Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Reexamination Certificate
2000-04-28
2001-08-21
Chilcot, Richard (Department: 3635)
Static structures (e.g., buildings)
With synthetic resinous component
Foam
C052S309700, C052S309110, C052S309120, C052S426000, C428S318400
Reexamination Certificate
active
06276104
ABSTRACT:
This invention relates generally to insulated building walls and more particularly to insulated concrete building walls.
BACKGROUND OF THE INVENTION
A known means of improving thermal resistance of exterior concrete building walls involves using thermally insulating plastic foam panels as exterior sheathing. While suitable for below ground applications, this means has shortcomings in above ground installation. For example, exposed thermal insulation panel portions can be unsightly. In addition, exposed thermal insulation panel portions may degrade as a result of the weather.
An alternate means, which overcomes shortcomings due to exposed thermal insulation panel portions, provides a composite wall by embedding a thermal insulation panel between two layers of concrete. In building composite walls of this type, one begins with by setting into place spaced-apart rigid forms that define a cavity bounded by wall surfaces. One continues by placing a thermal insulation foam board having opposed major planar surfaces into the cavity to divide the cavity into two subcavities. Pouring concrete into the subcavities yields the composite wall after concrete curing and form removal. Punching connectors through the foam at approximately 12 inch (30.5 centimeter (cm)) intervals before pouring concrete into the subcavities forms a securely connected sandwich of the foam board between the concrete layers after the concrete has cured.
In order to prevent distortion or bursting of the thermal insulation boards, a customary practice involves pouring the concrete in stages, alternating between subcavities to balance forces applied by the weight of the concrete on the opposite sides of the foam boards or panels. For example, a 9 foot wall (2.7 meters (m)) may be formed by pouring concrete into a subcavity on one side of the foam board to a height of about 3 feet (0.9 m), then pouring concrete into a second subcavity on the other side of the foam panel to a height of about 6 feet (1.8 m), then pouring concrete to a height of about 9 feet (2.7 m) in the first subcavity, and then filling the remainder of the second subcavity. Pouring the concrete for composite concrete and foam board walls in stages is undesirable because, at the conclusion of each stage, it is generally necessary to stop pouring concrete, reposition equipment, and begin pouring the next stage. These steps can add significantly to the time required to construct the composite walls. It would be more desirable if the cavities on the opposite sides of the thermal insulation board could be filled with concrete without regard to balancing forces applied by the weight of the concrete on the opposite sides of the insulation panel.
SUMMARY OF THE INVENTION
The invention provides an improved method of forming a composite wall comprising a thermal insulation foam board disposed between concrete layers, and to the resulting composite wall. The thermal insulation foam board has opposed, spaced-apart and generally parallel primary surfaces each of which has a thermal plastic facer film adhered thereto. Each facer film has a thickness of from 0.35 mils (10 micrometers (&mgr;m) to 10.0 mils (250 &mgr;m), an ultimate elongation of less than (<) 200 percent (%) in both machine and transverse directions, a yield tensile strength of at least (≧) 7,000 pounds per square inch (psi) (48,400 kilopascals (kPa)) in both machine and transverse directions, and a 1% secant modulus ≧200,000 psi (1,380 megapascals (mPa)) in both machine and transverse directions. The facer films adhere to the panel with a peel strength of ≧100 grams per inch (gm/in) (39.4 gm/centimeter (gm/cm). Thermal insulation foam boards that have films bonded thereto and meet the above criteria are significantly stronger than thermal insulation foam boards that either lack such thermoplastic facer films or have facer films that fail such criteria.
In accordance with the method of the invention, set rigid forms into place to define a thickness for the composite wall and circumscribe a cavity. Set the thermal insulation foam board described above into place between the forms to define two subcavities, each subcavity being defined by a form and a proximate primary surface of the thermal insulation foam board. Fill the subcavities are filled with concrete. Cure the concrete to form a composite wall in accordance with the invention.
The significant improvement in the strength of the thermal insulation foam boards used in accordance with the method of this invention allows the concrete to be poured into the subcavities without regard to balancing forces applied by weight of the concrete against a primary surface of the insulation board. As a result, one subcavity can be completely filled to a height of, for example, 9 feet (2.7 m), while the subcavity on the other side of the insulation board remains unfilled, without causing significant distortion or rupture of the insulation panel The ability to fill the cavities with concrete without regard to balancing forces applied by the weight of the concrete can significantly reduce the time required to fabricate composite walls.
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patent: 4489530 (1984-12-01), Chang
patent: 4795763 (1989-01-01), Gluck et al.
patent: 4804366 (1989-02-01), Long
patent: 5335472 (1994-08-01), Phillips
patent: 5522194 (1996-06-01), Graulich
patent: 5673525 (1997-10-01), Keith et al.
patent: 5695870 (1997-12-01), Kelch et al.
patent: 2018875 (1979-10-01), None
patent: WO 97/18360 (1997-05-01), None
Plastic Foams, Part II; Frisch et al, pp. 544-585, Marcel Dekker, Inc., 1973.
Plastic Materials, Brydson, 5thedition, pp. 426-429, Butterworths, 1989.
Deibel Ronald D.
Long, Sr. Robert T.
Chilcot Richard
The Dow Chemical Company
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