System for constructing insulated concrete structures

• US 20020124508A1
• Filed: 03/09/2001
• Published: 09/12/2002
• Est. Priority Date: 03/09/2001
• Status: Active Grant

• Current Assignee: Daniel D. Dunn, Daniel V. Sorensen, David C. Dunn
• Original Assignee: Daniel D. Dunn, Daniel V. Sorensen, David C. Dunn
• Inventors: Dunn, Daniel D., Dunn, David C., Sorensen, Daniel V.
• Granted Patent: US 6,647,686 B2
• Time in Patent Office: Days
• US Class Current: 52/426
• CPC Class Codes: E04B 2/8641 using dovetail-type connections
• CPC Class Codes: E04B 2002/867 Corner details

Abstract

A system for constructing insulated concrete structures comprising panels molded from a closed cell foam plastic, with a facing material attached to the outside surface of panels adding substantial strength to panels during material handling and construction, providing a substrate for finish materials and adding UV resistance to panel surfaces. Panels are placed horizontally in an opposing and parallel spaced-apart relationship. Vertical studs are embedded in panels extending the full height of the panels, each stud has a flange and groove connected with a web. Spreaders slide vertically into the grooves of studs in opposing panels creating a form with a cavity between panels. Each spreader has opposing flanges connected by horizontal members, horizontal members having multiple formations, thus when spreaders are stacked the formations compliment each other allowing wall reinforcing to be locked in any preferred location. A chase way is provided in panels to accommodate electrical wiring. Locations of studs and chase ways are shown by markings on the facing. Reinforcing clips provide additional means for securing wall reinforcing to maintain proper alignment. Panels are placed horizontally end to end in rows and stacked vertically, rows of panels being staggered from each other so panel ends in adjacent rows do not line up vertically. Spreaders are stacked vertically in such a manner as to engage studs half their height above and below horizontal joints between rows of panels. Hinged forms, corner forms and bearing ledge forms are also provided for versatility in constructing the above mentioned insulated concrete structures.

Claims

1. A system for constructing insulated concrete structures comprising:

panels molded from a closed cell foam plastic, having inside and outside surfaces, top, bottom and end edges, said panels placed horizontally in an opposing and parallel, spaced-apart relationship;

a facing material attached to the outside surface of each panel;

at least two vertical studs embedded in each panel extending the full height of the panels, said studs spaced longitudinally and parallel from each other;

a plurality of spreaders at each stud location, extending between opposing panels and engaging the studs in opposing panels thereby creating a form with a cavity between the inside surfaces of the panels;

a chase way provided in panels to accommodate electrical wiring, chase way located in panels between inside and outside surfaces of panels and parallel to inside and outside surfaces of panels;

reinforcing clips providing a means for securing wall reinforcing to maintain proper alignment.

2. The system for constructing insulated concrete structures as claimed in claim 1 wherein said foam plastic has adhesive capabilities, adhering to embedded studs and attached facing thereby forming an integral unit.

3. The system for constructing insulated concrete structures as claimed in claim 1 further comprising:

an interlocking means, a tongue extending from and parallel to the top edge of each panel, and a complementary groove recessed into and parallel to the bottom edge of each panel.

4. The system for constructing insulated concrete structures as claimed in claim 1 wherein the facing adds substantial strength to the panels,

provides a substrate for the application of finish materials, also

provides a UV resistant surface on the panels, and

is marked for visually locating embedded studs and chase ways.

5. The system for constructing insulated concrete structures as claimed in claim 1 wherein said studs comprise:

a flange for fastening finish materials to and a groove for receiving spreaders, with a web member extending there between to interconnect the flange and groove.

6. The system for constructing insulated concrete structures as claimed in claim 5 wherein said webs comprise:

a vertical member extending between and oriented transversely to the flange and the groove;

in a second embodiment the webs comprise a vertical member extending between and oriented transversely to the flange and the groove, having a plurality of apertures along its length.

7. The system for constructing insulated concrete structures as claimed in claim 1 wherein said spreaders comprise:

a first flange and second flange for engaging studs, flanges oriented in an opposing parallel relationship, flanges being connected by horizontal members, each horizontal member having multiple formations to accommodate wall reinforcing.

8. The system for constructing insulated concrete structures as claimed in claim 7 wherein formations in the topmost horizontal members are located in the top of said members, and

wherein formations in the bottommost horizontal members are located in the bottom of said members,

thus, when spreaders are stacked the formations in the top and bottom horizontal members compliment the formations of adjacent spreaders allowing wall reinforcing to be locked in any preferred location.

