Reinforced insulated concrete form

• US 8,555,583 B2
• Filed: 04/02/2010
• Issued: 10/15/2013
• Est. Priority Date: 04/02/2010
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): Canfield, Robert
• Application Number:
  US12/753,220
• Publication Number:
  US 20110239566A1
• Time in Patent Office: 1,292 Days
• Field of Search: 523/091.1, 523/091.2, 523/14, 523/15, 524/26, 523/092, 526/52, 526/56, 249/41, 249/190
• US Class Current: 52/309.12
• CPC Class Codes: B23P 11/00 Connecting or disconnecting metal parts or objects by metal-working techniques not otherwise provided for connecting sheet metal or metal tubes, rods or profiles B21D39/00; riveting B21J; soldering, unsoldering, welding B23K; hand tools for connecting wire or strip B25B25/00; connecting metal parts by adhesives F16B11/00
• CPC Class Codes: E04B 1/161 with vertical and horizontal slabs, both being partially cast in situ
• CPC Class Codes: E04B 2/44 using elements having specially-designed means for stabilising the position; Spacers for cavity walls masonry wall ties E04B1/4178
• CPC Class Codes: E04B 2/8617 with spacers being embedded in both form leaves
• CPC Class Codes: E04B 2/8647 with ties going through the forms
• CPC Class Codes: E04C 2/20 of plastics
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04C 5/07 Reinforcing elements of material other than metal, e.g. of glass, of plastics, or not exclusively made of metal metal elements with non-structural coatings E04C5/01
• CPC Class Codes: E04F 13/00 Coverings or linings, e.g. for walls or ceilings flooring E04F15/00; decoration of surfaces, mosaic work B44, e.g. paper-hanging B44C7/00; made of webs, e.g. of fabrics or wallpaper , as such, or their manufacturing D03D, D04G, D04H, D06N, D21H; construction of false ceilings E04B9/00; roofings or similar water-tight coverings against precipitation E04D
• CPC Class Codes: E04G 11/06 for walls, e.g. curved end panels for wall shutterings; filler elements for wall shutterings; shutterings for vertical ductsE04G11/04 takes precedence
• CPC Class Codes: E04G 17/0658 remaining completely or partially embedded in the cast material
• CPC Class Codes: E04G 9/05 the form surface being of plastics
• CPC Class Codes: F16B 19/004 made in one piece F16B21/084 takes precedence
• CPC Class Codes: F16B 21/071 the socket being integrally formed with a component to be fasted, e.g. a sheet, plate or strip
• CPC Class Codes: F16B 21/086 the shank of the stud, pin or spigot having elevations, ribs, fins or prongs intended for deformation or tilting predominantly in a direction perpendicular to the direction of insertion
• CPC Class Codes: F16B 5/065 the plates being one on top of the other and distanced from each other, e.g. by using protrusions to keep contact and distance
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1057 Subsequent to assembly of laminae
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

The invention comprises a foam insulating panel having an outer surface and a reinforcing member adhered to at least a portion of the outer surface of the foam insulating panel. An insulated concrete form and a method of using the insulated concrete form are also disclosed.

Claims

1. A product comprising:

a first foam insulating panel having a first primary surface and an opposite second primary surface, wherein the first foam insulating panel is polystyrene foam;

a first reinforcing member contacting and substantially covering the first primary surface of the first foam insulating panel, wherein the first reinforcing member is a discontinuous layer or a mesh;

a quantity of plastic concrete disposed on the second primary surface of the first foam insulating panel; and

an anchor member comprising a first enlarged portion and an elongate portion, wherein the first enlarged portion is adjacent a first end of the elongate portion, the anchor member being disposed such that the elongate portion extends at least partially through the first foam insulating panel and at least a portion of the first reinforcing member is disposed between the first primary surface of the first foam insulating panel and the first enlarged portion of the anchor member and wherein at least a portion of the elongate portion is embedded in the quantity of plastic concrete, wherein the first enlarged portion is a flange extending radially outwardly from the elongate portion.

