[특허]Apparatus and method for construction of structures utilizing insulated concrete forms

Airlite Plastics Co.

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특허 상세정보

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내보내기 페이스북 공유 트위터 공유 카카오톡 공유

Apparatus and method for construction of structures utilizing insulated concrete forms

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	E04B-002/00 E04C-005/00 E04C-005/07
미국특허분류(USC)	052/439; 052/309.11; 052/426; 052/404.1; 249/191; 249/216
출원번호	US-0665130 (2012-10-31)
등록번호	US-8919067 (2014-12-30)
발명자 / 주소	Crosby, Bradley J. Gredys, Patrick D. Klassen, Glen
출원인 / 주소	Airlite Plastics Co.
대리인 / 주소	Banner & Witcoff, Ltd.
인용정보	피인용 횟수 : 2 인용 특허 : 274

초록

An insulated concrete form including of first and second spaced sidewalls forming a cavity therebetween, said sidewalls having an inside surface and interconnected by a plurality of form ties, and a form insert made of an insulative material positioned adjacent the inside surface of at least one sidewall which thereby increases the R-value of the resulting structure.

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1. An assembly comprising: an insulated concrete form having a first sidewall, a second sidewall, and a plurality of form ties, wherein the first sidewall and the second sidewall are constructed of expanded polystyrene foam;the first sidewall having an inside surface, an outside surface, and a first sidewall thickness defined in a first horizontal direction between the inside surface and the outside surface;the first sidewall further having a first sidewall top surface, a first sidewall bottom surface, and a first sidewall height defined in a vertical direction between the first sidewall top surface and the first sidewall bottom surface;the first sidewall further having a first sidewall front side, a first sidewall rear side, and a first sidewall length defined in a second horizontal direction between the first sidewall front side and the first sidewall rear side;the plurality of form ties comprise a first form tie and a second form tie, wherein the first form tie and second form tie connect the first sidewall to the second sidewall such that the first form tie and the second form tie space the first sidewall from the second sidewall to define a cavity in between the first sidewall and the second sidewall, wherein a cavity thickness is defined in the first horizontal direction spanning between the first sidewall and the second sidewall;the first form tie having a first lateral member oriented transverse the first sidewall and the second sidewall;the second form tie having a second lateral member oriented transverse the first sidewall and the second sidewall;the first lateral member is spaced a distance from the second lateral member in the second horizontal direction along the first sidewall length of the insulated concrete form, wherein the distance between the first lateral member and the second lateral member in the second horizontal direction along the first sidewall length of the insulated concrete form is defined as a form tie spacing distance;wherein a first portional surface area of the inside surface of the first sidewall is defined in the vertical direction between the first sidewall top surface and the first sidewall bottom surface and in the second horizontal direction between the first lateral member and the second lateral member;a form insert having a form insert outward face, a form insert inward face, and a form insert thickness defined in the first horizontal direction between the form insert outward face and the form insert inward face, wherein the form insert thickness is about 5% to about 200% of the first sidewall thickness and less than the cavity thickness;the form insert further having a form insert front side, a form insert rear side, and a form insert length defined in the second horizontal direction between the form insert front side and the form insert rear side; andthe form insert further having a form insert top surface, a form insert bottom surface, and a form insert height defined in the vertical direction between the form insert top surface and the form insert bottom surface;the form insert further having a front ledge defined in the form insert front side and a rear ledge defined in the form insert rear side; wherein the front ledge is adapted to engage at least a portion of a first upper surface of the first lateral member and the rear ledge is adapted to engage at least a portion of a second upper surface of the second lateral member;the form insert further being formed of an insulative material and having an R-Value of at least about 4;wherein the form insert outward face is positioned in contact with the inside surface of the first sidewall such that the combined thickness of the first sidewall and the form insert is greater than the thickness of the second sidewall, and wherein the form insert outward face covers at least about 80% of the first portional surface area; andwherein the insulating concrete form and the form insert comprise permanent components of an insulated concrete structure comprising a concrete wall intermediate the form insert and the second sidewall of the insulated concrete form. 2. The assembly of claim 1 wherein the form insert is formed of expanded polystyrene foam and the form insert thickness is about 0.5 inch to about 3.0 inches and wherein the form insert front side is in contact with the first lateral member and the form insert rear side is in contact with the second lateral member. 3. The assembly of claim 1 wherein the plurality of form ties further comprise a plurality of lateral members, each of the plurality of lateral members being spaced a distance from at least one other of the plurality of lateral members in the second horizontal direction at a distance corresponding to the form tie spacing distance; a plurality of form inserts, wherein the plurality of form inserts are positioned such that an outward face of the plurality of inserts is in contact with the inside surface of the first sidewall. 