9. The system for constructing insulated concrete structures as claimed in claim 1 wherein said reinforcing clips comprise:

tempered deformed wire clips that provides additional means of securing wall reinforcing to maintain proper alignment.

10. In a system for constructing insulated concrete structures, a hinged form comprising:

panels molded from a closed cell foam plastic, having inside and outside surfaces, top, bottom and end edges, said panels placed horizontally in an opposing and parallel, spaced-apart relationship,

at least one horizontal or vertical hinge member embedded in at least one of the opposing panels, said hinge member having a first flange and a second flange oriented in an opposing and parallel relationship with a flexible hinge section between the flanges, flanges being connected to hinge section by web members, web members having a plurality of apertures along their length;

at least two vertical studs embedded in each panel, said studs spaced longitudinally and parallel from each other;

a plurality of spreaders at each stud location, extending between opposing panels and engaging the studs in opposing panels thereby creating a form with a cavity between the inside surfaces of the panels.

11. In a system for constructing insulated concrete structures, a corner form comprising:

inside and outside corner panels molded from a closed cell foam plastic, having inside and outside surfaces, top, bottom and end edges, said panels placed in an opposing and parallel, spaced-apart relationship;

at least two vertical studs embedded in each panel on each side of corner, studs extending substantially the full height of the panels, said studs spaced longitudinally and parallel from each other;

a plurality of spreaders at each stud location, extending between opposing panels and engaging the studs in opposing panels thereby creating a form with a cavity between the inside surfaces of the panels.

14. The system for constructing insulated concrete structures as claimed in claim 13 further comprising:

an interlocking means, a tongue extending from and parallel to the top edge of each panel, and a complementary groove recessed into and parallel to the bottom edge of each panel,

the embedded studs extending through the groove in each panel and the tongue of each panel having slots that correspond with the spacing of the studs, such that when forms are stacked the studs will engage the slots in the tongue of the row below, aligning studs of adjacent panels vertically.

15. The system for constructing insulated concrete structures as claimed in claim 13 wherein the end interface of panels comprises:

a stud halfway into, and protruding halfway from, the end edge of a first panel, and

a complimentary slot in the end edge of a second panel, such that when the panels are placed end to end the panels interlock and spreaders may be installed to connect the opposing pairs of panels.

12. In a system for constructing insulated concrete structures, a bearing ledge form comprising:

first and second panels molded from a closed cell foam plastic, having inside and outside surfaces, top, bottom and end edges, said panels placed in an opposing and parallel, spaced-apart relationship,

first panel extending vertically in a first plane, then extending on a second plane at an angle to first plane and then extending on a third plane parallel and offset to first plane, thus forming a haunch used as a bearing ledge;

at least two vertical studs embedded in first panel extending the height of first plane, said studs spaced longitudinally and parallel from each other;

at least two bearing ledge connectors embedded in first panel, located vertically above embedded studs,

said bearing ledge connectors having a partial height flange and a full height groove oriented in an opposing and parallel relation, connected by at least one horizontal member and a web,

said flange beginning at the top of the connector and extending downwards,

web extending at an angle from the bottom of the flange to the bottom of the groove, and having a plurality of apertures along its length,

horizontal member having formations to accommodate wall reinforcing;

at least two vertical studs embedded in second panel extending the full height of the panel, said studs spaced longitudinally and parallel from each other;

a plurality of spreaders at each stud location, extending between opposing panels and engaging the studs and bearing ledge connectors in opposing panels thereby creating a form with a cavity between the inside surfaces of the panels.

13. A system for constructing insulated concrete structures comprising:

multiple opposing form panels being placed end to end in horizontal rows and stacked vertically,

panels may be staggered from each other in such a manner that ends of opposing panels are offset and end joints between adjacent rows of stacked panels do not line up vertically;

at least two vertical studs embedded in each panel extending the full height of the panels;

a plurality of spreaders at each stud location, the spreaders being “

full height spreaders,”

substantially less in height than the vertical height of the panels, and “

half height spreaders,”

half the height of the full height spreaders,

spreaders being stacked vertically, starting with a half height spreader with full height spreaders thereafter, such that at the top of each row of panels there is a full height spreader that engages the studs in the row below half its height and engages the studs in the row above the remaining half of its height.