초록 ▼

The present invention uses insulating concrete forms (ICF) in the construction of residential buildings. An entire wall panel is formed from polystyrene panels that may be cut by a hot wire machine. If necessary, hat channel shaped metal may be inserted into hat channel slots. Columns of polystyrene

The present invention uses insulating concrete forms (ICF) in the construction of residential buildings. An entire wall panel is formed from polystyrene panels that may be cut by a hot wire machine. If necessary, hat channel shaped metal may be inserted into hat channel slots. Columns of polystyrene are removed so that concrete posts may be poured therein after the wall panel has been secured into place with rebar being located therein. Rebar and concrete also are formed along the top of the wall panel. Electrical and plumbing connection pathways are provided in the wall panel at the time of cutting with hot wire. Each wall panel is separately designed and cut by hot wire while still at the factory, but are all connected together to form an ICF residence. Openings are provided for doors and windows and are buck framed. Hat channels are inserted as necessary for strength and/or connection thereto.

대표청구항 ▼

1. A method of manufacturing an insulated form building, the method comprising the following steps: creating at least one passageway in a wall panel, said wall panel having an outer surface, said passageway operable to receive cabling, conduit, ducting, and/or pipes when the polystyrene is removed f

1. A method of manufacturing an insulated form building, the method comprising the following steps: creating at least one passageway in a wall panel, said wall panel having an outer surface, said passageway operable to receive cabling, conduit, ducting, and/or pipes when the polystyrene is removed from said passageway;creating at least one column in said wall panel, said column operable to receive structural fill material when the polystyrene is removed from said column;cutting from said outer surface into said wall panel at least until said cut path breaches said column opening, wherein said cut deviates from a straight line between said outer surface and said column opening to form a lip, said lip having abutting regions, said abutting regions compressing together when said structural fill material is introduced to said column opening;creating at least one support/alignment opening into said wall panel, said support/alignment opening operable to receive a material for supporting wall finish and/or aligning said panels;creating a male end in one end of said wall panel; andcreating a female end in another end of said wall panel, said other end being substantially opposite from said male end and wherein said female end is operable to receive the male end of another panel and thereby align the panels. 2. The method of claim 1, wherein said creating steps are performed at a location other than the final installation location. 3. The method of claim 1, with the additional steps of: creating a window void out of said wall panel, wherein said window void is operable to receive a window when the polystyrene is removed from said window void; and/orcreating a door void out of said wall panel, wherein said door void is operable to receive a door when the polystyrene is removed from said door void. 4. The method of claim 1, with the additional step of creating a top opening into a top of said wall panel, said top opening operable to receive structural fill material. 5. The method of claim 4, with the additional steps of: inserting said male end of a first wall panel into the female end of a second wall panel;removing the polystyrene from at least one column and thereby creating a column void;inserting at least one column reinforcing member into said column void;inserting at least one top reinforcing member into said top opening, said top reinforcing member coupled to said column reinforcing member;inserting structural fill material into said top opening and said column void substantially simultaneously. 6. The method of claim 4, with the additional steps of: removing the polystyrene from said support/alignment opening to create a support/alignment void; andinserting material for supporting wall finish and/or aligning said panels into said support/alignment void. 7. An insulated form building, the building comprising: at least one wall panel having an outer surface, said panel made substantially of polystyrene and comprising: a passageway opening, said passageway opening operable to receive cabling, conduit, ducting, and/or pipes when the polystyrene is removed from said passageway opening;a support/alignment opening, said support/alignment opening operable to receive a material for supporting wall finish and/or for aligning multiple of said panels;a column opening, said column opening operable to receive structural fill material when the polystyrene is removed from said column opening;a cut, said cut beginning from said outer surface and traveling into said wall panel at least until said cut breaches said column opening, wherein said cut deviates from a straight line between said outer surface and said column opening to form a lip, said lip having abutting regions, said abutting regions compressing together when said structural fill material is introduced to said column opening;a male end; anda female end, wherein said female end is operable to receive the male end of another panel and thereby align the panels. 