Abstract:
An insulated concrete forming panel comprising an insulative interior wall portion that provides a form for supporting uncured concrete, wherein the uncured concrete forms a concrete structural portion upon curing of the uncured concrete, and wherein the insulative interior wall portion remains attached to the concrete structural portion after formation.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority to U.S. Provisional Patent Application No. 60/978,545, filed Oct. 9, 2007. 
     
    
     BACKGROUND 
       [0002]    Poured concrete walls are often used in construction to make wall assemblies for structures. The concrete is typically poured into a void that is formed between two steel form structures. When the forms are removed after the concrete cures, the wall consists of concrete that has no insulative properties beyond those of the concrete itself. To add to the insulative properties of the concrete, insulated concrete forms (ICFs) are used to construct wall assemblies. ICFs are generally constructed of insulative polymer panels or interlocking blocks that provide a form for the poured concrete and also form a part of the outside and inside finished wall assembly. ICF techniques can be used to pre-fabricate building panels. Examples of such panels and methods of making such panels are contained in U.S. Patent Application Publication No. 2006/0251851 and U.S. Patent Application Publication No. 2006/0191232, both of which are incorporated herein by reference. 
         [0003]    Concrete is the only structural material in a typical ICF and as such carries all of the weight, building and lateral loads imposed on a wall section. The forms do not contribute to the load carrying capacity of the complete wall. The two exposed foam sections (interior and exterior) of a typical ICF must be covered with a fire resistant material in order to obtain required fire ratings. 
       SUMMARY 
       [0004]    In various embodiments, the present invention is directed to single face insulated concrete forms in which an insulative polymer acts as one side of a form for fresh (uncured), or poured concrete and a removable concrete form acts as the other side of the form. When used with standard modular concrete forms, embodiments of the present invention allow the typical three step construction process (forming, insulating and furring) to be combined into one step. The modular nature and matching of connecting points and ties with industry standards for the systems and methods described herein require little or no additional worker skills as compared with using typical concrete forms. 
         [0005]    According to various embodiments, the deformed section of the steel stud, when extending into the concrete, supplements or replaces standard reinforcement of the concrete wall section. This allows the steel studs to supplement the concrete by creating a composite action within the wall structure and allows for the concrete section to be reduced in thickness while maintaining the load properties of the finished wall. 
         [0006]    According to various embodiments, after removal of the interior and exterior modular forms a concrete wall is created having an insulating face with exposed furring studs for easy placement of all utilities within the wall. 
         [0007]    Those and other details, objects, and advantages of the present invention will become better understood or apparent from the following description and drawings showing embodiments thereof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0008]    The accompanying drawings illustrate examples of embodiments of the invention. In such drawings: 
           [0009]      FIG. 1  illustrates a perspective view of an embodiment of an insulated concrete form system; 
           [0010]      FIG. 2  illustrates a side view of an embodiment of the insulated concrete form system of  FIG. 1 ; 
           [0011]      FIG. 3  illustrates a perspective view of an embodiment of the interior wall portion of the insulated concrete form system of  FIG. 1 ; 
           [0012]      FIG. 4  illustrates a perspective view of an embodiment of the interior wall portion of the insulated concrete form system of  FIG. 1 ; 
           [0013]      FIG. 5  illustrates an embodiment of a connector portion of the interior wall portion of the insulated concrete form system of  FIG. 1 ; 
           [0014]      FIG. 6  illustrates an embodiment of the connector portion of the interior wall portion of the insulated concrete form system of  FIG. 1  having a reinforcing member extending therethrough; 
           [0015]      FIG. 7  illustrates an embodiment of a locking mechanism for securing the reinforcing member to the connector portion of the interior wall portion of the insulated concrete form system of  FIG. 1 ; 
           [0016]      FIG. 8  illustrates an embodiment of the insulated concrete form system of  FIG. 1  having reinforcing members located between the interior wall portion and the concrete form; 
           [0017]      FIG. 9  illustrates an embodiment of an insulated concrete form system having a removable interior form; 
