Patent Abstract:
An insultated wall system comprises a plurarity of foldable blocks, each having two panels of rigid insulated foam, multiple inserts embedded in the panels, and ties between pairs of inserts. Each insert has one or more connectors, each with an end hole that swivelably receives the end leg of a tie in a manner that enables the block to fold. Each connector further has a top opening that releaseably captures the middle leg of the tie and rigidly locks the block against folding. The connectors are double-ended, and the inserts are invertible in the panels. Corner and T-walls are made by simple cuts in the standard blocks. Plates and ties are used to hold together the blocks of a main wall and an intersecting T-wall. The connectors of a panel may contact either the connectors of the other panel, or the other panel itself, when the block is folded.

Full Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention pertains to wall construction, and more particularly to apparatus for erecting insulated concrete walls.  
           [0003]    2. Description of the Prior Art  
           [0004]    It is well known to construct walls using insulated concrete forming systems. For the purposes of the present invention, the term “insulated concrete forming” means a concrete forming system using stay-in-place forms of foam plastic insulation for constructing cast-in-place concrete walls. Insulated concrete forming systems combine the inherent structural integrity of concrete with the energy efficiency of rigid insulation.  
           [0005]    Typically, insulated concrete forming systems include a number of blocks, each comprising a pair of parallel panels spaced apart by the thickness of the concrete wall. The panels are held to each other at the proper spacing by ties of metal, plastic, or other material. The blocks are stacked on top of and alongside each other to suit a particular wall. After all the blocks have been are erected in place, concrete is poured in the space between the panels.  
           [0006]    Representative companies that manufacture insulated concrete forming systems include R-Forms, Inc. of Naples, Fla.; and Poly-Forms LLC of Taftville, Conn. Other examples of insulated concrete forms may be seen in U.S. Pat. Nos. 4,706,429; 4,730,422; 4,731,968; 4,765,109; 4,866,891; 4,884,382;5,140,794; 5,428,933; 5,625,989; 5,657,600; 5,735,093; 5,992,114; and 6,363,683. The form of the foregoing patents are rigid in that the panels are always spaced a fixed distance apart.  
           [0007]    U.S. Pat. Nos. 4,742,659, 4,888,931, 4,901,494 and 5,890,337 disclose forms that have at least limited capabilities of folding. However, none of the foldable forms is rigidly lockable in the unfolded configuration.  
           [0008]    A common characteristic of many prior insulated concrete forming systems was that the panels were rigidly tied together at the factory to make a block. As a result, the envelopes of the blocks were fixed. The space between the panels occupied a large percentage of the total block envelope. The space between the panels, which was vital for eventually receiving poured concrete, nevertheless was highly undesirable for shipping and storage purposes. In some prior designs, the ties were separate from the panels such that the panels could be laid flat against one another for shipping and storage. Once the ties were assembled between two panels, however, the resulting blocks were permanently rigid unless the ties were removed.  
           [0009]    Prior insulated concrete forming systems suffered another handicap concerning corners of a wall. To suit both L-corners and T-corners, the prior systems required special blocks. The costs associated with designing, manufacturing, storing, and using multiple kinds of corner blocks was undesirable.  
           [0010]    Thus, despite the widespread availability of insulated concrete forming systems, further developments to them are desirable.  
         SUMMARY OF THE INVENTION  
         [0011]    In accordance with the present invention, an insulated concrete wall system is provided that greatly simplifies the process of constructing insulated concrete walls. This is accomplished by apparatus that includes panels, inserts, and ties that are incorporated into foldable blocks.  
           [0012]    The panels are made of conventional rigid insulative foam material such, but not limited to, as expanded polystyrene. The panels can be of any practical height, length, and thickness. The panel top and bottom surfaces are formed with interlocks such as short posts and matching cavities.  