8. The building of claim 7, wherein said male end is a tongue and said female end is a groove. 9. The building of claim 7, wherein said panel additionally comprises: a window opening, wherein said window opening is operable to receive a window when the polystyrene is removed from said window opening; and/ora door opening, wherein said door opening is operable to receive a door when the polystyrene is removed from said door opening. 10. The building of claim 9, wherein said panel additionally comprises: a window buck, said window buck coupled to the sides of said window opening after said polystyrene is removed from said window opening; and/ora door buck, said door buck coupled to the sides of said door opening after said polystyrene is removed from said door opening. 11. The building of claim 7, comprising at least two panels, wherein said male end of one panel is inserted into said female end of another panel to form a wall, said panels additionally comprising a top opening, said top opening operable to receive structural fill material. 12. The building of claim 11, wherein the polystyrene is removed from at least one of said column openings thereby creating a column void, wherein said column void is filled with structural fill material and at least one column reinforcing member. 13. The building of claim 12, wherein said top opening is substantially filled with structural fill material and at least one top reinforcing member, said top reinforcing member coupled to said column reinforcing member and wherein said column void and said top opening are filled with structural fill material substantially simultaneously. 14. The building of claim 13, wherein said column void and/or said top opening are lined with a substantially waterproof lining prior to filling with said structural fill material. 15. The building of claim 13, wherein a top plate is coupled to said structural fill material in said top opening immediately after said fill is inserted into said top opening. 16. The building of claim 7, wherein said panels include a full size panel and a top panel, wherein the height of said top panel is less than the height of said full size panel and said top panel is aligned with a top of said full size panel such that a void remains below a bottom of said top panel. 17. The building of claim 16, additionally comprising a bottom panel, wherein the combined height of said bottom panel and said top panel are less than the height of said full size panel and said bottom panel is aligned with a bottom of said full size panel such that said void is between a top of said bottom panel and said bottom of said top panel, said void operable to receive a window. 18. The building of claim 7, wherein said structural fill material is at least one of: concrete;sand;compacted earth;plastic;wood; andcomposite. 19. An insulated form building, the building comprising: at least two polystyrene wall panels, said panels comprising: an outer surface;an inner surface;a male end;a female end;a top;a bottom; anda series of openings, said openings between said outer surface and said inner surface, wherein said openings are made at a geographical location other than the final installation location and comprising: a passageway opening, said passageway opening operable to receive cabling, conduit, ducting, and/or pipes when the polystyrene is removed from said passageway opening;a support/alignment opening, said support/alignment opening operable to receive a material for supporting wall finish and/or aligning said panels when the polystyrene is removed from said support/alignment opening;a column opening, said column opening operable to receive structural fill material when the polystyrene is removed from said column opening;a cut, said cut beginning from said outer surface and traveling into said wall panel at least until said cut breaches said column opening, wherein said cut deviates from a straight line between said outer surface and said column opening to form a lip, said lip having abutting regions, said abutting regions compressing together when said structural fill material is introduced to said column opening; anda top opening, said top opening operable to receive structural fill material;wherein said female end of one panel receives the male end of another panel and thereby aligns the panels. 20. The building of claim 19, wherein: the polystyrene is removed from at least one of said passageway openings leaving a passageway void and cabling, conduit, ducting, and/or pipes are inserted into said passageway void;the polystyrene is removed from at least one of said support/alignment openings leaving a support/alignment opening void and material for supporting wall finish and/or aligning said panels is inserted into said support/alignment opening void;the polystyrene is removed from at least one of said column openings leaving a column void and at least one column reinforcing member is inserted into said column void; andat least one top reinforcing member is inserted into said top opening, said top reinforcing member coupled to said column reinforcing member and structural fill material is inserted into said top opening and said column void substantially simultaneously. 21. The building of claim 20, wherein said material for supporting wall finish and/or aligning said panels is a hat channel. 22. The building of claim 10, wherein said polystyrene is substantially one pound to two pound density foam.