Interlocking and insulating form pattern assembly for...

Static structures (e.g. – buildings) – Facers; e.g. – modules – mutually bonded by internal settable... – Section filling hollow or channel module

Reexamination Certificate

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Details

C052S605000, C052S606000, C052S604000, C052S612000, C052S589100, C052S592100, C052S592400, C052S592500, C052S592600, C052S582100

Reexamination Certificate

active

06240693

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to insulating block forms having hollowed interiors which are used in creating a wall structure for receiving a poured concrete. More particularly, the present invention relates to a method for extrusion forming such a block form structure, such method being capable of producing a minimized number of blocks in erecting a typical wall structure.
2. Description of the Prior Art
Traditional building construction has in the past involved the use of cinder blocks formed out of cement which are transported to a job site and are arranged in a standard stacking fashion with the use of building mortar to construct a wall structure. While providing an effective means for constructing a wall, such cinder block assemblies are noted to be fairly highly temperature conductive in that they easily transfer both heat and cold through the wall to the surrounding internal environs. This fact has recently become more appreciated in view of the higher efficiency heating and cooling systems which are now in use.
Over the past several years conventional cinder blocks have been replaced to an extent by highly insulated building blocks constructed out of a plastic or expanded polystyrene. The purpose of such materials is to provide greatly increased thermal insulation or R values to the construction in an attempt to limit the loss of heat and cool air conductivity through the walls of the structure, particularly the foundation. The building blocks have a desired length, width and height and are typically hollowed internally in some desired fashion so that, upon stacking the blocks together, the hollowed internal portions form continuously extending horizontal and vertical channels for receiving a poured concrete. In this fashion, a wall structure can be effectively constructed from the form patterns and the concrete reinforcing added as a final construction step. Examples of such form block structures are illustrated in the art in U.S. Pat. Nos. 5,123,222 and 5,014,480, issued to Guarriello et al., U.S. Pat. No. 5,024,035, issued to Hanson et al., and U.S. Pat. Nos. 4,894,969 and 4,884,382, both issued to Horobin. A further example of an interlocking and insulated form pattern assembly for creating a wall structure for receiving such a poured concrete is illustrated in U.S. Pat. No. 5,839,243, issued to Martin, which teaches such a form pattern assembly which are stackable with the vertically and longitudinally filling passageways and which further includes separate moisture drainage channels extending in interconnected fashion both horizontally and vertically within the form structures so as to provide internal drainage of the form assembly.
SUMMARY OF THE PRESENT INVENTION
The present invention is a novel and improved interlocking and insulating form pattern assembly and method of manufacture for use in assembling a wall structure for receiving a poured concrete. The form pattern assembly includes an elongate form structure having a substantially rectangular configuration with a height, a length and a width. As will be subsequently described in more detail, the form structures provide a specific improvement over such prior art forms in that they are each typically manufactured in an extruding process so as to provide overall heights of either 4 or 6 feet, exclusive of their widths or unlimited overall running lengths, and further, upon being stacked according to a desired arrangement, will facilitate the construction of wall structures ranging from 8 to 12 feet and of generally unlimited lengths.
The form structure includes a plurality of interiorly and arcuately formed walls which define in combination a first plurality of vertically spaced and parallel extending concrete filling passageways. A second plurality of longitudinally spaced and parallel extending concrete filling passageways interconnect with the first plurality of vertically extending passageways and establish an overall conduit network within the associated form structure. Projecting tongue portions extend from first and second sides of each form structure and at least along selected locations of a first surface. Recessed groove portions likewise extend from first and second sides of the selected form structure and at least along selected locations of a second oppositely facing surface. The arrangement of the tongue and groove portions on opposite facing surfaces of each form structure permit an initial form structure to be stacked in aligned fashion upon one or more additional form structures according to a specified arrangement and so that the vertically extending passageways and the longitudinally extending passageways extend continuously throughout the overall stacking arrangement. Additional vertically extending cavities are formed through the form structure proximate the first and second sides. The cavities align upon creation of the stacking arrangement and each is suitable for receiving a fastener engageable and elongate insert for facilitating subsequent attachment of a wall covering surface against a selected side or sides of the wall structure.
The initial row of form structures of the stacking arrangement are set upon a footing and the stacking arrangement completed prior to the wall structure receiving a poured concrete to fill the vertically and longitudinally extending concrete filling passageways. The form structures, and particularly those forming the initial stacked row or those which are configured to correspond with a grading elevation exterior the structure, include a substantially “U” shaped recess formed within and extending along a selected outwardly facing surface of the form structure. An elongate brick ledge insert is provided and includes, in cross section, a first leg and a second angularly extending leg. The brick ledge is affixedly secured upon an upwardly facing shoulder surface of the “U” shaped recess and is suitable for being filled by cement to provide a level surface for a brick ledge for assembling an exterior brick wall.
According to a further preferred embodiment of the invention, a plurality of elongated and plasticized strips of material are secured against an exteriorly facing side of the form structure, and typically the inwardly facing side corresponding with a basement or upper floor of an enclosed structure. The strips are typically secured against the exterior facing surface at spaced apart intervals for facilitating subsequent attachment of drywall or other wall covering surface and provide a potential alternative to the use of the additional vertically extending cavities with fastener engageable and elongated inserts for providing a securing location for attaching the drywall.
According to a further preferred embodiment, a guide is provided for securing a first elongate form structure with a further elongate form structure in end-to-end fashion. The guide in one embodiment defines a generally “I” shape in cross section for receiving in axially extending fashion opposing inserting ends of the elongate form structures. The guide in another embodiment includes first and second spaced and parallel extending surfaces for abutting against oppositely facing surfaces of the form structure. The first and second extending surfaces are interconnected together by assembleable web portions extending therebetween, the web portions defining an end abutting surface between end faces of said form structures. The assembleable variant of the guide permits either axial end-to-end or angled corner location of succeeding form structures.
A method for producing a form pattern assembly is also disclosed according to the present invention and includes the steps of extruding the elongate form structure having a substantially rectangular configuration with a height, a length and a width. The extrusion includes a plurality of spaced apart, parallel extending and elongated concrete filling passageways which are defined by interiorly and arcuately extruded walls extending axially along the running extruded length. The ext

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