           [0013]    Embedded in the interior face of each panel are a number of inserts. The inserts are made from a tough but slightly flexible plastic material, such as, but not limited to, nylon or polypropylene. Each insert in comprised of a planar base and at least one web upstanding from the base. The web supports one or more connectors. Each connector has a top surface parallel to the plane of the base and a notch defined by an end surface and a side surface. There is an end hole in the notch end surface. An arcuate portion of the end hole is in the notch side surface. The connector further has an opening in the top surface. The longitudinal axis of the top opening is perpendicular to and intersects the longitudinal centerline of the end hole. The longitudinal axis of the top opening lies in the plane of the notch end surface. The top opening is bounded by the notch end and side surfaces such that the top opening subtends an angle of approximately 270 degrees. The diameter of the top opening is substantially the same as the diameter of the end hole. Preferably, the notch side surface is not coplanar with the end hole longitudinal centerline or the top opening longitudinal axis. Projecting on opposite sides of the connector are a pair of tabs. The tabs lie in a plane that is parallel to the plane of the base. The connector end hole and top opening cooperate to releaseably lock a tie to the insert. The tie is made from a steel wire that is bent to have a pair of end legs and a middle leg. The tie steel wire has a diameter sized to fit with a specific clearances in the connector end hole and top opening.  
           [0014]    To lock a tie to a connector, an end leg of the tie is Inserted into the connector end hole. The tie is inserted until the tie middle leg contacts the notch end surface. At that point, the longitudinal centerline of the tie middle leg is offset from the top opening longitudinal axis by an amount equal to the rod radius. The tie can be swiveled such that the tie middle leg is within approximately 20 degrees of being parallel to the top opening longitudinal axis, at which point the tie middle leg contacts the notch side surface. The tie is locked to the connector by applying a swivel force to the tie against the notched side surface while simultaneously applying a linear force that pushes the tie end leg further into the connector end hole. That action causes a deflection of the connector material sufficient to allow the tie middle leg to enter the top opening. Immediately thereafter, the connector material around the top opening resiliently returns to its undeflected condition. The tie middle leg is then captured in the top opening, and the tie is locked to the connector.  
           [0015]    It is an important feature of the present invention that each connector is double-ended. That is, the notch end and side surfaces, end hole, and top opening are duplicated on opposite ends of the connector. The end holes of the double-ended connector are preferably coincident. As a result, the insert is invertible when embedded in a panel.  
           [0016]    In another aspect of the invention, two double-ended connectors are used with each insert. The connectors may be supported by separated webs, in which case the connectors are preferable joined by a longitudinally extending plate.  
           [0017]    The bases and webs of as many inserts as desired are embedded into a panel. The tabs of the connectors are used to hold the inserts in place in a mold while the panel material is formed up around the inserts webs and bases.  
           [0018]    The multiple ties and inserts are used to hold two panels together and form the block of the invention. One end leg of a tie is inserted into the end opening of an insert connector in one panel. The other end leg of the tie is inserted into the end hole of an insert connector in another panel. When the ties are pushed and swiveled as described, the ties lock to the inserts to make a rigid block.  
           [0019]    In accordance with a further aspect of the invention, however, the ties and inserts also act as hinges that enable the blocks to fold and unfold. For that purpose, the tie end legs are inserted into the associated connector end holes, but the ties are not locked to the connectors. In that situation, the ties end legs can swivel in the respective connectors. Doing so moves the panels closer to and further away from each other, while always keeping them parallel to each other. Only when the ties are locked to the connectors do the panels remain rigidly at a fixed distance apart. In that manner, the blocks are foldable for shipping and storage. At the job site, the blocks are unfolded for erecting into forms for a wall.  
           [0020]    At the job site, as many blocks as required are stacked on top of and alongside each other to create a form for a poured concrete wall. The thickness of the poured wall is determined by the length of the ties middle legs. The interlocks on the panels top and bottom surfaces hold adjacent blocks in place. When the forms have been erected from the individual blocks, concrete is poured to make a very strong insulated wall.  
           [0021]    Further in accordance with the present invention, special blocks for corners and T-walls are not necessary. To make a form for a corner, the external panel of a first block is cut an amount equal to the thickness of the external panel of the intersecting block of the intersecting wall. The internal panel of the first block is cut an amount equal to the overall width of the intersecting block. The external panel of the intersecting block does not require any cutting. The internal panel of the intersecting block is cut an amount equal to the thickness of the external panel of the first block plus the thickness of the concrete of the first wall. Thus, three simple cuts through three panels are sufficient to make a corner.  
