Patent Abstract:
A system of building modules that may readily be assembled into wall structures that, when filled with concrete, form an insulated, roughly-finished wall structure ready to receive both exterior and interior wall treatments. The building modules may be readily assembled by relatively untrained personnel and form 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.

Full Description:
RELATED APPLICATIONS 
       [0001]    This application is a Continuation-in-Part application of U.S. patent application Ser. No. 12/288,114 filed Oct. 17, 2008 which is included in its entirety herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    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 
       [0003]    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 poured therein, the reusable forms are typically removed and stored for later use on another project. 
         [0004]    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. 
         [0005]    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. 
         [0006]    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 
       [0007]    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. 
         [0008]    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. 
         [0009]    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. 
         [0010]    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 blocks useful for laying up a modular form for filling with concrete. 
         [0011]    U.S. Pat. No. 4,924,641 for POLYMER BUILDING WALL FORM CONSTRUCTION, issued May 15, 1990 to James H. Gibbar, Jr. teaches a polymer building wall form wherein forms prefabricated of polymer are assembled together, spaced apart by integrally connecting polymer or blocks or spacers and erected upon a foundation footing through their insertion upon L-shaped ties. 
         [0012]    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 footer or other foundation. 
         [0013]    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. 
         [0014]    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. 
         [0015]    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 a plastic prefabricated form system. 
         [0016]    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. 
         [0017]    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. 
         [0018]    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. 
         [0019]    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. 
         [0020]    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. 
         [0021]    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 form system that may be erected and then filled with concrete. 
         [0022]    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. 
         [0023]    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. 
         [0024]    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. 
         [0025]    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. 
         [0026]    Published United States Patent Application No. 2005/0275124 for INSULATED CONCRETE FORM SYSTEMS AND METHODS OF MAKING AND USING THE SAME, published Dec. 15, 2005 upon application by Kenneth Franklin discloses a form system wherein flat insulating panels are tied together by a plurality of tying members. 
         [0027]    Published United States Patent Application No. 2007/0094973 for ASSEMBLAGE CONCRETE FORMS AND METHOD FOR MANUFACTURING THEREOF, published May 3, 2007 upon application by Qinjiang Zhu discloses a form system where steel mesh plates and a plurality of joining pieces in cooperation with insulating sheets are assembled to construct a concrete form. 
         [0028]    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 
       [0029]    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. 
         [0030]    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. 
         [0031]    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. 
         [0032]    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. 
         [0033]    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. 
         [0034]    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. 
         [0035]    It is an additional object of the invention to provide a building module for constructing a pre-insulated, lost form concrete wall that achieves high R-values using a combination of insulating materials and air spaces while minimizing the amount of insulating material. 
         [0036]    It is a still further object of the invention to provide a building module in varied lengths, typical lengths being multiples of 16 inches. 
         [0037]    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. 
         [0038]    It is an additional object of the invention to provide a building module that may be shipped knocked down to a construction site and assembled thereat. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0039]    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: 
           [0040]      FIG. 1  is a perspective view of a building module in accordance with the invention having a spline and groove module to module sealing system; 
           [0041]      FIG. 2  is a front elevational view of the building module of  FIG. 1 ; 
           [0042]      FIG. 3   a , is a left end elevational view of the building module of  FIG. 1 ; 
           [0043]      FIG. 3   b  is a left end elevational view of the building module of  FIG. 1  but having an end sealing member in place therein; 
           [0044]      FIG. 4  is a perspective view of a building module in accordance with the invention having a tongue and groove module to module sealing system; 
           [0045]      FIG. 5   a  is a left end elevational view of the building module of  FIG. 4 ; 
           [0046]      FIG. 5   b  is a left end elevational view of the building module of  FIG. 4  but having an end sealing member in place therein; 
           [0047]      FIGS. 6   a - 6   d  are partial top plan views of four configurations of a building module using tongue and groove features for end-to-end module sealing; 
           [0048]      FIG. 7  is a top plan schematic view of a corner building module in accordance with the invention; 
           [0049]      FIGS. 8   a  and  8   b  are left side and rear elevational schematic views, respectively of building module of  FIG. 7 ; 
           [0050]      FIG. 9  is an exploded, perspective, schematic view of a pair of building modules joined top-to=bottom using a spline; 
           [0051]      FIGS. 10   a - 10   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 in accordance with the invention and 
           [0052]      FIG. 11  is cross-sectional view of a typical wall constructed using the building modules of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0053]    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. 