           [0018]      FIG. 10  illustrates an embodiment of an insulated concrete form system having exterior and interior concrete form portions configured in a modular fashion; 
           [0019]      FIG. 11  illustrates a side perspective view of an embodiment of an insulated concrete form system; 
           [0020]      FIG. 12  illustrates an embodiment of an insulated concrete form system that includes locking mechanisms; 
           [0021]      FIG. 13  illustrates an embodiment of a removable interior form that is attached to the interior wall portion of an insulated concrete form system; 
           [0022]      FIG. 14  illustrates an embodiment of a locking mechanism for securing the various portions of an insulated concrete form system that secures the removable interior form, the interior wall portion and the exterior removable form; 
           [0023]      FIG. 15  illustrates a side view of an embodiment of a stud for an interior wall portion of an insulated concrete form system; 
           [0024]      FIG. 16  illustrates a perspective view of a stud for an interior wall portion of an insulated concrete form system; 
           [0025]      FIG. 17  illustrates a cross-sectional view of an embodiment of an insulated concrete form system after the forms have been removed; 
           [0026]      FIG. 18  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed; 
           [0027]      FIG. 19  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed; 
           [0028]      FIG. 20  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed; 
           [0029]      FIG. 21  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed; and 
           [0030]      FIG. 22  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed. 
       
    
    
     DESCRIPTION 
       [0031]    Various embodiments of the present invention are directed to an insulated concrete form system. In various embodiments, the system includes an insulated pre-studded portion that acts as both a form during the concrete pour and an attached interior wall portion after the pour and removal of an exterior form. Various embodiments also include removable interior forms that may be constructed of a lightweight material. 
         [0032]    Various embodiments are directed to a single face, stay in place, insulated concrete forming panel. In various embodiments, the forms are designed to work with industry standard removable modular concrete forms, either in a double sided or single sided configuration. In various embodiments, the foam form panel contains structural members molded within an expandable foam body that fixes the position of and insulates the members which may be constructed of, for example, light gauge steel. In such embodiments, the expandable foam core body with the fixed members contributes to the structural integrity of the assembly during the concrete casting process. Embedding a portion of the members within the concrete portion of a wall allows a reduction in the concrete steel reinforcement. The structural members may be of any length and orientation and are molded within the foam core using, for example, a continuous or semi-continuous process. 
         [0033]    In various embodiments, the exposed portion of the structural members extending from the bottom of the foam panel and running the length of the panel create a composite wall connection that allows the concrete and light gauge metal stud to better resist the forces of gravity, structural loading and soil pressures. The opposing exposed steel member acts as a furring stud to allow for plumbing and electrical chases and as the attachment point for the modular concrete forms. The structural metal studs also aid the modular concrete forms in resisting the forces applied when the concrete is poured. 
         [0034]    In various embodiments, the foam surface of the panel prevents the concrete core from contacting the interior portion of the modular forms, thereby extending their useful life and speeding the cleaning of the forms after use. The foam surface also reduces the amount of temporary form bracing required to withstand the pouring forces of the concrete. 
         [0035]    In various embodiments, the opposing exposed stud is used to apply finishing materials such as drywall or other materials to provide the finishing of the interior walls. The opposing flush surface of the steel member may be used to mechanically attach the concrete, window bucks, door bucks, concrete to panel tie steel, etc. The molded portion of the stay in place form can vary in its depth to create the proper insulation based on the building design and intended use. The foam depth can also vary (e.g., from 1 inch to 16 inches) to provide for differing concrete pour thickness support during the casting phase of construction while using the same modular concrete forms and ties. 
         [0036]    In various embodiments, the steel members can be varied in dimension (including the gauge of steel used) depending on the concrete depth and reinforcement positioning required by structural engineers in the design of differing wall heights and loading requirements. The panels can be reversed with the foam to the exterior and used as a foam surface to attach cost-effective foam architectural detailing. 