           [0022]    The two corner blocks are partially held together by the inserts and ties as described above. In addition, another tie is used between the external panel of each corner block and a tie that is between the two panels of the intersecting block. In that manner, the blocks maintain their rigidity at the corners without any need for special corner blocks.  
           [0023]    To form a T-wall, the present invention further includes two pairs of inside and outside T-wall plates. No changes are required to one panel of the block of a main wall at the intersection with two T-wall. The other panel of the main wall block is cut out by an amount equal to the thickness of the concrete of the T-wall. An outside T-wall plate mates with the interlocks of the uncut panel of the main wall block opposite each panel of the intersecting T-wall block. An inside T-wall plate mates with the interlocks of each panel of the intersecting wall block and with the cut panel of the main wall block. A tie is inserted through holes in the inside and outside T-wall plates. The blocks at a T-wall are thus firmly held together without any need for special blocks.  
           [0024]    The versatility of the present invention is further demonstrated by the ability to pour very thin concrete walls. The lower limit of wall concrete thickness is twice the height of the insert connectors, i.e., the connectors of the inserts in the two block panels abut. In that case, staple-shaped ties rather than the ties previously described are used to hold the block panels together.  
           [0025]    The method and apparatus of the invention, using multiple ties that are releasably lockable in insert connectors, thus erect insulative forms for poured concrete walls. The same blocks are used at corners and T-walls, even though the blocks can be folded for shipping and storage.  
           [0026]    Other advantages, benefits, and features of the present invention will become apparent to those skilled in the art upon reading the detailed description of the invention.  
       
    
    
     BRIEF DESCRIPTIONS OF THE DRAWINGS  
       [0027]    [0027]FIG. 1 is a perspective view of a typical insulated concrete wall system according to the present invention.  
         [0028]    [0028]FIG. 2 is a front view of the exterior face of a panel of the present invention.  
         [0029]    [0029]FIG. 3 is a top view of FIG. 2.  
         [0030]    [0030]FIG. 4 is a bottom view of FIG. 2.  
         [0031]    [0031]FIG. 5 is a cross-sectional on an enlarged scale taken along line  5 - 5  of FIG. 1.  
         [0032]    [0032]FIG. 6 is a perspective view of the insert of the invention.  
         [0033]    [0033]FIG. 7 is an end view of FIG. 6.  
         [0034]    [0034]FIG. 8 is a front view of a portion of the insert of the invention.  
         [0035]    [0035]FIG. 9 is a top view of a connector.  
         [0036]    [0036]FIG. 10 is a view showing a tie holding two panels of a block of the invention.  
         [0037]    FIGS.  11 A- 11 C are schematic diagrams of typical blocks according to the invention shown in folded conditions.  
         [0038]    [0038]FIG. 12 is a view generally similar to FIG. 5, but showing a tie that is not locked in a connector.  
         [0039]    [0039]FIG. 13 is a top view of two standard blocks used for a corner.  
         [0040]    [0040]FIG. 14 is a top view of a T-wall according to the present invention.  
         [0041]    [0041]FIG. 15 is a top view of an outside T-wall plate according to the invention.  
         [0042]    [0042]FIG. 16 is an end view of FIG. 15.  
         [0043]    [0043]FIG. 17 is a top view of an inside T-wall plate according to the invention.  
         [0044]    [0044]FIG. 18 is an end view of FIG. 17.  
         [0045]    [0045]FIG. 19 is a perspective view of modified insert according to the present invention.  
         [0046]    [0046]FIG. 20 is a partial front view of the modified insert of FIG. 19.  
         [0047]    [0047]FIG. 21 is a top view of the modified insert.  
         [0048]    [0048]FIG. 22 is a cross sectional view of a block using a staple shaped tie. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0049]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.  
         [0050]    General  
         [0051]    Referring to FIG. 1, an insulated concrete wall system  1  is illustrated that includes the present invention. The insulated concrete wall system  1  is comprised of a number of interfitting blocks  3  that are designed, constructed, and used according to the present invention.  