         [0054]    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. 
         [0055]    Referring first to  FIGS. 1 ,  2 , and  3   a , there are shown a perspective, a front elevational, and an end elevational, schematic view of a building module  100  in accordance with the invention. Module  100  is substantially hollow and has the form of a rectangular parallelepiped. 
         [0056]    Module  100  has a pair of vertical members, front vertical member  102   a  and rear vertical member  102   b , each having an upper edge  124 , a lower edge  126 , a left edge  128 , aright edge  130 , a width “L”  122 , and a height “H”  132 . 
         [0057]    Top member  104   a  and bottom member  104   b  are both sandwiched between front vertical member  102   a  and rear vertical member  102   b . An upper major surface, not specifically identified, of top member  104   a  is substantially flush with an upper edge  124  of both front and rear vertical members  102   a ,  102   b , respectively. Likewise, a lower major surface, not specifically identified, of bottom member  104   b  is substantially flush with lower edge  126  of both front and rear vertical members  102   a ,  102   b , respectively. 
         [0058]    Top member  104   a  and bottom member  104   b  are typically secured to front vertical member  102   a  and rear vertical member  102   b  using fasteners or adhesive, neither shown. The process and hardware for joining members (for example, top member  104   a  to front vertical member  102   a ) one to another is believed to be well known to those of skill in the art and, consequently, neither is discussed in further detail herein. The invention is intended to include any and all suitable processes and/or hardware suitable for joining members one to another. 
         [0059]    Typically, pressure treated plywood is used to form front and rear 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. 
         [0060]    Top front and top rear horizontal support strips  106   a ,  106   b , respectively are fastened to respective ones of front vertical member  102   a  and rear vertical member  102   b  in respective top front and rear corners adjacent respective points of intersection with top member  104   a.    
         [0061]    Likewise, bottom front and bottom rear horizontal support strips  108   a ,  108   b , respectively are fastened to respective ones of front vertical member  102   a  and rear vertical member  102   b  in respective bottom front and rear corners adjacent respective points of intersection with bottom member  104   b.    
         [0062]    Optional front and rear middle horizontal support strips  150   a ,  150   b  may be fastened to respective ones of front vertical member  102   a  and rear vertical member  102   b  proximate a vertical, midpoint thereof. 
         [0063]    In the embodiment chosen for purposes of disclosure horizontal support strips  106   a ,  106   b ,  108   a ,  108   b ,  150   a , and  150   b  are typically formed from pressure treated 1×2 “nailer” strip or furring strip material. Horizontal support strips  106   a ,  106   b ,  108   a ,  108   b ,  150   a , and  150   b  typically extend continuously across the entire width, not specifically identified, of respective ones of front vertical member  102   a  and rear vertical member  102   b.    
         [0064]    Referring now also to  FIG. 3   b , there is shown an end, elevational view of building module  100  with a sealed end. In building modules  100  that must have an end sealed, horizontal support strip  106   a ,  106   b ,  108   a ,  108   b ,  150   a , and  150   b  may be shortened by an amount equal to the thickness of an end sealing member  158  that is sandwiched between front vertical member  102   a , rear vertical member  102   b , top member  104   a , and bottom member  104   b . An outer major surface, not specifically identified, of end sealing member  158  is disposed substantially flush with left edge  128  of both front and rear vertical members  102   a ,  102   b , respectively. It will be recognized that  FIG. 3   b  shows the left end of building module  100  sealed. However, the right end, not shown, of building module  100  may likewise be sealed by installing an end sealing member  158  at the right end thereof. End sealing members  158  are typically used to leave window and door openings or the like in the concrete wall to be constructed using building modules  100 . 
