Removable composite insulated concrete form, insulated precast concrete table and method of accelerating concrete curing using same

• US 10,065,339 B2
• Filed: 05/12/2014
• Issued: 09/04/2018
• Est. Priority Date: 05/13/2013
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): Gupta, Yogendra N
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US14/275,854
• Publication Number:
  US 20140333010A1
• Time in Patent Office: 1,576 Days
• Field of Search: 249 1, 249 13, 249 78
• CPC Class Codes: B28B 1/14 by simple casting, the material being neither forcibly fed nor positively compacted for molten material B28B1/54
• CPC Class Codes: B28B 7/34 Moulds, cores, or mandrels of special material, e.g. destructible materials for slip casting B28B1/26
• CPC Class Codes: B28B 7/36 Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded articlelubricating surfaces of moulds, cores or mandrels B28B7/38
• CPC Class Codes: C04B 14/00 Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone expanding or defibrillating materials C04B20/00
• CPC Class Codes: C04B 14/043 Alkaline-earth metal silicates, e.g. wollastonite
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 14/465 Ca-silicate, e.g. wollastonite
• CPC Class Codes: C04B 16/08 porous, e.g. expanded polystyrene beads or microballoons
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/241 Paper, e.g. waste paper; Paper pulp
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 2201/30 for heat transfer properties such as thermal insulation values, e.g. R-values
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 26/04 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 26/14 Polyepoxides
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 28/04 Portland cements
• CPC Class Codes: C04B 28/08 Slag cements
• CPC Class Codes: C04B 38/08 : by adding porous substances
• CPC Class Codes: C04B 40/0263 : Hardening promoted by a rise in temperature C04B40/024 takes precedence
• CPC Class Codes: C04B 7/02 : Portland cement
• CPC Class Codes: E04G 9/10 : with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

The invention comprises a concrete form. The concrete form comprises a first panel having a first primary surface for contacting plastic concrete and a second primary surface opposite the first surface, wherein the first panel is made from a rigid plastic sheet or a metal sheet; and a second panel spaced from the second primary surface of the first panel, wherein the second panel is made from a rigid plastic sheet or a metal sheet. The concrete form also comprises a layer of insulating material disposed between the first panel and the second panel. A method of using the concrete form is also disclosed.

Claims

1. A concrete casting table comprising:

a first horizontal concrete forming panel having a first primary surface adapted for forming and contacting plastic concrete and a second primary surface opposite the first primary surface, wherein the first concrete forming panel defines a plane;

a second horizontal panel having a first primary surface and a second primary surface opposite the first primary surface;

a first continuous layer of insulating material continuously contacting the second primary surface of the first concrete forming panel and the second primary surface of the second panel, the layer of insulating material substantially covering the second primary surface of the first panel;

a plurality of vertical side members, each of which has a first primary surface adapted for forming plastic concrete and a second primary surface opposite the first primary surface, wherein the first horizontal concrete forming panel and the plurality of vertical side members define a concrete mold cavity;

a second continuous layer of insulating material substantially covering the second primary surface of each of the plurality of vertical side members;

a removable third layer of insulating material covering the concrete mold cavity, and

a frame disposed on the first primary surface of the second panel, the frame comprising a plurality of bracing members oriented transversely with respect to the first primary surface of the second panel, wherein no portion of the frame is in the plane defined by the first concrete forming panel.

2. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each comprise a conductive heat insulating material or a radiant heat reflective material.

3. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each have insulating properties equivalent to at least 0.25 inch of polystyrene foam.

4. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each have insulating properties equivalent to at least 0.5 inch of polystyrene foam.

5. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each have insulating properties equivalent to at least 1 inch of polystyrene foam.

6. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each have insulating properties equivalent to at least 2 inches of polystyrene foam.

7. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each comprises a layer of refractory insulating material in an adhesive.

8. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each comprises a layer of ceramic fibers in an adhesive.

9. The concrete casting table of claim 8, wherein the adhesive is polyurethane or epoxy.

10. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each comprises Wollastonite in an adhesive.

11. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each comprises closed cell polymeric foam.

12. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each comprise a rigid insulating polymeric foam.

13. The concrete casting table of claim 1, wherein the first and second continuous layers of insulating material each comprise a polymeric foam of polyvinyl chloride, urethane, polyurethane, polyisocyanurate, phenol, polyethylene, polyimide or expanded polystyrene.

14. The concrete casting table of claim 1, wherein the removable third layer of insulating material has insulating properties equivalent to at least 1 inch of polystyrene foam.

15. The concrete casting table of claim 1, wherein the removable third layer of insulating material has insulating properties equivalent to at least 2 inch of polystyrene foam.

16. The concrete casting table of claim 1, wherein the removable third layer of insulating material comprises a polymeric foam of polyvinyl chloride, urethane, polyurethane, polyisocyanurate, phenol, polyethylene, polyimide or expanded polystyrene.

17. The concrete casting table of claim 14, wherein the removable third layer of insulating material comprises a polymeric foam of polyvinyl chloride, urethane, polyurethane, polyisocyanurate, phenol, polyethylene, polyimide or expanded polystyrene.

18. The concrete form of claim 15, wherein the removable third layer of insulating material comprises a polymeric foam of polyvinyl chloride, urethane, polyurethane, polyisocyanurate, phenol, polyethylene, polyimide or expanded polystyrene.

19. The concrete form of claim 6, wherein the removable third layer of insulating material has insulating properties equivalent to at least 2 inch of polystyrene foam.