Multiple layer polymer foam and concrete system for forming concrete walls, panels, floors, and decks

• US 20080041004A1
• Filed: 08/15/2006
• Published: 02/21/2008
• Est. Priority Date: 08/15/2006
• Status: Active Grant

• Current Assignee: Gibbar Family Irrevocable Trust
• Original Assignee: Faye F. Gibbar, James H. Gibbar
• Inventors: Gibbar, Faye F., Gibbar, James H.
• Granted Patent: US 7,810,293 B2
• Time in Patent Office: Days
• US Class Current: 52/309.12
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material

Abstract

Multiple layers of polymer foam form structural concrete into a desired planar shape that retains a foam panel when flat or upright. The polymer foam has a planar shape and an exterior surface with multiple channels into the panel. The channels are generally wider at the bottom and narrower towards the top, preferably a trapezoidal shape. In use, the panel is placed flat within a forming frame, exterior surface upwards. Then concrete is poured upon the exterior surface and into the channels. The trapezoidal shape of the channel prevents removal of the panel from the concrete. The concrete panel can then be used flat or upright as specified for a construction project.

Claims

1. An insulated concrete section comprising:

a foam panel generally rectangular in shape having a length much greater than its width, an exterior surface, an opposite interior surface, at least one chase in said interior face parallel to the length of said panel, at least one channel in said exterior face;

reinforcement located within and proximate to said channel and to said exterior face; and

,

concrete placed upon said exterior surface and into said channel forming a tee having an upright web, said concrete extending beyond said panel forming a header and an opposite footer across the width of said panel;

whereupon the concrete attains a certain thickness upon said exterior surface and said panel and said concrete attain a certain combined thickness.

2. The insulated concrete wall panel of claim 1 further comprising:

said chases having a rectangular shape in cross section; and

,

said channels having a rectangular shape in cross section of greater depth and width than said chases.

3. The insulated concrete wall panel of claim 2 further comprising:

at least one stud located within said at least one chase, secured to said reinforcement, and extending into said header and said footer.

4. The insulated concrete wall panel of claim 1 further comprising:

said channels having a generally contoured cross section with the wider base of the cross section towards said interior face formed in said channel thereby locking said panel onto said concrete.

5. The insulated concrete wall panel of claim 4 wherein said contoured channel is of a trapezoidal shape.

6. The insulated concrete wall panel of claim 4 wherein said channel has a contoured cross section with a wider base of the cross section towards the interior face of said tee formed in said channel.

7. The insulated concrete wall panel of claim 4 wherein said channel has a rectangular cross section

8. The insulated concrete wall panel of claim 4 further comprising:

at least one stud located within said at least one chase, secured to said reinforcement, and extending into said header and said footer.

9. The insulated concrete wall panel of claim 1 further comprising:

said reinforcement having at least one loop extending outward from said header for lifting said panel.

10. The insulated concrete wall panel of claim 1 further comprising:

said panel having at least one opening allowing communication through said exterior surface and said interior surface; and

,

said reinforcement having framing proximate said opening and towards said header, said framing transferring loads borne by said tees intersected by said opening.

11. The insulated concrete wall panel of claim 1 further comprising:

a concrete layer positioned upon said interior face of said panel, generally prior to placement of concrete upon the exterior surface of said foam panel.

12. The insulated concrete wall panel of claim 11 wherein outer layer of drywall, insulation, paneling, sheeting, plaster, additional concrete, textile or fabric affixed to the concrete layer positioned upon the interior surface of the formed panel.

13. The insulated concrete wall panel of claim 11 wherein the outer layer of concrete is continuous through the header and the footer of said panel and integrated with its interior reinforcement to create a continuous concrete bond between the inside and outside concrete panels in developing a structural composite having foam insulation intermediate thereof.

14. The insulated concrete wall panel of claim 1 and further comprising:

said exterior surface having a groove along the perimeter edge for insertion of an integrated edge form.

15. The insulated concrete wall panel of claim 3 and further comprising:

at least one metal tie securing within the exterior concrete and allowing movement for expansion and contraction.

16. The insulated concrete wall panel of claim 15 wherein said stud is provided within the foam, and embedded within the concrete to provide for adjustments in the panel design during usage.

17. The insulated concrete wall panel of claim 1 and further comprising:

said chase within the interior face being designed to retain electrical or plumbing conduits within the area of said chase.