Surface panel and associated ICF system for creating decorative and utilitarian surfaces on concrete structures

• US 6,360,505 B1
• Filed: 09/03/1999
• Issued: 03/26/2002
• Est. Priority Date: 09/04/1998
• Status: Expired due to Fees

• Current Assignee: Michael Boynoff
• Original Assignee: Michael Boynoff
• Inventors: Johns, William A.
• Primary Examiner(s): Cuomo, Peter M.
• Assistant Examiner(s): Fisher, Michael J.
• Application Number:
  US09/389,725
• Time in Patent Office: 935 Days
• Field of Search: 523/111, 523/113, 523/15, 523/29, 523/39, 523/41, 524/26, 524/39, 525/926, 249/14, 249/15, 249/16
• US Class Current: 52/311.1
• CPC Class Codes: E04F 13/0733 for corners
• CPC Class Codes: E04F 13/147 with an outer layer imitating natural stone, brick work or the like
• CPC Class Codes: E04G 9/10 with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air

Abstract

A surface panel for creating decorative and utilitarian motif surfaces on concrete structures is disclosed. This surface panel allows motif surfaces of brick, stone, tile or siding to be applied to the exterior and interior of concrete structures. The surface panel can be used with other surface panels, or alternatively, as a component of an insulating concrete form (ICF) system. When used with an ICF system, the exterior surface of a concrete structure has a motif surface of brick, stone, tile or siding, while the interior of the structure has an insulating polystyrene surface. The surface panel described herein allows concrete structures including buildings, walls, pillars, and stanchions to be built efficiently and without skilled labor.

Claims

1. An insulating surface panel for creating concrete structures having motif components imbedded in a surface thereof, said surface panel comprising:

a) an exterior surface;

b) a plurality of motif components, each of said plurality of motif components having a front part and a back part;

c) an adhesive; and

d) an interior surface opposite from said exterior surface for contacting a pourable concrete mixture, said interior surface comprising a plurality of recessed regions separated by borders, each of said plurality of recessed regions being sized and shaped to conform to the front part of one of said plurality of motif components, wherein the front part of each of said plurality of motif components is glued into one of said plurality of recessed regions which conforms to the motif component'"'"'s front part, with said adhesive, such that the back part of each motif component protrudes beyond said interior surface; and

wherein said insulating surface panel is composed of an insulating foam, whereby each motif component is tightly secured in said insulating surface panel and the front part of each motif component is protected from contact with concrete.

2. The insulating surface panel of claim 1 wherein said insulating foam comprises polystyrene.

3. The insulating surface panel of claim 2 wherein said adhesive is a quickly deteriorating glue which deteriorates and releases each of said motif components from said insulating surface panel in about two days.

4. The surface panel of claim 3 further comprising a tongue along a first surface and a groove along a second surface, whereby a plurality of surface panels may be stacked.

5. The surface panel of claim 4 wherein said recessed regions comprise a rectangular planar bottom surface surrounded by substantially vertical boarders.

6. The surface panel of claim 5, wherein said plurality of motif components are bricks.

7. An insulating concrete form for creating a motif on at least one surface of a concrete structure when concrete is poured into the insulating concrete form, said insulating concrete form comprising:

a) an insulating interior panel, said insulating interior panel composed of an insulating foam and said insulating panel being oriented vertically;

b) an insulating surface panel positioned vertically and opposite from said insulating interior panel, said insulating surface panel composed of an insulating foam, comprising

i) an exterior surface,

ii) a plurality of motif components, each of said plurality of motif components having a front part and a back part,

iii) an adhesive; and

iv) an interior surface opposite from said exterior surface for contacting a pourable concrete mixture, said interior surface comprising a plurality of recessed regions separated by borders, each of said plurality of recessed regions being sized and shaped to conform to the front part of one of said plurality of motif components, wherein the front part of each of said plurality of motif components is glued into one of said plurality of recessed regions which conforms to the motif component'"'"'s front part, with said adhesive, such that the back part of each motif component protrudes above said interior surface;

whereby each motif component is tightly secured in said insulating surface panel and the front part of each motif component is protected from contact with concrete;

c) at least one spacer positioned between said insulating interior panel and said insulating surface panel to hold said insulating interior panel and said insulating surface panel in uniform spaced relation; and

d) a plurality of fasteners attached to said at least one spacer and extending through said insulating exterior panel and said insulating surface panel so as to hold said insulating interior panel and said insulating surface panel together to form a well for pouring a concrete mixture therein.

