Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Patent
1995-06-07
1997-02-04
Smith, Creighton
Static structures (e.g., buildings)
With synthetic resinous component
Foam
52426, 52439, E04C 100
Patent
active
055986757
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The present invention relates to a building unit and more particularly, to a monolithic foam panel unit employed in concrete wall construction.
BACKGROUND OF THE INVENTION
There has been numerous related building units proposed in the art herein previously. Typically of the prior art arrange-ments is exemplified by U.S. Pat. No. 4,731,968. This reference discloses a building unit including the use of an apertured tie members for interconnecting the panels. The patentee extols the advantages of providing aperture in the tie which occupy pressure and tension zones within the foam panels when concrete is charged therebetween. The patentee does not teach a system of employing similar polymers for both the tie members and panels resulting in a superior unit.
Delozier, in U.S. Pat. No. 4,223,501, discloses a concrete form in which the panels are connected by both expanded metal ties and second apertured ties embedded into the panels. This patent does not disclose a fusibly interconnected system to which finishing material may be easily affixed, such as that of the present invention.
Young, in U.S. Pat. No. 4,706,429, teaches the use of a synthetic tie for interconnecting the panels. This system relies on slotted panels into which flanged sections of the ties interfit. The patent does not contemplate the advantages associated with fusible connection between tie and panel and further only provides a minor area on the flange portions, thus preventing rapid and simple fastening of finishing material to the assembled unit.
Further related prior art includes the following U.S. Pat. Nos. 4,228,962, 4,604,843, 4,706,429, 4,862,660, 4,889,310 and 5,065,561.
SUMMARY OF THE INVENTION
Although the prior art has provided a diverse range of structures for the ties and panels, there has been no provision for a fusibly interconnected unit. The present invention satiates the need for such an arrangement, and in one aspect of the invention there is provided an insulated wall construction form comprising: a pair of spaced apart panels, each having an inside surface and an outside surface adapted to receive concrete therebetween, the panels comprising a first polymer; and tie members extending between and interconnecting the panels, the tie members comprising a second polymer compatible with the first polymer for fused engagement with the panels.
The panels for use in the present invention, according to one embodiment, comprise expanded polystyrene (EPS) and serve as a permanent form for concrete construction. Such panels are particularly advantageous for using in building structures since speed of assembly is attractive as well as the exceptional thermal insulation properties. Generally speaking, EPS depending on the thickness and density thereof can provide an R value of 200 or greater in excess of code requirements. In addition, expanded polystyrene does not deteriorate in service, is non-nutritive to pests, rodents and insects and is one of the least energy consuming types of insulation to produce.
Generally speaking, other polymers will provide utility where the panel and tie are compatible such that fusion therebetween is possible. As a further example, one may employ expandable polypropylene for the panel composition and propylene or polyethylene for the tie. Other suitable combinations will be readily appreciated by those skilled.
In terms of the tie members, the use of a synthetic polymeric material completely circumvents problems and limitations previously encountered when metal ties were employed.
The use of metal ties establishes a thermal bridge thus having negative energy consequences. Further, metal ties, such as those in the prior art are only surrounded by the material of the panel, rather than being fused to form a consolidated monolithic unit. The "surrounding" type of wall is plagued with problems. One of the primary problems is that once positioned within the panel, subsequent application of auxiliary coverings, e.g. wallboard is difficult and often results in fasteners used for th
REFERENCES:
patent: 4229920 (1980-10-01), Lount
patent: 4288962 (1981-09-01), Kavanaugh
patent: 4706429 (1987-11-01), Young
patent: 4862660 (1989-09-01), Raymond
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