Concrete form structure

Details Concrete form structure Concrete form structure

1999-12-22

2002-06-11

Stephan, Beth A. (Department: 1732)

Static structures (e.g., buildings)

Facer held by stiffener-type frame

Back-to-back facers spaced by concealed framing

C052S234000, C052S309120

Reexamination Certificate

active

06401417

ABSTRACT:

FIELD OF THE INVENTION
This invention relates generally to concrete forms and, particularly provides a concrete form structure capable of being retained as an integral part of the finished concrete formation.
BACKGROUND OF THE INVENTION
Pre-fabricated building panels have become increasingly popular in the building industry so as to provide a building structure erectable in less time and lower cost than conventional on site construction materials and techniques. Conventional pre-fabricated building wall systems have involved molding techniques which include the teardown of the forming means after the completion of the molding process. The prior art includes many different formations which may be completed at a factory site and shipped to the building construction site for installation. These systems generally offer little flexibility in design and construction. Often the molding techniques employed require the forming structures, i.e. the molds, to be separated from the molded pieces and require a mold or forming structure to be employed for each unit with that forming structure to be disassembled, occasionally destroyed and a new forming structure to be constructed for each piece produced. Not only does such singular forming structure use require the step of forming structure teardown for each building panel formed, resulting in additional expense in time and materials, but also results in reduced productivity of the completed building walls. Other conventional molding methods require the application of mold release materials to the interior walls of the mold structure, yet, in view of the size and weight of the resulting product, still require disassembly of the mold structure. In many instances, different molds must be constructed for the formation of the many varieties in function that must be provided for the completion of the intended buildings. Each change in function for the building wall requires construction of a one-time forming structure dedicated to the production of a single one of the specific function building wall. Some building walls must be installed with different footing structures, different framework forms such as including singular and multiple window frames, mounting upon stone beds, concrete footings, caissons, load-bearing frameworks, non-load bearing frameworks, building walls coupled or incorporating joists and joist supports, different types of bearing walls, interior and exterior non-load bearing and load bearing walls, variations in bracing, strapping, spandrel walls, coupling means for joining building wall units and panels together and other functional and constructional variables including variable heights, lengths and thickness.
Another problem encountered with the pre-fabricated wall systems proposed by the prior art is the difficulty in providing access therein for workmen to install in-wall and through-wall services. Further, production of pre-fabricated building walls and panels which offer facility in joining units together in constructing the buildings is another problem encountered with the use of such “prefabs”. Integration of inter-related units into the object being constructed also has been more difficult with the available structures and methods presently available to the construction art.
Further difficulty is experienced when considering combinations of different materials such as concrete wall panels with brick and/or brick facing. Such combinations of different construction materials have gained in popularity, where a section of the building being constructed includes concrete exterior walls and, in addition, brick faced sections. Providing pre-fabricated building walls which are combination brick facings and concrete panels is esthetically attractive but difficult and expensive to produce. Means to provide such combinations have not as yet been provided except by the use of embossing a brick pattern upon a concrete surface. The resultant product is far from the esthetic appearance obtained when actual brick is employed. The method and result produced in accordance with the method of the invention enables such contrasting materials to be provided.
Provision of versatile pre-fabricated wall systems and structures at relatively low cost for facile installation and production is a need also not fulfilled by the methods and structures offered by the prior art. Additionally, provision of pre-fabricated cementitious building wall panels which are relatively light in weight yet structurally strong, which can be used as basement walls, foundations, floors and roofs, which are esthetically and physically strong, which can be easily assembled to other of these elements, which are capable of varied attractive appearance, which offer excellent thermal-resistive characteristics and which are capable of multi-level incorporation, likewise has been sadly lacking.
A system that involves fully self-contained pre-fabricated building walls and panels which incorporate the forming structure as a part thereof, yet allows for considerable variation in the their interior, structural content, has not become available despite a long felt need therefor. It is this need that is satisfied with the pre-fabricated building panel system provided by the invention.
Of the plurality of pre-fabricated building walls provided by the prior art, several will be discussed hereinafter to illustrate the state of the art pertinent to the herein described invention. Among these are U.S. Pat. No. 5,526,629 (Cavaness, Jun. 18, 1996), 5,524,412 (Cori, Jun. 11, 1996), 4,276,730 (Lewis, Jul. 7, 1981), 4,494,353, (Lewis, Jan. 22, 1985, 4,885,884 (Schilger, Dec. 12,1989), 4,619,032 (Sudrabin, Oct. 28, 1986), 4,930,278 (Staresina et al, Jun. 5, 1990), 4,271,111 (Sheber, Jun. 2, 1981), 4,669,240 (Amormino, Jun. 11, 1987), 4,649,682 (Barrett,Jr, Mar. 17, 1987), 4,909,007 (Bodnar, Mar. 20, 1990), 3,885,008 (Martin, May 20, 1975), 4,751,803, (Zimmerman, Jun. 21, 1988), 3,965,635, (Renkert, Jun. 29, 1976), 4,570,398 (Zimmerman, Feb. 18, 1986), 4,605,529, (Zimmerman, Aug. 12, 1986), 3,730,476 (Prichard, Jr. May 1, 1973), 4,934,121, (Zimmerman, Jun. 19, 1990), 5,055,252 (Zimmerman, Oct. 8, 1991), 5,216,863 (Nesssa et al, Jun. 8, 1993) and 5,491,947 (Kim, Feb. 20, 1996).
Cavaness provides a composite building panel comprising a framework formed of a perimetric frame assembly, an array of plural elongate metal studs arranged parallel and spaced within the frame assembly. Each of the metal studs is of elongate C-shaped cross-sectional configuration with middle section wider than a pair of front and rear right angle flanges, the front one of the flanges being embedded in a concrete slab, the concrete slab defining the front of the panel and the remaining portions of the studs defining open spaces or cavities accessible for installation of services, insulation and means for joining one panel to others.
Once the frame assembly is completed, form members are attached about the perimeter thereof defining a mold for receiving the during the pouring of the concrete defining the concrete slab serving as the front of the panel. The floor of the mold is a forming pad adapted to rest upon a planar surface. The mold is oriented horizontally during the pouring of the concrete into the rear of the panel embedding the front portion of the stud, including the front flange thereof. The mold is knocked down (disassembled) when the curing of the concrete is completed.
The free portions of the stud array define cavities to provide for the installation of the requisite services, i.e. plumbing, electrical wiring and insulation. A wall board can be placed over the rear portion of the frame and attached thereto so that the cavities are covered, the wall board functioning as the interior facing wall of installed panel. The panels can be joined end to end by bolting the end studs forming a butt joint. Increased cost is experienced due to the necessity of disassembling the mold after each panel formation. Incorporation of the additional framework components required for varied functional building requirements w

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