8. The insulating concrete form of claim 7 wherein said insulating foam comprises polystyrene.

9. The insulating surface panel of claim 8 wherein said adhesive is a quickly deteriorating adhesive which deteriorates and releases each of said motif components from said insulating surface panel in about two days.

10. The insulating concrete form of claim 9 further comprising a first support panel disposed outside of said insulating surface panel and a second support panel disposed outside of said insulating interior panel such that said first support panel is held in place by at least one of said plurality of fasteners and said second support panel is held in place by at least one of said plurality of fasteners, whereby said first support panel and said second support panel provide structural strength to said insulating concrete form.

11. The insulating concrete form of claim 10 wherein said at least one spacer is sinusoidally shaped so as to provide a guide for positioning reinforcing bars within the valleys of said at least one spacer.

12. The insulating concrete form of claim 10 wherein said insulating interior panel comprises:

a) a second exterior surface,

b) a second plurality of motif components, each of said second plurality of motif components having a front part and a back part,

c) an adhesive; and

d) a second interior surface opposite from said second exterior surface for contacting a pourable concrete mixture, said second interior surface comprising a second plurality of recessed regions separated by borders, each of said second plurality of recessed regions being sized and shaped to conform to the front part of one of said second plurality of motif components, wherein the front part of each of said second plurality of motif components is glued into one of said second plurality of recessed regions which conforms to the one motif component'"'"'s front part, with said adhesive, such that the back part of each of said second plurality of motif components protrudes above said second interior surface, whereby the front part of each of said second plurality of motif components is protected from contact with concrete, and whereby said insulating concrete form creates a concrete structure with motif components imbedded on two surfaces when concrete is poured into the form.

13. The insulating concrete form of claim 10 wherein said first support panel and said second support panel are chosen from the group consisting of plywood sheets and reinforced plastic panels.

14. A method for casting in place a vertical concrete structural wall with at least one surface decorated with motif components imbedded therein comprising the steps of:

a) erecting an insulating concrete form in position to cast said vertical structural wall, said insulating concrete form comprising

i) an insulating interior panel composed of an insulating foam,

ii) an insulating surface panel composed of said insulating foam, positioned opposite said insulating interior panel, said insulating surface panel comprising an exterior surface, and an interior surface opposite from said exterior surface for contacting a pourable concrete mixture, said interior surface comprising a plurality of recessed regions separated by borders,

iii) at least one spacer positioned between said insulating exterior panel and said insulating surface panel to hold said insulating exterior panel and said insulating surface panel in uniform spaced relation, and

iv) a plurality of fasteners attached to said at least one spacer and extending through said insulating exterior panel and said insulating surface panel so as to hold said insulating interior panel and said insulating surface panel together to form a well for pouring a concrete mixture therein;

b) gluing a plurality of motif components, each motif component having a front part and a back part, into said recessed regions of said interior surface of said insulating surface panel with an adhesive, wherein the front part of each of said plurality of motif components is glued into one of said plurality of recessed regions such that it is formably held within the one region into which it is glued, and such that the back part of each motif component protrudes above said interior surface;

c) filling the well of said insulating concrete form with a pourable concrete mixture to form the structural wall therein;

d) allowing said pourable concrete wall to cure in place;

e) removing said insulating surface panel to reveal a wall surface with motif components imbedded therein.

15. The method of claim 14 wherein said insulating foam comprises polystyrene.

16. The method of claim 15 wherein said adhesive is a quickly deteriorating adhesive which deteriorates and releases each of said motif components from said insulating surface panel in about two days.

17. The method of claim 16 wherein;

a) said insulating interior panel comprises a second exterior surface, and a second interior surface opposite from said second exterior surface for contacting a pourable concrete mixture, said second interior surface comprising a second plurality of recessed regions separated by borders; and

b) wherein the method further comprises the steps of;

i) gluing a second plurality of motif components, each of said second plurality of motif components having a front part and a back part, into said recessed regions of said second interior surface of said insulating interior panel, wherein the front part of each of said second plurality of motif components is glued into one of said second plurality of recessed regions such that it is formably held within the one recessed region into which it is glued, and such that the back part of each of said second plurality of motif components protrudes above said second interior surface, and

ii) removing said insulating panel after said pourable concrete wall has cured to reveal a second surface of said wall with motif components imbedded therein.

18. A concrete wall constructed according to the method of claim 15.