         [0052]    Each block  3 , such as block  3 A, is made of two panels  5  of a rigid insulating foam. A number of inserts  7  are embedded into each panel  5 . Each insert  7  has at least one connector  9  that is exposed. The connectors  9  of the inserts of two panels are held together with ties  11  such that the panels are parallel to each other. The panels are spaced apart a distance D that is determined by the length of the ties  11 .  
         [0053]    The blocks  3  are stacked on top of and alongside each other in the outline of the wall of a building or other structure. As many blocks are used as are required for the particular job at hand. After all the blocks are in place, the space  13  between their panels  5  is filled with concrete and appropriate reinforcing items. The concrete cures to make a very strong and insulated wall.  
         [0054]    Panels  
         [0055]    Looking also at FIGS.  2 - 4 , the two panels  5  of each block  3  are rectangular in shape, having a top surface  14 , a bottom surface  16 , and end surfaces  18 . Each panel also has an interior face  20  and an exterior face  22 . The panel is made from a sturdy and rigid but lightweight insulative material. A preferred material is a foam made of expanded polystyrene. Although the panels can be of any practical size, we prefer a size of 16 inches high, 48 inches long, and 2.50 inches thick. It will be appreciated that panels of other dimensions are also fully within the scope of the present invention.  
         [0056]    The panels  5  include interlocks  32 . The illustrated interlocks  32  are a pattern of short posts  26  on one of the panel top or bottom surfaces  14  or  16 , respectively. The other top or bottom surface of each panel has a complimentary pattern of cavities  30 . Although the posts  26  and cavities  30  are shown as being round, other shapes such as squares or octagons are also acceptable. The preferred spacing of the interlocks posts and cavities is 1.00 inches. The number of rows of the posts and cavities in the interlocks is dependent upon the thickness of the panel. When the panel thickness permits, a land  34  is provided between the panel interior face  20  and the adjacent row of posts or cavities.  
         [0057]    On the exterior face  26  of each panel  5  are a number of grooves  36 . Each groove  36  runs from the top surface  14  to the bottom surface  16 . The grooves are preferably one inch apart. The grooves at four inches from the end surfaces  18 , designated at reference numerals  36 A, are two grooves that are separated slightly. There are additional double grooves  36 B at eight inch spacings from the grooves  36 A.  
         [0058]    Insert  
         [0059]    Turning to FIGS.  5 - 9 , the insert  7  of the invention includes a base  15  that defines a plane  17 . One or more webs  19  upstand from the base  15 . At least one, and preferable two, connectors  9  are supported on the web  19 . As illustrated, there are two identical connectors  9  and  9 ′ supported by respective webs and  19 ′.  
         [0060]    Each connector  9  and  9 ′ has a pair of side walls  10  and  12 , and end walls  38  and  40 . The connector further has a top surface  25 . A pair of flanges  23  and  24  project transversely from the side walls  10  and  12 , respectively. A pair of tabs  27  and  28  project transversely from the side walls at the top surface  25 . The two connectors are joined by a plate  21 , which preferably is aligned with the flanges  23  and  24 .  
         [0061]    In each connector end wall  38  is a notch  29 . The notch is defined by an end surface  31  between the flange  23  and the top surface  25 . The notch is also defined by a side surface  33  between the flange  23  and the top surface. Preferably, the planes of the ends and side surfaces  31  and  33 , respectively, are perpendicular to each other and also perpendicular to the plane  17  of the base  15 .  
         [0062]    In the notch end surface  31  is a hole  35 . The longitudinal centerline  37  of the end hole  35  is perpendicular to the notch end surface. The longitudinal centerline  37  of the end hole  35  is offset by a distance X from the notch side surface  33  in the direction of the flange  28 . The offset distance X is less than the diameter of the end hole  35 . Consequently, there is an arcuate recess  39  in the notch side surface  33  that is an extension of the end hole  35 .  