4. The assembly of claim 1, the form insert further having a plurality of vertical slots defined in the form insert, each of the vertical slots having an open end defined in the form insert bottom surface and a closed end defined adjacent the form insert top surface; each of the vertical slots being spaced in the second horizontal direction at distance from at least one other of the vertical slots, the distance corresponding to the form tie spacing distance such that the vertical slots accommodate a plurality of lateral members of the plurality of form ties. 5. The assembly of claim 1 wherein an overall inside surface area of the first sidewall is defined in the vertical direction between the first sidewall top surface and the first sidewall bottom surface and in the second horizontal direction between the first sidewall front side and the first sidewall rear side; and wherein the outward face of the form insert covers at least about 80% of the overall inside surface area of the first sidewall. 6. The assembly of claim 1, wherein the front ledge and rear ledge are positioned at a predetermined distance from the form insert top surface so that the form insert top surface is substantially aligned with the first sidewall top surface when the front ledge is engaged with the first upper surface of the first lateral member and the rear ledge is engaged with the second upper surface of the second lateral member. 7. The assembly of claim 1, wherein the form insert front side is in contact with the first lateral member and the form insert rear side is in contact with the second lateral member. 8. An assembly comprising: an insulated concrete form having a first sidewall, a second sidewall, and a plurality of form ties, wherein the first sidewall and second sidewall are constructed of expanded polystyrene foam; the first sidewall having an inside surface, an outside surface, and a first sidewall thickness defined in a first horizontal direction between the inside surface and the outside surface; the first sidewall further having a first sidewall top surface, a first sidewall bottom surface, and a first sidewall height defined in a vertical direction between the first sidewall top surface and the first sidewall bottom surface;the first sidewall further having a first sidewall front side, a first sidewall rear side, and a first sidewall length defined in a second horizontal direction between the first sidewall front side and the first sidewall rear side;the plurality of form ties comprise a first form tie and a second form tie, wherein the first form tie and second form tie connect the first sidewall to the second sidewall such that the first form tie and the second form tie space the first sidewall from the second sidewall to define a cavity in between the first sidewall and the second sidewall, wherein a cavity thickness is defined in the first horizontal direction spanning between the first sidewall and the second sidewall;the first form tie having a first lateral member oriented transverse the first sidewall and the second sidewall;the second form tie having a second lateral member oriented transverse the first sidewall and the second sidewall;the first lateral member is spaced a distance from the second lateral member in the second horizontal direction along the first sidewall length of the insulated concrete form, wherein the distance between the first lateral member and the second lateral member in the second horizontal direction along the first sidewall length of the insulated concrete form is defined as a form tie spacing distance;wherein a first portional surface area of the inside surface of the first sidewall is defined in the vertical direction between the first sidewall top surface and the first sidewall bottom surface and in the second horizontal direction between the first lateral member and the second lateral member;a form insert having a form insert outward face, a form insert inward face, and a form insert thickness defined in the first horizontal direction between the form insert outward face and the form insert inward face;the form insert further having a form insert front side, a form insert rear side, and a form insert length defined in the second horizontal direction between the form insert front side and the form insert rear side; andthe insert further having a form insert top surface, a form insert bottom surface, and a form insert height defined in the vertical direction between the form insert top surface and the form insert bottom surface;a front ledge defined in the form insert front side and a rear ledge defined in the form insert rear side; wherein the front ledge engages a portion of a first upper surface of the first lateral member and the rear ledge engages a portion of a second upper surface of the second lateral member, wherein insert further having an R-Value of at least about 5;wherein the form insert front side is in contact with the first lateral member and the form insert rear side is in contact with the second lateral member;wherein the form insert outward face of the form insert is in contact with the inside surface of the first sidewall and wherein the form insert outward face of the form insert covers at least about 80% of the first portional surface area; andwherein the insulating concrete form and the form insert comprise permanent components of an insulated concrete structure comprising a concrete wall intermediate the form insert and the second sidewall of the insulated concrete form. 9. The assembly of claim 8, wherein the front ledge and rear ledge are positioned at a predetermined distance from the form insert top surface so that the form insert top surface is substantially aligned with the first sidewall top surface when the front ledge is engaged with the first upper surface of the first lateral member and the rear ledge is engaged with the second upper surface of the second lateral member. 10. The assembly of claim 9 wherein the form insert is formed of expanded polystyrene foam and the form insert thickness is about 0.5 inch to about 3.0 inches; wherein the form insert length increases from the form insert bottom surface toward the form insert top surface over at least a portion of the form insert height. 11. The assembly of claim 8, wherein the form insert front side and the form insert rear side having raised embossments adapted to enable friction fit engagement between the form insert and the first and second lateral members and wherein the form insert thickness is about 5% to about 200% of the first sidewall thickness and less than the cavity thickness. 12. The assembly of claim 11 wherein the form insert top surface is substantially aligned with the first sidewall top surface. 