A shaped insulation insert, an insulated concrete wall structure, and a method of producing same is disclosed. The insert is to be embedded in a concrete wall and comprises an elongate, rigid foam insert including an integrally formed base section and cap section symmetrically disposed on the base s
A shaped insulation insert, an insulated concrete wall structure, and a method of producing same is disclosed. The insert is to be embedded in a concrete wall and comprises an elongate, rigid foam insert including an integrally formed base section and cap section symmetrically disposed on the base section. The elongate insert has a length sufficient to form a vertical interior surface expanse of the concrete wall, and flat side surfaces that are sufficient to enable a plurality of inserts to be placed horizontally side-by-side to form a horizontal interior surface expanse of the concrete wall. The insert includes opposed end sections extending from outer ends of the intersection of the cap and base sections to an outer edge portion for disposing adjacent inserts in the concrete wall. The insulated concrete wall structure comprises an interior section including an inner insulation portion effective to produce a saving of concrete. The insulation portion includes a plurality of shaped elongate insulation inserts embedded in an outer concrete portion. The elongate inserts each has flat side edge sections on outer edge portions and coupling devices grasp facing flat side edge sections of juxtaposed inserts each having flat edges to interconnect juxtaposed inserts in their side-by-side disposition. Vertical re-bar and horizontal reinforcement rods within the concrete portion provide strength compensation for the lesser amount of concrete used in the production of the concrete wall.
대표청구항▼
1. An insulation insert shaped to be embedded in a concrete wall structure, said insert consisting essentially of: a) an elongate, rigid foam insert including an integrally formed base section and a single cap section that is symmetrically disposed on the base section, which has a bottom outer base
1. An insulation insert shaped to be embedded in a concrete wall structure, said insert consisting essentially of: a) an elongate, rigid foam insert including an integrally formed base section and a single cap section that is symmetrically disposed on the base section, which has a bottom outer base surface and opposed base end sections each with a bottom, outer edge portion surface, an upper, outer edge portion surface to be embedded in the concrete of a concrete wall structure, and each base end section extends to an opposed outer flat end side surface that is perpendicular to said bottom and upper outer edge portion surfaces, said cap section having a top peak cap surface to be embedded in the concrete of a concrete wall structure;b) said bottom outer base surface being opposed to said upper, top peak cap surface and extends between said opposed outer flat end side surfaces, said bottom outer base surface having a length sufficient to form a vertical interior surface expanse of the concrete wall structure, and said outer flat end side surfaces are sufficient to enable said side surfaces of a plurality of inserts to be placed side-by-side to form a horizontal interior surface expanse of the concrete wall structure and said plurality of inserts thereby provides a corrugated shaped internal construction form including cap section side walls of adjacent inserts to provide a corrugated shape to the concrete that acts to create between cap section side walls of adjacent inserts vertically placed concrete columns in the concrete wall structure whereby said columns provide additional lateral and vertical strength to the wall structure and implements structural integrity to a concrete wall structure;c) said opposed base end sections each extend about 3″ outwardly from opposed intersections of the outer cap surface of said single cap section with the upper, outer edge portion surfaces to the outer flat end side surfaces of the opposed base end sections for disposing an entire top peak cap surface and upper, outer edge portion surfaces of each of said plurality of adjacent inserts in a concrete portion of said concrete wall structure;d) said opposed base end sections and cap section each have a thickness of about 2″ so that the insert has a thickness of about 4″ at its base and cap sections;e) said insert has an overall width between the outer, flat end side surfaces of the opposed base end sections selected from a group of about 15¾″ to about 17¾″, said top peak cap surface of said cap section has a width selected from a group of from about 8″ to about 10″, and the width between intersections where the symmetrically disposed cap section intersects the base section is from about 10″ to about 12″. 2. An insulation insert as defined in claim 1, wherein said insert is composed of polystyrene foam or any other suitable foam insulation. 3. An insulation insert as defined in claim 1, wherein said insert is composed of polymeric material selected from the group of polyvinyl chloride, polyethylene, polypropylene, and nylon. 4. An insulation insert as defined in claim 1, wherein said top peak cap surface includes two inclined side walls each extending from an outer end intersection of the cap and base sections to opposed outer ends of the width of the top of the peak cap section; andeach inclined side wall extends less than about 1″ outwardly of the width of the peak cap surface and depends on the amount of incline of the inclined surface portions. 