         [0037]      FIG. 1  illustrates a perspective view of an embodiment of an insulated concrete form system  10 . The system  10  includes a removable concrete form  12  that may be constructed of any suitable material such as, for example, steel, plastic, wood, etc. The system  10  also includes an interior wall portion  14 . The interior wall portion  14  may be constructed of an insulating material such as, for example, a polymer such as a matrix of molded expanded polystyrene (EPS) or any expandable or non-expandable material (e.g., foam based material) or plastic that may, in one embodiment, include one or more performance enhancing additives. 
         [0038]    The interior wall portion  14  includes various embedded and exposed structural and non-structural members that are constructed of, for example, light gauge steel, wood, plastic, or a composite material of any natural or engineered composition. The members include studs  16  that allow for utilities to be run in the interior of the finished wall and also allow for finish materials such as drywall to be attached to the interior of the finished wall. Reinforcing members  18  connect the interior wall portion  14  and the concrete form  12  and provide either sole reinforcement or reinforcement that supplements conventional reinforcement of the concrete that is poured to fill void  20  between the interior wall portion  14  and the concrete form  12 . 
         [0039]      FIG. 2  illustrates a side view of an embodiment of the insulated concrete form system  10  of  FIG. 1 .  FIG. 3  illustrates a perspective view of an embodiment of the interior wall portion  14  of the insulated concrete form system  10  of  FIG. 1 .  FIG. 4  illustrates a perspective view of an embodiment of the interior wall portion  14  of the insulated concrete form system  10  of  FIG. 1 . The embodiment shown in  FIG. 4  includes reinforcement members  22  that further reinforce the interior wall portion  14 . 
         [0040]      FIG. 5  illustrates an embodiment of a connector portion  24  of the interior wall portion  14  of the insulated concrete form system  10  of  FIG. 1 . The connector portion  24  is molded into the interior wall portion  14  and provides an attachment point for structural elements  16 ,  22  and provides points at which the reinforcing members  18  can pass through and be securely connected to the interior wall portion  14 .  FIG. 6  illustrates an embodiment of the connector portion  24  of the interior wall portion  14  of the insulated concrete form system  10  of  FIG. 1  having the reinforcing member  18  extending therethrough. 
         [0041]      FIG. 7  illustrates an embodiment of a locking mechanism  26  for securing the reinforcing member  18  to the connector portion  24  (not shown in  FIG. 7 ) of the interior wall portion  14  of the insulated concrete form system  10  of  FIG. 1 . As can be seen in  FIG. 7 , the connector portion  24  has a stud  16  attached thereto and the reinforcing member  18  extends through the connector portion  24  and an opening in the stud  16 . The locking mechanism  26  secures the reinforcing member  18  to the interior wall portion  14  and prevents the interior wall portion  14  from separating from the concrete form  12  during the concrete pour. The locking mechanism  26  includes a horizontal member  28  and a vertical member  31 . 
         [0042]      FIG. 8  illustrates an embodiment of the insulated concrete form system  10  of  FIG. 1  having reinforcing members  30  located between the interior wall portion  14  and the concrete form  12 . As can be seen in  FIG. 8 , the reinforcing members  30  are reinforcing bars (rebar) that are arranged in a grid. The reinforcing members  30  may be made of any type of material, such as a metal or polymer. 
         [0043]      FIG. 9  illustrates an embodiment of an insulated concrete form system  32  having a removable interior form  34 . The interior form  34  may be constructed of any suitable material such as, for example, steel, plastic, wood, etc. In one embodiment, the interior form  34  is constructed of molded polypropylene. 
         [0044]      FIG. 10  illustrates an embodiment of an insulated concrete form system  36  having exterior and interior concrete form portions  12 ,  34  configured in a modular fashion such that the interior form portions  34  fit between the studs  16 . 
         [0045]      FIG. 11  illustrates a side perspective view of an embodiment of an insulated concrete form system  38  that is configured prior to a concrete pour.  FIG. 12  illustrates an embodiment of an insulated concrete form system  40  that includes locking mechanisms  26 . 
