Insulated concrete form and method of using same

• US 9,982,445 B2
• Filed: 04/17/2017
• Issued: 05/29/2018
• Est. Priority Date: 09/28/2011
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): Ference, James M
• Application Number:
  US15/489,649
• Publication Number:
  US 20170218644A1
• Time in Patent Office: 407 Days
• Field of Search: 5230911, 5230912, 52410, 52426, 52562, 52565, 5230916, 52699, 523094, 249 40, 249 41, 249190, 249216
• CPC Class Codes: E04B 1/161 with vertical and horizontal slabs, both being partially cast in situ
• CPC Class Codes: E04B 1/21 Connections specially adapted therefor
• CPC Class Codes: E04B 1/38 Connections for building structures in general
• CPC Class Codes: E04B 1/4178 Masonry wall ties with insulation-layer locating devices E04B1/7616; replacing or adding wall ties E04G23/0222
• CPC Class Codes: E04B 2/40 the walls being characterised by fillings in all cavities in order to form a wall construction
• CPC Class Codes: E04B 2/8647 with ties going through the forms
• CPC Class Codes: E04B 2002/8688 Scaffoldings or removable supports therefor
• CPC Class Codes: E04B 5/38 with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element beams placed against one another and acting as permanent forms E04B5/23
• CPC Class Codes: E04B 9/245 by means of screws, bolts or clamping strips held against the underside of the supporting construction E04B9/26 takes precedence
• CPC Class Codes: E04C 2/20 of plastics
• CPC Class Codes: E04C 5/168 Spacers connecting parts for reinforcements and spacing the reinforcements from the form
• CPC Class Codes: E04C 5/18 Spacers of metal or substantially of metal E04C5/168 takes precedence
• CPC Class Codes: E04C 5/20 of material other than metal or with only additional metal parts, e.g. concrete or plastics spacers with metal binding wires E04C5/168 takes precedence
• CPC Class Codes: E04F 13/0803 with load-supporting elongated furring elements between wall and covering elements
• CPC Class Codes: E04F 13/0832 without load-supporting elongated furring elements between wall and covering elements
• 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 11/12 of elements and beams which are mounted during erection of the shuttering to brace or couple the elementsE04G11/18 takes precedence
• CPC Class Codes: E04G 11/48 Supporting structures for shutterings or frames for floors or roofs struts E04G25/00
• CPC Class Codes: E04G 17/0654 remaining completely or partially embedded in the cast material
• CPC Class Codes: E04G 17/0658 remaining completely or partially embedded in the cast material
• CPC Class Codes: E04G 17/0754 : remaining completely or partially embedded in the cast material
• CPC Class Codes: E04G 17/14 : Bracing or strutting arrangements for formwalls; Devices for aligning forms E04G25/00 takes precedence; connecting and aligning E04G17/04
• CPC Class Codes: Y10T 29/49632 : Metal reinforcement member for nonmetallic, e.g., concrete, structural element

Abstract

The invention comprises a connector for a pair of opposed spaced concrete forming panels. The connector comprises an elongate spacer member having flanges formed thereon intermediate a central portion thereof and each opposite end thereof. A portion of at least one end of the spacer member is sized and shaped to selectively engage an elongate panel bracing member. A composite insulated concrete form and a method of using the insulated concrete form are also disclosed.

Claims

1. A method comprising:

providing a first foam insulating panel spaced from a second foam insulating panel, wherein the first foam insulating panel has a first primary surface and an opposite second primary surface, wherein the second foam insulating panel has a first primary surface and an opposite second primary surface, whereby a concrete receiving space is defined between the first primary surface of the first foam insulating panel and the first primary surface of the second foam insulating panel, wherein the first foam insulating panel comprises a first layer of reinforcing material disposed on the second primary surface of the first foam insulating panel;

supporting the first foam insulating panel in a vertical position with a first support structure comprising a plurality of horizontal frame members and at least one vertical frame member, wherein the plurality of horizontal frame members of the first support structure comprise a first horizontal frame member, a second horizontal frame member and a third horizontal frame member disposed intermediate the first and second horizontal frame members and wherein the first, second and third horizontal frame members are vertically spaced from each other, wherein the first layer of reinforcing material is disposed between the second primary surface of the first foam insulating panel and the first support structure;