2. The product of claim 1, wherein the first reinforcing member is made from plastic or fiberglass.

3. The product of claim 1, wherein the first reinforcing member is a fiberglass mesh.

4. The product of claim 1 further comprising an exterior finish material attached to the first reinforcing member.

5. The product of claim 4, wherein the exterior finish material is stucco, thin brick, tile, stone, an acrylic finish or gypsum board.

6. The product of claim 1 further comprising:

a second foam insulating panel spaced from the first foam insulating panel and having a first primary surface and an opposite second primary surface, wherein the second foam insulating panel is polystyrene foam;

a second reinforcing member substantially covering the first primary surface of the second foam insulating panel; and

wherein the quantity of plastic concrete is disposed between the first and second foam insulating panels and is disposed on the second primary surface of the second foam insulating panel.

7. The product of claim 6, wherein the anchor member further comprises a second enlarged portion adjacent a second end of the elongate portion, wherein the elongate portion extends through both the first and second foam insulating panel and wherein at least a portion of the second reinforcing member is disposed between the first primary surface of the second foam insulating panel and the second enlarged portion of the anchor member.

8. The product of claim 7 further comprising an interior finish material attached to the second reinforcing member.

9. The product of claim 8, wherein the interior finish material is stucco, thin brick, tile, stone, an acrylic finish or gypsum board.

10. The product of claim 7, wherein the second enlarged portion comprises a disc-shaped member selectively attachable to the elongate portion.

11. The product of claim 7, wherein the elongate portion of the anchor member comprises a second collar adapted to form a seal with the second primary surface of the second foam insulating panel.

12. The product of claim 7, wherein the second enlarged portion is adapted to form a seal with the first primary surface of the second foam insulating panel.

13. The product of claim 7, wherein:

the second foam insulating panel has a first transverse edge and a second transverse edge;

the first foam insulating panel is parallel to and spaced from the second foam insulating panel, the first foam insulating panel has a first transverse edge and a second transverse edge, the first and second foam insulating panels being oriented vertically;

the first transverse edge of the second foam insulating panel being horizontally aligned with the first transverse edge of the first foam insulating panel; and

the second transverse edge of the first foam insulating panel being vertically higher than the second transverse edge of the second foam insulating panel.

14. The product of claim 13, wherein the second transverse edge of the first foam insulating panel is higher than the second transverse edge of the second foam insulating panel by an amount approximately equal to a thickness of a concrete ceiling formed adjacent the second transverse edge of the first foam insulating panel.

15. The product of claim 7, wherein the second reinforcing member is adhered to the first primary surface of the second foam insulating panel.

16. The product of claim 1, wherein the first enlarged portion comprises a disc-shaped member selectively attachable to the elongate portion.

17. The product of claim 1, wherein the elongate portion of the anchor member comprises a first collar adapted to form a seal with the second primary surface of the first foam insulating panel.

18. The product of claim 1, wherein the first enlarged portion is adapted to form a seal with the first primary surface of the first foam insulating panel.

19. The product of claim 1, wherein the first foam insulating panel is rectangular and has a first transverse edge and a second transverse edge, the first primary surface being longer in a longitudinal direction than the second primary surface adjacent the first transverse edge and the second primary surface being longer in a longitudinal direction than the first primary surface adjacent the second transverse edge.

20. The product of claim 1, wherein the first reinforcing member is adhered to the first primary surface of the first foam insulating panel.

21. The product of claim 1, wherein the first foam insulating panel is of a size such that it extends from a floor to a ceiling of a building.

22. The product of claim 1, wherein the first foam insulating panel defines an opening extending from the first primary surface to the second primary surface, the opening having a “

+”

shape.

23. The product of claim 1, wherein the quantity of plastic concrete is at least partially cured.

24. The product of claim 1, wherein the flange comprises a disc-shaped member selectively attachable to the elongate portion.