         [0065]    Building module  100  has grooves  156  disposed in at least one edge, not specifically identified of front vertical member  102   a  and rear vertical member  102   b . In addition top grooves  152  may be formed along a top edge, not specifically identified, of front and rear vertical members  102   a ,  102   b , respectively. Finally, bottom grooves  154  may be formed along a bottom edge, not specifically identified, of front and rear vertical members  102   a ,  102   b , respectively. Grooves  152 ,  154 ,  156  are sized and configured to receive a spline  160 , best seen in  FIG. 9 . Spline  160  is used to provide a seal between horizontal and/or vertical seams formed between adjacent building modules  100 . Note that  FIG. 9  shows spline  160  only between vertically stacked building modules  100 . It will be recognized that a similar construction, not shown, may be used to provide end-to-end sealing between a pair of horizontally aligned building modules  100 . 
         [0066]    Rebar-accepting holes  114  and half-holes  116  are provided to stabilize reinforcing bar (i.e., rebar) once building modules are laid up into a wall structure and before pouring concrete. The use of rebar to reinforce concrete walls is believed to be well known to those of skill in the art and neither rebar nor its use is further described herein. 
         [0067]    Front and rear foam insulation sheets  110   a ,  110   b , respectively are attached to inward-facing surfaces of corresponding ones of horizontal support strips  106   a ,  108   a ,  106   b ,  108   b ,  150   a , and  150   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 inward-facing surfaces of horizontal support strips  106   a ,  108   a ,  106   b ,  108   b ,  150   a , and  150   b , respectively, using a suitable adhesive or any other suitable attachment method such as caulk, small nails or screws, staples, or other similar fasteners believed to be known to those of skill in the art. 
         [0068]    Front and rear air spaces  112   a ,  112   b , respectively, are formed between respective surfaces of front and rear insulation sheets  110   a ,  110   b , and vertical members  102   a ,  102   b.    
         [0069]    Openings  118  are provided in top and bottom members  104   a ,  104   b , respectively, to allow pouring concrete into the central, interior space, not specifically identified, remaining within building modules  100 . The assembly and filling of multiple building modules  100  is described in detail hereinbelow. 
         [0070]    It will be recognized by those of skill in the art that commercially available foam backed plywood may be used for front and rear vertical members  102   a ,  102   b , respectively, thereby eliminating the need for foam insulation  110   a ,  110   b  and horizontal support strips  106   a ,  108   a ,  106   b ,  108   b ,  150   a , and  150   b . However, it should be noted that this construction eliminates front and rear air spaces  112   a ,  112   b , respectively. Elimination of front and rear air spaces  112   a ,  112   b  lowers the overall R-value of the finished concrete wall. 
         [0071]    Each building module  100  has an overall length “L”  122  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. 
         [0072]    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. 
         [0073]    Referring now to  FIGS. 4 ,  5   a , and  5   b , there is shown an alternate embodiment of a building module  100  ( FIG. 1 ) having a tongue and groove module to module sealing system, generally at reference number  100 ′.  FIG. 4  shows a perspective, schematic view of building module  100 ′ while  FIGS. 5   a  and  5   b  show a left end elevational view of the building module  100 ′ of  FIG. 4 , and a left end elevational view of the building module  100 ′ of  FIG. 4  but having an end sealing member in place therein, respectively. The only difference between building modules  100  and  100 ′ is that building module  100  is equipped with square grooves  152 ,  154  on upper and lower surfaces, respectively, each adapted to receive a spline  160  whereas building module  100 ′ is equipped with protruding tongues  162  on an upper surface and a curvilinear groove  164  on lower surfaces, the curvilinear groove  164  being sized and configured to receive tongue  162 . 