5. An insulated concrete wall structure for a building, said wall structure consisting essentially of: a) an outer concrete portion and an inner insulation portion being effective to produce a saving of concrete;b) said insulation portion including a plurality of shaped vertically disposed elongate, rigid foam insulation inserts each having an integrally formed base section and a cap section symmetrically disposed on the base section;c) said cap section including a flat, top surface and two opposing inclined side walls each extending from intersections of the cap and base sections to opposed ends of said flat, top surface of the cap section, said cap section side walls of adjacent inserts act to create between adjacent inserts vertically placed corrugated concrete columns in the concrete wall structure whereby the columns provide additional lateral and vertical strength to the wall structure;d) each said base section includes opposed base end sections each with a bottom, outer edge portion surface, and an upper, outer edge portion surface that is embedded in said outer concrete portion, and each base end section extends about 3″ outwardly from each intersection of the cap and base sections to opposed outer flat end side surfaces that are perpendicular to said bottom and upper outer edge portion surfaces;e) coupling means for grasping facing flat end side edge surfaces with said perpendicular bottom and upper outer edge portion surfaces of juxtaposed inserts, to interconnect facing flat end side edge surfaces of said juxtaposed inserts in their side-by-side disposition; andf) vertical re-bar and horizontal reinforcement rods are located within the concrete portion to provide strength compensation for the lesser amount of concrete used in the production of said concrete wall structure. 6. An insulated concrete wall structure as defined in claim 5, wherein each insert has a length sufficient to form a vertical interior surface expanse of the concrete wall structure. 7. An insulated concrete wall structure as defined in claim 5, wherein said coupling means includes edge strips selected from the group of F-shaped edge strips, H-shaped edge strips, and C-shaped edge strips that fit over and receive adjacent facing flat end side edge surfaces with said perpendicular bottom and upper outer edge portion surfaces of juxtaposed insulation inserts,each said edge strip has inwardly directed projections that are embedded in said concrete portion and are effective to hold the insulation panels in place. 8. An insulated concrete wall structure as defined in claim 5, wherein said two cap section side walls each extend from an outer end intersection of the cap and base sections to opposed outer ends of the width of the top of the peak cap section; andeach inclined side wall extends outwardly of the width of the peak cap surface and depends on the amount of incline of the inclined surface portions. 9. An insulated concrete wall structure as defined in claim 8, wherein the overall depth thickness of the wall structure is selected from the group of about 9¾″ to about 11¾″; and the embedded inserts displace about 4″ of the concrete at said cap sections in the wall and about 2″ of concrete at the adjacent outer edge portions of said inserts. 10. An insulated concrete wall structure as defined in claim 5, wherein said embedded insulation inserts form the interior of the concrete portion and create a corrugated concrete shape construction needed to provided structural integrity to the insulated concrete wall structure. 11. A method for producing an insulated concrete wall structure, said method comprising: a) vertically disposing laterally spaced inner and outer molding surfaces to provide a wall mold cavity for forming said wall structure, said wall mold cavity having an upwardly directed top opening into which hardenable material is to be poured and hardened to produce said wall structure within said wall mold cavity,b) disposing an inner insulation portion against said inner molding surface to effectively produce a saving of concrete, said insulation portion including a plurality of shaped elongate insulation inserts each including an integrally formed base section and a single cap section that is symmetrically disposed on the base section to form opposed intersections therebetween, said base sections each has opposed end wall sections each with a bottom, outer edge portion surface, and an upper, outer edge portion surface, and each end wall section extends to an opposed outer flat end side surface that is perpendicular to the bottom and upper, outer edge portion surfaces, and said upper, outer edge portion surfaces, and said cap sections each has a top peak cap surface that are to be embedded in the concrete of a concrete wall structure;c) said elongate inserts each including outer edge portions each having a bottom and upper, edge potion surface and said flat end side edge surfaces that face adjacent inserts, and coupling means for grasping said bottom and upper, outer edge portion surfaces and said facing flat end side edge surfaces of juxtaposed inserts to interconnect juxtaposed inserts in their side-by-side disposition;d) said inserts each including opposed base end sections each extending about 3″ outwardly from said opposed intersections of the top peak cap surface of said single cap section to the outer flat end side surfaces of the opposed base end sections for disposing said top peak cap surface and upper, outer edge portion surfaces of each of said plurality of adjacent inserts in the concrete of said concrete wall structure;e) said opposed end sections and cap section each have a thickness of about 2″ so that the insert has a thickness of about 4″ at its base and cap sections;f) said insert has an overall width between the outer side surfaces of the outer opposed end sections selected from a group of about 15¾″ to about 17¾″, said flat top of the cap section has a width selected from a group of from about 8″ to about 10″, and the width between intersections where the symmetrically disposed cap section intersects the base section is from about 10″ to about 12″:g) disposing vertical re-bar at locations in the molding cavity laterally spaced inwardly from the coupling means connecting said outer edge portion surfaces of insulation inserts;h) disposing horizontal reinforcement rods at locations within the molding cavity to provide strength compensation for the lesser amount of concrete used in the production of said concrete wall structure;i) pouring hardenable material into said top opening and allowing it to harden to produce said insulated wall structure within said wall mold cavity having said embedded insulation inserts located on the interior of the mold cavity to create a shaped concrete construction needed to provide structural integrity to the insulated concrete wall structure; andj) removing said inner and outer molding surfaces of said wall mold cavity to reveal said concrete construction. 