25. A product comprising:

a first foam insulating panel having an exterior primary surface and an opposite interior primary surface, wherein the first foam insulating panel is polystyrene foam;

a second foam insulating panel having an exterior primary surface and an opposite interior primary surface, wherein the second foam insulating panel is polystyrene foam, the second foam insulating panel being spaced from the first foam insulating panel, the interior primary surfaces of the first and second foam insulating panels defining a concrete receiving space therebetween;

a first reinforcing member contacting and substantially covering the exterior primary surface of the first foam insulating panel;

a second reinforcing member contacting and substantially covering the exterior primary surface of the second foam insulating panel;

an anchor member comprising a first enlarged portion, a second enlarged portion and an elongate portion, wherein the first enlarged portion is adjacent a first end of the elongate portion and the second enlarged portion is adjacent a second end of the elongate portion, the anchor member being disposed such that the elongate portion extends at least partially through the first and second foam insulating panels and at least a portion of the first reinforcing member is disposed between the first primary surface of the first foam insulating panel and the first enlarged portion of the anchor member and at least a portion of the second reinforcing member is disposed between the first primary surface of the second foam insulating panel and the second enlarged portion of the anchor member, wherein the first and second enlarged portions are selectively attachable to the elongate portion, but once attached to the elongate portion the first and second enlarged portions are not removable from the elongate portion.

26. The product of claim 25, wherein the first reinforcing member is a discontinuous layer, a mesh or a web.

27. The product of claim 25, wherein the first reinforcing member is a continuous layer, a fabric or a sheet.

28. The product of claim 25, wherein the first reinforcing member is a mesh.

29. The product of claim 25, wherein the first reinforcing member is made from plastic or fiberglass.

30. The product of claim 25, wherein the first reinforcing member is a fiberglass mesh.

31. The product of claim 25 further comprising an exterior finish material attached to the first reinforcing member.

32. The product of claim 31, wherein the exterior finish material is stucco, thin brick, tile, stone, an acrylic finish or gypsum board.

33. The product of claim 25 further comprising an interior finish material attached to the second reinforcing member.

34. The product of claim 33, wherein the interior finish material is stucco, thin brick, tile, stone, an acrylic finish or gypsum board.

35. The product of claim 25 further comprising a quantity of plastic concrete disposed between the first and second foam insulating panels and wherein the quantity of plastic concrete is disposed on the second primary surface of the first foam insulating panel and the second primary surface of the second foam insulating panel.

36. The product of claim 35, wherein the quantity of plastic concrete is at least partially cured.

37. The product of claim 25, wherein at least a portion of the elongate portion of the anchor member is embedded in the quantity of cured concrete.

38. The product of claim 25, wherein the first enlarged portion comprises a flange extending radially outwardly from the elongate portion.

39. The product of claim 25, wherein the first enlarged portion comprises a disc-shaped member selectively attachable to the elongate portion.

40. A product comprising:

a first foam insulating panel having an exterior primary surface and an opposite interior primary surface, wherein the first foam insulating panel is polystyrene foam;

a second foam insulating panel having an exterior primary surface and an opposite interior primary surface, wherein the second foam insulating panel is polystyrene foam, the second foam insulating panel being spaced from the first foam insulating panel, the interior primary surfaces of the first and second foam insulating panels defining a concrete receiving space therebetween;

a first reinforcing member contacting and substantially covering the exterior primary surface of the first foam insulating panel, wherein the first reinforcing member is a discontinuous layer or a mesh;

a second reinforcing member contacting and substantially covering the exterior primary surface of the second foam insulating panel, wherein the second reinforcing member is a discontinuous layer or a mesh; and

an anchor member comprising a first enlarged portion, a second enlarged portion and an elongate portion, wherein the first enlarged portion is adjacent a first end of the elongate portion and the second enlarged portion is adjacent a second end of the elongate portion, the anchor member being disposed such that the elongate portion extends at least partially through the first and second foam insulating panels and at least a portion of the first reinforcing member is disposed between the first primary surface of the first foam insulating panel and the first enlarged portion of the anchor member and at least a portion of the second reinforcing member is disposed between the first primary surface of the second foam insulating panel and the second enlarged portion of the anchor member; and

a quantity of at least partially cured concrete disposed between the first and second foam insulating panels and wherein the quantity of at least partially cured concrete is adhered to the second primary surface of the first foam insulating panel and to the second primary surface of the second foam insulating panel.