         [0074]    It will be recognized that similar tongue and groove arrangements may be provided on ends of module  100 ′ to facilitate side-to-side sealing of modules  100 ′ one to another. It will be further recognized that four module configurations may be provided. Referring now to  FIGS. 6   a - 6   d , there are shown top plan, schematic views of four possible end configurations of module  100 ′. In  FIG. 6   a , module  100 ′ has vertical grooves  168  on a left end and vertical tongues  166  on a right end. In  FIG. 6   b , module  100 ′ has vertical tongues  166  on a left end and vertical grooves  168  on a right end. In  FIG. 6   c , module  100 ′ has vertical grooves  168  at both a right and a left end thereof. Finally, in  FIG. 6   d , module  100 ′ has vertical tongues  166  at both a left and a right end thereof. 
         [0075]    Referring now also to  FIG. 7 , there is shown top plan view of a building module  200  adapted for forming corners in cooperation with building modules  100 / 100 ′. A vertically disposed front member  202   a , a vertically disposed rear member  202   b , a vertically disposed inside side member  202   c , a vertically disposed outside side member  202   d  each has a top edge, a bottom edge, a left edge, and a right edge, an inward facing major surface, and an outward facing major surface, none of which are specifically identified. 
         [0076]    Vertically disposed front member  202   a  and vertically disposed outside side member  202   d  are disposed in a mutually orthogonal relationship, meeting at outside corner  204 . A vertically oriented, substantially square member  208  is disposed at corner  206  contacting the inward facing major surface of vertically disposed front member  202   a  adjacent the right edge thereof and the inward facing major surface of vertically disposed outside side member  202   d  adjacent a left edge thereof. Vertically disposed front member  202   a  and vertically disposed outside side member  202   d  are attached to vertically disposed member  208  using any suitable hardware or other fastening method. Dimensions of vertically oriented, substantially square member  208  are chosen to be compatible with the interior construction of building module  200  (i.e., with dimensions of other internal members thereof). 
         [0077]    Likewise, vertically disposed rear member  202   b  and vertically disposed inside side member  202   c  are disposed in a mutually orthogonal relationship and meet at an inside corner  206 , a right edge of vertically disposed rear member contacting a forward facing edge of vertically disposed inside side member  202   c.    
         [0078]    An L-shaped planar top member  222   a  has a front edge  224 , a right edge  226 , a first portion of a rear edge  228 , a first portion of a left edge  230 , a second portion of a rear edge  232 , a second portion of a left  234 . L-shaped planar top member  222   a  is sandwiched between vertically-oriented members  202   a ,  202   b ,  202   c ,  202   d  such that front edge  224  is abutted against an inward-facing major surface of vertically-disposed front member  202   a ; right edge  226  is abutted against an inward-facing major surface of vertically oriented outside side member  202   d ; first portion of left edge  230  is abutted against an inward-facing major surface of vertically-disposed inside side member  202   c ; and second portion of rear edge  232  is abutted against an inward-facing major surface of vertically-disposed rear member  202   b . An outward-facing major surface of L-shaped planar top member  222   a  is aligned with an upper edge of all of vertically disposed members  202   a ,  202   b ,  202   c , and  202   d.    
         [0079]    Referring now also to  FIGS. 8   a  and  8   b , there are shown left side and rear elevational views, respectively of building module  200  of  FIG. 7 . 
         [0080]    An L-shaped planar bottom member  222   b  also has a front edge  224 , a right edge  226 , a first portion of a rear edge  228 , a first portion of a left edge  230 , and a second portion of a rear edge  232 , a second portion of a left  234 . L-shaped planar bottom member  222   b  is sandwiched between vertically-oriented members  202   a ,  202   b ,  202   c ,  202   d  such that front edge  224  is abutted against an inward-facing major surface of vertically-disposed front member  202   a ; right edge  226  is abutted against an inward-facing major surface of vertically oriented outside side member  202   d ; first portion of left edge  230  is abutted against an inward-facing major surface of vertically-disposed inside side member  202   c ; and second portion of rear edge  232  is abutted against an inward-facing major surface of vertically-disposed rear member  202   b . An outward-facing major surface of L-shaped planar bottom member  222   b  is aligned with a lower edge of all of vertically disposed members  202   a ,  202   b ,  202   c , and  202   d.    