         [0046]      FIG. 13  illustrates an embodiment of a removable interior form  34  that is attached to the interior wall portion  14  of the insulated concrete form systems described herein. As can be seen in  FIG. 13 , the stud  16  includes a dimpled surface  17  adjacent the interior form  34 . The surface  17  facilitates removal of the interior form  34 .  FIG. 14  illustrates an embodiment of the locking mechanism  26  for securing the various portions of the insulated concrete form systems described herein. The locking mechanism includes the vertical member  28  and the horizontal member  31  and secures the removable interior form  34 , the interior wall portion  14  and the exterior removable form (not shown in  FIG. 14 ). 
         [0047]      FIG. 15  illustrates a side view of an embodiment of a stud  16  for the interior wall portion  14  of the insulated concrete form systems described herein. The stud  16  includes fusion slots  44  that facilitate anchoring the portion of the stud  16  that is contained in the interior wall portion  14 . The stud  16  also includes wiring chase slots  46  that facilitate the routing of wires, pipes, etc. through the stud  16  during the finishing process of the structure that includes the concrete wall that was constructed using the insulated concrete form systems. 
         [0048]    The stud  16  further includes slots  48  that permit the reinforcing members  18  to extend through the stud  16 . The stud also includes wedge bolt punch holes  50 . 
         [0049]      FIG. 16  illustrates a perspective view of a stud  16  for the interior wall portion  14  of the insulated concrete form systems described herein. The stud  16  includes a strip  52  that has fusion slots  44 . When in use, the fusion slots  44  are embedded in the interior wall portion  14 . 
         [0050]      FIG. 17  illustrates a cross-sectional view of an embodiment of an insulated concrete form system after the forms have been removed and the concrete  54  is cured. The stud  16  includes a portion with the strips  52  embedded in the interior wall portion  14 . The stud also includes the slots  48  for insertion of the reinforcing members  18 .  FIG. 18  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed. In the embodiment of  FIG. 18 , the stud  16  extends further into the interior wall portion  14 . 
         [0051]      FIG. 19  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed. In the embodiment illustrated in  FIG. 19 , the stud  16  extends through the interior wall portion  14  into the concrete  54  to provide further reinforcement of the system. Also, in the embodiment illustrated in  FIG. 19 , the interior wall portion  14  includes a V-shaped cutout section. 
         [0052]      FIG. 20  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed. In the embodiment illustrated in  FIG. 20 , the stud  16  includes extended strips  56  embedded in the interior wall portion  14  that provide further stability to the system. 
         [0053]      FIG. 21  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed. In the embodiment illustrated in  FIG. 21 , the interior wall portion  14  has a larger V-shaped cutout portion than the embodiment illustrated in  FIGS. 19 and 20 . 
         [0054]      FIG. 22  illustrates a cross-sectional view of another embodiment of an insulated concrete form system after the forms have been removed. In the embodiment illustrated in  FIG. 22 , the stud does not extend beyond the interior wall portion  14 , but is instead completely embedded in the interior wall portion  14  and the concrete  54 . 
         [0055]    In the embodiments illustrated herein in which the stud  16  extends into the concrete  54 , the stud  16  acts as a reinforcing member in the concrete and can supplement or replace other reinforcing techniques. 
         [0056]    In various embodiments, the interior wall portion  14  may include panels that are oriented on different planes, thus creating walls for specific purposes, such as below-grade and above-grade walls, retaining walls with attached architectural details and sandwich insulated walls containing concrete on both exposed wall surfaces. 
         [0057]    Various embodiments of the systems and methods described herein allow for concrete structures that use less concrete, thus reducing costs and the weight of the structure. Various embodiments of the systems and methods described herein eliminates or reduces the amount of bracing necessary for creating poured concrete walls and allow for relatively easier installation than traditional concrete poured walls. 
         [0058]    The present invention has been described with reference to specific details of particular embodiments thereof. It is not intended that such details be regarded as limitations upon the scope of the invention.