supporting the second foam insulating panel in a vertical position with a second support structure comprising a plurality of horizontal frame members and at least one vertical frame member, wherein the plurality of horizontal frame members of the second support structure comprise a fourth horizontal frame member, a fifth horizontal frame member and a sixth horizontal frame member disposed intermediate the fourth and fifth horizontal frame members and wherein the fourth, fifth and sixth horizontal frame members are vertically spaced from each other;

placing a quantity of plastic concrete in the concrete receiving space;

allowing the quantity of plastic concrete in the concrete receiving space to at least partially cure; and

removing the first and second support structures.

2. The method of claim 1, wherein the first and second foam insulating panels each comprise polystyrene, polyisocyanurate or polyurethane.

3. The method of claim 2, wherein the first and second foam insulating panels each have a thickness of at least 2 inches.

4. The method of claim 2, wherein the first and second foam insulating panels each have a thickness of at least 3 inches.

5. The method of claim 2, wherein the first and second foam insulating panels each have a thickness of at least 4 inches.

6. The method of claim 2, wherein the first and second foam insulating panels each have a thickness of approximately 2 inches to approximately 8 inches.

7. The method of claim 1, wherein the second foam insulating panel comprises a second layer of reinforcing material disposed on the second primary surface of the second foam insulating panel.

8. The method of claim 7, wherein the first and second layers of reinforcing material each comprise a woven fabric, a nonwoven fabric, a continuous material or a discontinuous material.

9. The method of claim 8, wherein the first and second layers of reinforcing material each comprise plastic or fiberglass.

10. The method of claim 8, wherein the first and second layers of reinforcing material each comprise a fiberglass mesh.

11. A method comprising:

providing a first foam insulating panel spaced from a second foam insulating panel, wherein the first foam insulating panel has a first primary surface and an opposite second primary surface, wherein the second foam insulating panel has a first primary surface and an opposite second primary surface, whereby a concrete receiving space is defined between the first primary surface of the first foam insulating panel and the first primary surface of the second foam insulating panel, wherein the first and second foam insulating panels comprise polystyrene, polyisocyanurate or polyurethane and have a thickness of at least 2 inches, wherein the first foam insulating panel comprises a first layer of reinforcing material disposed on the second primary surface of the first foam insulating panel, wherein the second foam insulating panel comprises a second layer of reinforcing material disposed on the second primary surface of the second foam insulating panel and wherein the first and second layers of reinforcing material each comprise a woven fabric, a nonwoven fabric, a continuous material or a discontinuous material;

supporting the first foam insulating panel in a vertical position with a first support structure comprising a plurality of horizontal frame members and at least one vertical frame member, wherein the plurality of horizontal frame members of the first support structure comprise a first horizontal frame member, a second horizontal frame member and a third horizontal frame member disposed intermediate the first and second horizontal frame members and wherein the first, second and third horizontal frame members are vertically spaced from each other, wherein the first layer of reinforcing material is disposed between the second primary surface of the first foam insulating panel and the first support structure;

supporting the second foam insulating panel in a vertical position with a second support structure comprising a plurality of horizontal frame members and at least one vertical frame member, wherein the plurality of horizontal frame members of the second support structure comprise a fourth horizontal frame member, a fifth horizontal frame member and a sixth horizontal frame member disposed intermediate the fourth and fifth horizontal frame members and wherein the fourth, fifth and sixth horizontal frame members are vertically spaced from each other, wherein the second layer of reinforcing material is disposed between the second primary surface of the second foam insulating panel and the second support structure;

placing a quantity of plastic concrete in the concrete receiving space;

allowing the quantity of plastic concrete in the concrete receiving space to at least partially cure; and

removing the first and second support structures.

12. The method of claim 11, wherein the first and second layers of reinforcing material each comprise a fiberglass mesh.