12. A method as defined in claim 11, wherein said horizontal reinforcement rods are laterally spaced within said mold cavity inwardly from the cap sections of the insulation inserts, said rods being disposed at a plurality of vertical locations that are laterally spaced with respect to each other within said mold cavity. 13. A method as defined in claim 11, wherein said plurality of shaped insulation inserts provide a corrugated insulation interior wall covering wherein the cap sections provide a corrugated form including cap section side walls that act to create between adjacent inserts vertically placed columns in the hardened concrete wall structure whereby said columns provide additional lateral and vertical strength to the wall structure. 14. An insulated concrete wall structure as defined in claim 5, wherein said coupling means includes H-shaped edge strips that fit over and receive adjacent facing flat end side edge surfaces with said perpendicular bottom and upper outer edge portion surfaces of juxtaposed insulation inserts,each said edge strip has inwardly directed projections that are embedded in said concrete portion and are effective to hold the insulation panels in place. 15. An insulation insert as defined in claim 1, wherein said base section has a width between the outer side surfaces of the outer opposed end sections of about 15¾″ for a mold cavity panel having a width of about 32″. 16. An insulation insert as defined in claim 1, wherein said base section has a width between the outer side surfaces of the outer opposed end sections of about 17¾″ for a mold cavity panel having a width of about 36″. 17. A method for producing a concrete building panel, said method comprising: a) providing a form having an upper end, a lower end, lateral edges extending therebetween, and a flat, horizontally disposed mold cavity side portion on which said form is placed to receive elements of the concrete building panel;b) providing a plurality of elongate, rigid foam inserts each including an integrally formed base section and cap section that is symmetrically disposed on the base section that includes opposed base end sections each with a bottom, outer edge portion surface, and an upper, outer edge portion surface, and each base end section extends about 3″ to an opposed outer flat end side edge surface that is perpendicular to said bottom and upper outer edge portion surfaces, and said cap section includes an top peak cap surface and the base section includes a bottom surface extending between opposed outer flat end side edge surfaces;c) said opposed base end sections each extends from opposed intersections of the top peak cap surface with the upper, outer edge portion surfaces to the outer flat end side surfaces of the opposed base end sections for disposing the top cap surface and upper, outer edge portion surfaces of adjacent inserts in the concrete of said concrete building panel;d) positioning within said form the plurality of elongate inserts side-by-side with said bottom surfaces of the inserts located side-by-side on said flat, horizontally disposed cavity side portion, and with coupling means grasping said facing flat end side edge surfaces and said perpendicular bottom and upper, outer edge portion surfaces of juxtaposed inserts to interconnect said juxtaposed inserts in their side-by-side disposition;e) positioning reinforcement rods within said form at locations laterally inwardly spaced from the coupling means and parallel to the elongate inserts;f) perpendicularly positioning further reinforcement rods to the parallel reinforcement rods within said form at locations inwardly laterally spaced from the outer peak cap surfaces and the upper, outer edge portion surfaces of the base sections of said juxtaposed inserts; andg) pouring hardenable concrete material into the mold cavity to form an outer concrete portion over the inserts and rods to embed the outer peak cap surfaces, the upper, outer edge portion surfaces of the base sections, and the rods in an outer concrete portion and allowing the concrete portion to harden to form said concrete building panel; andh) removing said concrete building panel from said form. 18. A method for producing a concrete building panel as defined in claim 17, wherein the overall depth thickness of said building panel is selected from the group of from about 9¾″ to about 11¾″;said peak of the cap section has a width selected from the group of from about 8″ to about 10″, and the width between the opposed intersections where the symmetrically disposed cap section intersects the base section is selected from the group of from about 10″ to about 12″;said opposed end sections and cap section each have a thickness of about 2″ so that the insert has a thickness of about 4″ at its base and cap sections;said insert has an overall width between the outer side surfaces of the outer opposed end sections selected from the group of from about 15¾″ to about 17¾″, said peak of the cap section has a width selected from the group of from about 8″ to about 10″, and the width between intersections where the symmetrically disposed cap section intersects the base section is selected from the group of from about 10″ to about 12″.
Tillie Etienne Lucien (La Colle sur Loup FR), Prefabricated structural elements for partitions and walls of buildings and partitions and walls consisting of such elem.
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