         [0081]    Top front and top rear horizontal support strips  210   a ,  210   b , respectively are fastened to respective ones of front vertical member  202   a  and rear vertical member  202   b  in respective top front and rear corners adjacent respective points of intersection with L-shaped planar top member  222   a.    
         [0082]    Top left and top right horizontal support strips  210   c ,  210   d , respectively are fastened to respective ones of left vertical member  202   c  and right vertical member  202   d  in respective top front and rear corners adjacent respective points of intersection with L-shaped planar top member  222   a.    
         [0083]    Likewise, bottom front and bottom rear horizontal support strips  236   a ,  236   b , respectively are fastened to respective ones of front vertical member  202   a  and rear vertical member  202   b  in respective bottom front and rear corners adjacent respective points of intersection with L-shaped planar bottom member  222   b.    
         [0084]    Likewise, bottom left and bottom right horizontal support strips  236   c ,  236   d , respectively are fastened to respective ones of left vertical member  202   c  and right vertical member  202   d  in respective bottom front and rear corners adjacent respective points of intersection with L-shaped planar bottom member  222   b.    
         [0085]    Optional front and rear middle horizontal support strips  238   a ,  238   b , respectively, may be fastened to respective ones of front vertical member  202   a  and rear vertical member  202   b , respectively, proximate a vertical midpoint of each thereof. 
         [0086]    Optional left and right middle horizontal support strips  238   c ,  238   d , respectively may be fastened to respective ones of left vertical member  202   c  and right vertical member  202   d , respectively, proximate a vertical midpoint of each thereof. 
         [0087]    In the embodiment chosen for purposes of disclosure horizontal support strips  210   a - 210   d ,  236   a - 236   d , and  238   a - 238   d  are typically formed from pressure treated 1×2 “nailer” strip or furring strip material. Horizontal support strips  210   a - 210   d ,  236   a - 236   d , and  238   a - 238   d  typically extend continuously across the entire width, not specifically identified, of respective ones of front vertical member  202   a , rear vertical member  202   b , left vertical member  202   c , and right vertical member  202   d . Top, bottom and middle horizontal support strips  210   a ,  238   a ,  236   a , respectively, abut vertically oriented, substantially square member  208  proximate outside corner  204   
         [0088]    Front foam insulation sheet  212   a , is attached to inward-facing surfaces of front horizontal support strips  210   a ,  236   a ,  238   a.    
         [0089]    Rear foam insulation sheet  212   b , is attached to inward-facing surfaces of rear horizontal support strips  210   b ,  236   b ,  238   b.    
         [0090]    Left foam insulation sheet  212   c , is attached to inward-facing surfaces of left horizontal support strips  210   c ,  236   c ,  238   c.    
         [0091]    Right foam insulation sheet  212   d , is attached to inward-facing surfaces of right horizontal support strips  210   d ,  236   d ,  238   d.    
         [0092]    Foam insulation sheets  212   a - 212   d  are typically attached to inward facing surfaces of respective horizontal support strips  210   a - 210   d ,  236   a - 236   d , and  238   a - 238   d  using an adhesive. Suitable construction grade adhesives are believed to be well known to those of skill in the art and, consequently, are not further described herein. 
         [0093]    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.    
         [0094]    Holes  216  and half-holes  218  are provided to receive rebar  614  ( FIG. 11 ) when building modules  100 ,  100 ′ or  200  are assembled in the manner described in detail hereinbelow. 
         [0095]    Concrete accepting Openings  220   a ,  220   b ,  220   c ,  220   d  are disposed in L-shaped planar top member  222   a  and a corresponding L-shaped planar bottom member  222   b  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. 