         [0063]    In the connector top surface  25  is an opening  41 . The top opening  41  has a longitudinal axis  43  that is perpendicular to and that intersects the longitudinal centerline  37  of the end hole  35 . The top opening has a diameter equal to that of the end hole. The top opening longitudinal axis  43  lies in the plane of the notch end surface  31 . Consequently, the top opening subtends an angle of approximately 270 degrees. In the particular connector  9  illustrated, there is-a ridge  45  on the top surface  25  around the top opening.  
         [0064]    It is an important feature of the present invention that each connector  9  and  9 ′ is double-ended. The connector  9 , for example, has a second notch  29 ′ that is defined by an end surface  31 ′ and side surface  33 ′. The end hole  35  extends completely through the connector between the two end surfaces  31  and  31 ′. There is a second top opening  41 ′ in the top surface  25  at the second notch  29 ′. A rib  46  on the top surface  25  connects the two ridges  45  and  45 ′ around the top openings  41  and  41 ′, respectively. The ridges  45  and  45 ′ have a common upper face  48  with the rib  46 .  
         [0065]    Preferred dimensions for the insert  7  include a length of approximately 15 inches and a base width of approximately 1.50 inches. The web height is approximately two inches, and the height H from the flanges  23  and  24  to the upper face  48  is 0.50 inches. The distance between the longitudinal axes  43  of the top openings  41  of the two connectors is eight inches, and the longitudinal axes  43  are at equal distances from the ends of the base.  
         [0066]    Tie  
         [0067]    The tie  11  is best shown in FIG. 10. The ties are made from metal material, such as steel. Each tie has a middle leg  47  and two end legs  49 . The tie legs  45  and  49  have a diameter that is slightly less than the diameter of the end holes  35  and top openings  41  and  41 ′ in the connectors  9 .  
         [0068]    In the middle leg  47  of each tie  11  are a number of seats  51 . The middle leg may be bent as shown to produce the seats  51 . There are preferably a center seat  51 A and two side seats  51 B, although that particular arrangement is not critical for the operation of the present invention. A satisfactory diameter for the tie material is a circular rod of 0.19 inches diameter. The end legs  49  may be approximately 1.50 inches long. The length of the middle leg is variable as will be explained in detail presently.  
         [0069]    Assembly and Operation  
         [0070]    With particular attention to FIG. 5, the inserts  7  are embedded in the panel  5  at the factory. For that purpose, the connectors  9  and  9 ′ of an insert are retained in an aluminum mold represented by phantom lines  53 . The connector tabs  27  and  28  cooperate with slots in the mold  53  to keep the inserts in place. The presence of the two connectors  9  and  9 ′, plus the fact that the connectors are double-ended, renders the inserts invertible in the mold. Consequently, orientation mistakes when loading the inserts into the mold are eliminated. It is preferred that the inserts be centered between the panel top and bottom surfaces  14  and  16 , respectively. For a panel that is 16 inches high and an insert with a 15 inch base  15 , the longitudinal axes  43  of the connectors are then four inches from the top and bottom surfaces.  
         [0071]    The inserts are further located so as to be centered on the grooves  36 A and  36 B. Accordingly, six inserts are used for a  48  inch long panel.  
         [0072]    The mold  53  is filled with a selected insulative material such as expanded polystyrene in a manner well known in the art. After the mold is removed, a rigid panel  5  has been produced having twelve connectors  9  and  9 ′ spaced on an eight inch grid exposed in the panel interior face  20 . For the particular insert  7  described, the height H of the connectors above the panel interior face is 0.50 inches.  
         [0073]    The panels  5  with the inserts  7  are ready to be assembled into the blocks  3 . Two panels are placed in parallel facing relation. A tie  11  is used between associated connectors  9  or  9 ′. One tie end leg  49  is pushed partially into the end hole of a connector of one panel, and the other tie end leg is pushed partially into the end hole of a connector of the second panel. The two panels are thus held together to make a block  3 . The panels are at a distance apart equal to the length of the tie middle leg  47 .  
