100  or  200  may readily be assembled by selecting two vertical members  102   a ,  102   b  and positioning them as shown in  FIG. 8 . Spacer bars  700  are used to properly set a horizontal distance between vertical members  102   a ,  102   b . Once spacer bars  700  are attached at both the top and bottom of vertical members  102   a ,  102   b , screws  712  or other fasteners, not shown, may be inserted through holes  710  into a surface of vertical members  102   a ,  102   b  to retain spacer bars  700  in position. 
         [0095]    Referring now also to  FIG. 9 , there is shown a top plan view of a corner building module  200 ′ assembled using spacer bars  700 . 
         [0096]    One additional advantage resulting from assembling the building modules  100 ,  200  using spacer bars  700  is that some thermal bridging from solid top and members  104   a ,  104   b  ( FIG. 1 ) is reduced, thereby creating a wall structure having a higher overall “R” value. 
         [0097]    It will be recognized that the length of spacer bars  700  may be varied to readily control the overall thickness of a wall constructed with building modules  100 ,  200 . 
         [0098]    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. 
         [0099]    Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.