Insulated concrete form and method of using same

Patent metadata

Field	Value
Publication number	US-9982445-B2
Application number	US-201715489649-A
Country	US
Kind code	B2
Filing date	Apr 17, 2017
Priority date	Sep 28, 2011
Publication date	May 29, 2018
Grant date	May 29, 2018

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.

First claim

What is claimed is:

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.

Assignees

• Ciuperca Romeo Ilarian

Inventors

• Ciuperca Romeo Ilarian

Classifications

• E04B1/4178

  Masonry wall ties (with insulation-layer locating devices E04B1/7616; replacing or adding wall ties E04G23/0222) · CPC title

• E04B1/161

  with vertical and horizontal slabs, both being partially cast in situ · CPC title

• E04F13/0803

  with load-supporting elongated furring elements between wall and covering elements · CPC title

• E04G11/12

  of elements and beams {which are mounted during erection of the shuttering to brace or couple the elements}(E04G11/18 takes precedence) · CPC title

• E04C5/20

  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 title