         [0096]    As previously mentioned, building modules (e.g., building modules  100 ,  100 ′,  200 ) may need to have an end sealed.  FIG. 3   b  shows a building module  100  having end sealing member  158  sealing one end thereof. The same techniques may be used to seal an end of building module  200 . Consequently, sealing an end of building module  200  is not discussed in further detail herein. 
         [0097]    Building modules  100 ,  100 ′, and  200  are adapted for interconnection, both top-to-bottom and end-to-end with other building modules. 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 (i.e., intermodule leakage) during the concrete pouring process. To accomplish this necessary sealing, each building module  100 ,  100 ′,  200  may be equipped with grooves to accommodate a spline or a tongue-and-groove arrangement. 
         [0098]    Referring now also to  FIG. 9 , there is shown an exploded, perspective, schematic view of a pair of building modules  100  being joined top-to-bottom to one another with an intervening spline  160 . It will be recognized that if tongue-and-groove sealing as shown in  FIGS. 4 ,  5   a ,  5   b , and  6   a  . . .  6   d  is used, no spline  160  is necessary. 
         [0099]    It will further 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. 
         [0100]    As previously stated, building modules  100 ,  200  are adapted to be assembled into a desired wall configuration. Referring now to  FIGS. 10   a - 10   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. The numbers inside the building module blocks are typical lengths, typically in inches conforming to United States building practices. It will be recognized that any combination of module lengths may be combined to make a desired building structure. 
         [0101]    In  FIG. 10   a , a door  502  and a window  504  are shown. In  FIG. 10   b , an “overhead” or garage door  506  may be placed. In  FIG. 10   c , two windows  508 ,  510  are shown. In  FIG. 10   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  are arbitrary and only used to illustrate the flexibility of using building modules  100 ,  200  in varying lengths. 
         [0102]    Referring now to  FIG. 11 , 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 . 
         [0103]    Building modules  100 ,  200  are designed for ease of use by persons of minimum skill. To erect a building, first, an appropriate footer  602  is placed in accordance with local building codes or accepted practices using conventional techniques. 
         [0104]    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 . It will be recognized that footer  602 , bolts  606 , and nuts  608  as well as any additional associated hardware, not shown, necessary to fasten U-shaped starting channels  604  to footer  602  form no part of the invention and are shown merely to show building modules  100 ,  100 ′,  200  in the intended usage environment. 
         [0105]    U-shaped channels  604  are typically placed at all seams, not specifically identified, between building modules  100 ,  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. 
         [0106]    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. 10   a - 10   d.    
         [0107]    As each building module  100 ,  200  is abutted to its neighbor, a spline  160  is inserted in grooves  156  (FIG.  1 ) as discussed hereinabove. Corner building modules  200  ( FIG. 7 ) are used to form corners. 
         [0108]    When a first course of building modules  100 ,  200  is complete, a spline  160  is inserted into top grove  152 . As each building module  100 ,  200  is placed above a lower course, the spline  160  forms a guide to align the next course of building modules  100 ,  200 , being received in bottom groove  154  of the next course of building modules  100 ,  200 . 
         [0109]    It will be recognized that no spline is required when using building modules  100 ′ that have tongue-and-groove structures (e.g.,  162 ,  164 ,  166 ,  168 ) that provide sealing between building modules  100 ′. 
         [0110]    When all courses of building modules  100 ,  200  are laid up, rebar  614  may be placed vertically in through-holes  114 ,  116 ,  216  and  218 . 
         [0111]    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 inch 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. 
         [0112]    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. 
         [0113]    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 ,  220   a ,  220   b ,  220   c , and  220   d.    
         [0114]    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 . 
         [0115]    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. 
         [0116]    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 
               
               
                   
                   
               
             
          
         
       
     
         [0117]    The use of novel building modules  100 ,  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. 
         [0118]    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. 
         [0119]    Having thus described the invention, what is desired to be protected by Letters Patent is presented in the subsequently appended claims.

Technology Classification (CPC): 4