13. The assembly of claim 8, further comprising a second insulated concrete form having a third sidewall and a fourth sidewall; wherein the insulated concrete form is stacked onto the second insulated concrete form such that the first sidewall is stacked onto the third sidewall;wherein the form insert outward face is positioned in contact with an inside surface of the third sidewall; andwherein the form insert top surface is substantially aligned with a top surface of the first sidewall and the form insert bottom surface is substantially aligned with a bottom surface of the third sidewall. 14. The assembly of claim 13, the form insert top surface having groove and the form insert bottom surface having a tongue, the tongue and groove being complimentary such that a like tongue can interlock with the groove and a like groove can interlock with the tongue. 15. A kit comprising: an insulated concrete form having a first sidewall, a second sidewall, and a plurality of form ties, wherein the first sidewall and the second sidewall are constructed of expanded polystyrene foam;the first sidewall having an inside surface, an outside surface, and a first sidewall thickness defined in a first horizontal direction between the inside surface and the outside surface; the first sidewall further having a first sidewall top surface, a first sidewall bottom surface, and a first sidewall height defined in a vertical direction between the first sidewall top surface and the first sidewall bottom surface; the first sidewall further having a first sidewall front side, a first sidewall rear side, and a first sidewall length defined in a second horizontal direction between the first sidewall front side and the first sidewall rear side;the plurality of form ties comprise a first form tie and a second form tie, wherein the first form tie and second form tie connect the first sidewall to the second sidewall such that the first form tie and the second form tie space the first sidewall from the second sidewall to define a cavity in between the first sidewall and the second sidewall, wherein a cavity thickness is defined in the first horizontal direction spanning between the first sidewall and the second sidewall;the first form tie having a first lateral member oriented transverse the first sidewall and the second sidewall;the second form tie having a second lateral member oriented transverse the first sidewall and the second sidewall;the first lateral member is spaced a distance from the second lateral member in the second horizontal direction along the first sidewall length of the insulated concrete form, wherein the distance between the first lateral member and the second lateral member in the second horizontal direction along the first sidewall length of the insulated concrete form is defined as a form tie spacing distance;wherein a first portional surface area of the inside surface of the first sidewall is defined in the vertical direction between the first sidewall top surface and the first sidewall bottom surface and in the second horizontal direction between the first lateral member and the second lateral member;a form insert having a form insert outward face, a form insert inward face, and a form insert thickness defined in the first horizontal direction between the form insert outward face and the form insert inward face;the form insert further having a form insert front side, a form insert rear side, and a form insert length defined in the second horizontal direction between the form insert front side and the form insert rear side; andthe insert further having a form insert top surface, a form insert bottom surface, and a form insert height defined in the vertical direction between the form insert top surface and the form insert bottom surface;a front ledge defined in the form insert front side and a rear ledge defined in the form insert rear side; wherein the front ledge engages a portion of a first upper surface of the first lateral member and the rear ledge engages a portion of a second upper surface of the second lateral member, wherein insert further having an R-Value of at least about 5;wherein the form insert front side is adapted to contact the first lateral member and the form insert rear side is adapted to contact the second lateral member;wherein the form insert outward face of the form insert is adapted to contact the inside surface of the first sidewall and wherein the form insert outward face of the form insert is adapted to cover at least about 80% of the first portional surface area; andwherein the insulating concrete form and the form insert are adapted to comprise permanent components of an insulated concrete structure comprising a concrete wall intermediate the form insert and the second sidewall of the insulated concrete form. 16. The kit of claim 15 wherein the form insert is formed of expanded polystyrene foam, the form insert thickness is about 0.5 inch to about 3.0 inches, the form insert length increases from the form insert bottom surface toward the form insert top surface over at least a portion of the form insert height, the form insert thickness is about 5% to about 200% of the first sidewall thickness and less than the cavity thickness, and wherein the front ledge and rear ledge are positioned at a predetermined distance from the form insert top surface so that the form insert top surface is substantially aligned with the first sidewall top surface when the front ledge is engaged with the first upper surface of the first lateral member and the rear ledge is engaged with the second upper surface of the second lateral member. 