         [0074]    According to an important aspect of the invention, the insert connectors  9  and the ties  11  cooperate to act as hinges that enable the blocks  3  to fold. FIGS.  11 A- 11 C show three typical configurations of folded blocks. In FIG. 11A, a block  3 A has a first panel  5 A with connectors  9 A, and a second panel  5 A′ with connectors  9 A′. The length of the ties middle legs  47 A is less than the spacings between connectors  9 A and  9 A′. Consequently, swiveling the ties end legs in the associated connector end holes  35  enables the connectors  9 A to contact the interior face  20 A′ of the panel  5 A′, and the connectors  9 A′ to contact the interior face  20 A of the panel  5 A. The envelope of the folded block  5 A is thus reduced by a distance equal to the length of the tie middle legs  47 A minus the height H of the connectors compared with the envelope of the unfolded block.  
         [0075]    In FIG. 11B, the lengths of the tie middle legs  47 B is equal to the spacings between the connectors  9 B and  9 B′ of the panels  5 B and  5 B′, respectively. In that situation, the opposing connectors  9 B and  9 B′ contact when the block  3 B is folded. The envelope of the folded block  3 B is reduced by a distance equal to the length of the middle legs  47 B of the ties  11 B minus twice the height H of the connectors  9 B and  9 B′.  
         [0076]    In FIG. 11C, the lengths of the middle legs  47 C of the ties  11 C is greater than the spacings between the connectors  9 C and  9 C′. In that situation, the connectors  9 C and  9 C′ contact the interior faces  20 C′ and  20 C, respectively, of the panels  5 C′ and  5 C when the block  3 C is folded. The envelope of the folded block  5 C is reduced by an amount equal to the length of the ties middle legs  47 C minus the height of the connectors  9 C and  9 C′.  
         [0077]    At the job site, the blocks  3  are unfolded, FIG. 1, by swiveling the ties end legs  49  in the end holes  35  of the connectors  9 . See FIG. 12. As the ties  11  swivel in the direction of arrow  55 , their middle legs  47  approach and contact the side surfaces  33  of the associated connector notches  29 . From that point, the ties  11  are further swiveled in the direction of arrow  55 . The insert material deflects slightly in the regions of the side surfaces to enable the tie middle legs to snap into the associated connector top openings  41 . The connector material resiliently returns to its undeflected configuration. At that point, the tie middle legs are locked in the connectors, and the block is rigid.  
         [0078]    The blocks  3  are stacked on top of and alongside of each other into a form  57 . The interlocks  32  aide in keeping the blocks in place. Steel reinforcing rods  59  are laid in selected seats  51 A or  51 B of the ties  11 . When the form  57  and reinforcing rods  59  are completed, concrete is poured in the space  13 .  
         [0079]    After the concrete has cured, a very strong and insulated wall has been created. The grooves  36 A and  36 B indicate the bases  15  of the inserts  7 . The grooves are very helpful for subsequent construction operations such as attaching drywall or other sheet goods  58  with fasteners  60  to the insulated concrete wall. The tabs  27  and  28  help anchor the inserts to the cured concrete and thereby provide resistance against the drywall fasteners  60 . Other types of wall finishes and building accessories can also be securedly fastened to the completed insulated concrete wall by means of the inserts. The metal ties  11  as opposed to ties made of plastic or combustible materials, prevent burn through in the event of intense fires. It is anticipated that a six inch net concrete wall will achieve a four hour fire rating.  
         [0080]    Corners  
         [0081]    Further in accordance with the present invention, the standard block  3  of the invention may be modified to use at corners of two intersecting walls. Turning to FIGS. 13 and 13A, a first block  61  for a first wall  63  is at a corner  76  with a second block  61 A of an intersecting wall  67 . The blocks  61  and  61 A are identical to the blocks  3  of the invention as described previously. The block  61 A has an external panel  69  and an internal panel  71 , each with inserts  73  and ties  75 . The block  61 A has an external panel  69 A, internal panel  71 A, inserts  73 A, and ties  75 A. The blocks  61  and  61 A need not have equal length ties  75  and  75 A, respectively.  