17. An insulated concrete form assembly comprising: an insulated concrete form component having a first insulated concrete form insulation material sidewall, a separate second insulated concrete form insulation material sidewall, and a plurality of tie members connecting the first and second sidewalls; wherein the first and second sidewalls are constructed of expanded polystyrene foam; wherein the first sidewall including an inside surface, a generally parallel outside surface, and a generally uniform maximum first sidewall thickness defined between the inside surface and the outside surface; the first sidewall further including a first sidewall top surface, a first sidewall bottom surface, and a first sidewall height defined in a direction between the first sidewall top surface and the first sidewall bottom surface, said first sidewall height generally transverse to said first sidewall thickness;the first sidewall further including a sidewall first edge side, a sidewall second edge side spaced from the first edge side, and a first sidewall length between the first edge side and the second edge side;said second sidewall spaced from said first wall by at least two form ties connecting said first and second sidewalls to define cavity between the first sidewall and the second sidewall, said cavity having a first dimension between the first sidewall and the second sidewall;at least two said form ties separated from each other in said cavity by a fixed spacing distance portion of said first sidewall length;wherein a first portion surface area of the inside surface of the first sidewall is defined bounded between the first sidewall top surface and the first sidewall bottom surface and the first form tie and the second form tie;a separate insulating material form insert having an insert first face, an insert second face, and an insert thickness between the insert first face and the insert second face, wherein the insert thickness is in the range of about 5% to about 200% of the first sidewall thickness and is less than the cavity first dimension;the form insert further having an insert first side, an insert second side generally transverse to the first face and second face, and an insert length between the insert first side and the insert second side; andthe form insert further having an insert top surface, an insert bottom surface, and an insert height between the insert top surface and the insert bottom surface generally transverse to the first face and second face and transverse to the first side and second side;the form insert further having a front ledge defined in the first side and a rear ledge defined in the second side; wherein the front ledge engages a portion of the first form tie and the rear ledge engages a portion of the second form tie;wherein the form insert further having an R-Value of at least about 5;wherein the front ledge and rear ledge are positioned at a predetermined distance from the insert top surface so that the insert top surface is substantially aligned with the first sidewall top surface when the front ledge is engaged with the portion of the first form tie and the rear ledge is engaged with the portion of the second form tie;wherein the first face of the insert is positioned against the inside surface of the first sidewall and wherein the first face of the insert covers at least a fraction of the first portion surface area in the cavity of the inside face of said first sidewall whereby the volume of the cavity is reduced generally by the volume of the form insert in contact with the portion surface area of the first sidewall inside face cavity,said concrete form and separate insert form in combination a modified mold cavity bounded by insulating material comprised of said first and second sidewalls and said form insert, wherein the concrete form and separate insert comprise permanent components of an insulated concrete structure comprising a concrete wall the separate insert and the second sidewall of the concrete form. 18. A form insert for use with an insulated concrete form having a first sidewall, a second sidewall, and a plurality of form ties, wherein the first sidewall and the second sidewall are constructed of expanded polystyrene foam, wherein the first sidewall and the second sidewall are positioned opposite each other in a spaced apart relationship, the plurality of form ties extending transversely between the first sidewall and the second sidewall, each form tie having a lateral member, the form insert comprising: a form insert outward face, a form insert inward face, and a form insert thickness defined in a first horizontal direction between the form insert outward face and the form insert inward face;the form insert further having a form insert front side, a form insert rear side, and a form insert length defined in a second horizontal direction between the form insert front side and the form insert rear side;the form insert further having a form insert top surface, a form insert bottom surface, and a form insert height defined in the vertical direction between the form insert top surface and the form insert bottom surface;the form insert further having a front ledge defined in the form insert front side and a rear ledge defined in the form insert rear side; wherein the front ledge is adapted to engage a first lateral member and the rear ledge is adapted to engage a second lateral member when the form insert is positioned within an insulated concrete form in between the first and second lateral members;the form insert further being formed of an insulative material and being adapted to increase the R-Value of a resulting structure of concrete wall intermediate the first sidewall and second sidewall of the insulated concrete form by at least about 4; andwherein the insulating concrete form and the form insert are adapted to comprise permanent components of an insulated concrete structure comprising a concrete wall intermediate the form insert and the second sidewall of the insulated concrete form. 19. The form insert of claim 18 wherein the front ledge and the rear ledge are positioned at a predetermined distance from the form insert top surface such that the form insert is adapted so that the form insert top surface is substantially aligned with a first sidewall top surface when the front ledge is engaged with the first lateral member and the rear ledge is engaged with the second lateral member. 20. The form insert of claim 19 wherein at least one of the front ledge and the rear ledge is in the form of a vertical slot defined in the form insert. 21. The form insert of claim 20 wherein an open end of the vertical slot is defined in the form insert bottom surface. 22. The form insert of claim 1 wherein at least one of the front ledge and the rear ledge is in the form of a vertical slot defined in the form insert. 23. The form insert of claim 22 wherein an open end of the vertical slot is defined in the form insert bottom surface.

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Apparatus and method for construction of structures utilizing insulated concrete forms

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Apparatus and method for construction of structures utilizing insulated concrete forms

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