         [0082]    To make the corner  76  of the walls  63  and  67 , the external panel  69  of the block  61  is cut at line  77  by an amount D1 equal to the thickness of the external panel  69 A of the block  61 A. The internal panel  71  of the block  61  is cut at line  79  by an amount D2 equal to the full width of the block  61 A. The internal panel  71 A of the block  61 A is cut at line  81  by an amount D3 equal to the thickness of the external panel  69  of the block  61  plus the spacing  13  between the two panels of the block  61 . The cuts are easily made using common hand or power tools by using the grooves  36  located on the exterior face  22  of the panels as guidelines (FIGS. 1 and 2). With the three cuts  77 ,  79 , and  81  made, the two resulting blocks  61 ′ and  61 A′ are placed in perpendicular intersecting arrangement as shown in FIG. 14A.  
         [0083]    It will be noticed in FIG. 13A that the usual ties  75  and  75 A do not work with the end inserts  73 E and  73 EA of the blocks  61  and  61 A, respectively. To properly hold the panels  69 ′ and  69 A′ in place, two corner ties  81  and  81 A are used. The corner tie  81  is used between the insert  73 E of the block  61  and the closest tie  71 A of the block  61 A. The corner tie  81 A is used between the insert  73 EA of the block  61 A and the closest tie  75  of the block  61 . For both the corner ties  81  and  81 A, one end leg is inserted into the end hole  35  of the associated insert  73 E or  73 EA. The other tie leg is hooked over an associated tie  75  or  75 A. In that manner, a corner  76  of the insulated concrete wall system  1  is constructed without the requirement of making or storing any special components at the factory.  
         [0084]    T-Walls  
         [0085]    Next looking at FIGS.  14 - 18 , the present invention is further concerned with erecting T-walls of the insulated concrete wall system  1 . In FIG. 14, a T-wall  83  intersects a main wall  85 . The T-wall  83  and main wall  85  may have different total widths. At the intersection  86 , the main wall  85  has a block  87 , and the T-wall has a block  89 . The T-wall block  89  is a standard block  3  with inserts  7  and ties  11 . The main wall block  87  is also factory made as a standard block  3  according to the present invention.  
         [0086]    To suit the T-wall intersection  86 , one panel of the block  87  is cut along lines  91  a distance D4 equal to the width of the concrete of the T-wall. Both panels  5  of the T-wall block  3  are brought into contact with the cut panel  88  of the block  87 . The space  92  between the panels  5  is aligned with the cut lines  91 .  
         [0087]    To hold the second panel  90  of the block  87  to the T-wall block  3 , four plates are used together with the standard ties  11 . Two outside T-wall plates  93  are constructed as specialized stamped plates having a number of holes  95 . The holes  95  are sized and spaced to fit over and receive several interlock posts  26 A of the second panel  90  of the block  87 . One edge  99  on the outside T-wall plate  93  is turned over at 180 degrees. A hole  101 , which is meant to receive one leg  45  of the tie  51 , is through the double layer of material at the turned-over edge  99 .  
         [0088]    An inside T-wall plate  103  also has a number of holes  105  for fitting over and receiving the posts  26 B of the panels  5  of the block  3 . An edge  107  of the inside T-wall plate  103  is turned over at 180 degrees. A hole  109 , which is meant to receive one leg  49  of the tie  51 , is through the double layer of material in the turned-over edge  107 .  
         [0089]    In use, an inside T-wall plate  103  is placed over each of the panels  5  of the block  3 . The turned-over edge  107  and hole  109  simulate the connector  9  and end hole  35  of an insert connector  9 . An outside T-wall plate  93  is placed over the second panel  90  of the block  87  opposite each of the panels  5  of the block  3 . The turned-over edge  99  and hole  101  of the outside T-wall plate simulate the connector  9  and end hole  35  of an insert  7 . A tie  11  is used between the holes  101  and  109  on the outside and inside T-wall plates, respectively, to hold the blocks  3  and together. The simple cuts  91  in the blocks of the invention plus the simple outside and inside T-wall plates obviate the need for special blocks for T-walls. For both the intersections  76  and  86 , cutting the standard blocks  3  as described maintains the vertical and horizontal alignments of the inserts connectors  9 . Accordingly, no strength from the ties  11  is lost.  
         [0090]    Modified Insert  
         [0091]    An important aspect of the present invention is that the inserts lend themselves to being economically manufactured. It is contemplated that the inserts will be manufactured on a production basis from a plastic material by an injection molding process. As described, the insert  7  is entireably suitable for being molded in conventional manner. To simplify the molding process, especially as it pertains to the end holes  35  in the connectors  9  and  9 ′, a modified insert  111  has been developed. See FIGS.  19 - 21 . The insert  111  has a base  15 ′, and webs  19 ′. The modified insert is invertible, having two double-ended connectors  113  that are supported on the webs  19 ′. Each connector  113  has a top surface  25 ′, two notches  29 ′, an end hole  35 ′ with a longitudinal centerline  37 ′, flanges  23 ′ and  24 ′, tabs  27 ′ and  28 ′, and top openings  41 ′ and  41 A. The two connectors of an insert may be connected by a plate  21 ′ that is aligned with the flanges  23 ′ and  24 ′.  
         [0092]    To avoid the expense of a mold that must reciprocate in the directions parallel to the end hole longitudinal centerline  37 , the connectors  113  are made with cutouts  115  and  117 . The cutout  115  is through the tab  27 ′ and side wall  10 ′ and breaks into the end hole  35 ′. One edge  119  of the cutout  115  may be at an angle to the side wall  10 , if desired. The cutout  115  also breaks into the top opening  41 ′. The cutout  117  is substantially identical to the cutout  115 . Because of the cutouts, only mold reciprocation perpendicular to the longitudinal centerline  37 ′ is required to make the end hole  35 ′ in the insert  111 ; no mold reciprocation parallel to the end hole longitudinal centerline  37 ′ is needed. The cutouts  115  and  117  have no effect on the performance of the connectors.  
         [0093]    Thin Concrete Wall.  
         [0094]    The versatility of the present invention is further demonstrated with regard to FIG. 22. In some buildings, it is desirable to pour very thin concrete walls. With the present invention, walls having a concrete thickness as little as twice the height H of the connectors can be constructed. In those situations, the usual ties  11  are not used. Instead, metal staple shaped ties  121  are used. The staple shaped tie  121  has end legs  123  and a middle leg  125 . Two panels  5  and  5 A with inserts  7  and  7 A are brought together side-by-side such that the connectors  9  and  9 A abut. The staple shaped tie is of the proper length to enable its end legs  123  to the inserted into the end holes  35  of the two connectors  9  and  9 A while still keeping the connectors in close contact. As a result, for an insert with a connector height H of 0.50 inches, a concrete wall only one inch thick can be poured without problem.  
       SUMMARY  
       [0095]    The results and advantages of insulated concrete walls can now be more fully realized. The insulated concrete wall system  1  provides both rapid erection of the blocks  3  into forms for receiving poured concrete as well as foldability of the blocks. This desirable result comes from using the combined functions of the insert connectors  9 . The ties  11  are selectively swivelable in the connector end holes  35 . The ties enable the blocks to fold for shipping and storage at a job site. The connector top openings  41  cooperate with the end holes to snap lock the ties in place and render the blocks rigid. The connectors are double-ended so that the inserts  7  are invertible in the panels  5 . No special blocks are required for corners of a wall. Instead, the standard blocks are cut in simple fashion to suit a corner. Similarly, no special blocks are needed for a T-wall. The specialized stamped plates  93  and  103  are used in conjunction with one cut and one standard block to suit a T-wall. The metal ties prevent burn through the insulated concrete wall system during a fire. The tabs  27  help anchor the panels to the concrete and also provide resistance to fasteners used for securing drywall and other building components to the insulated concrete wall.  
         [0096]    It will also be recognized that in addition to the superior performance of the insulated concrete wall system of the invention, its construction is such as to cost little, if any, more than traditional insulated concrete wall systems. In fact, the versatility and productivity of the invention contributes significantly to reducing the total costs of constructing an insulated concrete wall.  
         [0097]    Thus, it is apparent that there has been provided, in accordance with the invention, an insulated concrete wall system that fully satisfies the aims and advantages set forth above.  
         [0098]    While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.

Technology Classification (CPC): 4