Static structures (e.g. – buildings) – Facers; e.g. – modules – mutually bonded by internal settable... – Retaining feature on module exterior
Reexamination Certificate
1999-03-25
2001-11-13
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Facers; e.g., modules, mutually bonded by internal settable...
Retaining feature on module exterior
C052S309800, C052S376000, C052S426000, C052S435000, C052S749100, C052S742140
Reexamination Certificate
active
06314696
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of building materials and, more specifically, to the field of non-removable insulating concrete forms.
2. Description of the Related Art
Reinforced concrete walls constructed using foam forming systems are well known in the building construction field, and many utilize “Insulating Concrete Forms” (ICFs). These systems all comprise an inner and outer panel spaced a specific distance apart, thus forming a void between panels into which concrete is placed. The differences between them center mainly around the “web”, whose function is to provide the specific parallel spacing desired between the foam panels; to hold the panels together; to resist the force of concrete during placement; and further to provide a system for attaching finishing materials to the wall.
U.S. Pat. No. 4,879,855 to Berrenberg discloses an attachment and reinforcement member for molded construction forms utilizing a web of expanded steel with flanges at right angles to the central web. U.S. Pat. No. 5,657,600 to Menson and U.S. Pat. No. 5,459,971 to Sparkman both show webs of polymeric material sharing a similar function as explained above. All of these prior art systems provide for the web to be embedded into the foam panels during manufacture. Each system provides for a specific form unit to be created, although there is no standard size, and most units are 48″L×16″H×11″D. The void between panels may also vary to form a concrete wall 6″ to 8″ thick.
All prior art systems which have been previously used by the inventor of the present invention provide such forms for the concrete wall. However, it was during the attachment of finishing materials to the wall that many inadequacies became apparent, as discussed below.
1. Metal webs preclude the use of nails for attaching any finishing materials to the wall. Thin sheet metal fails to hold nails and, therefore, screws must be used. Siding materials such as wood and vinyl, however, are most preferably nailed. Fasteners used for vinyl are hidden, therefore, screws could be used but getting tradespeople to accept screws is problematic. Screwguns, cords and batteries cannot replace the simplicity of a hammer. Wood sidings usually require that fasteners remain visible and, aesthetically speaking, screws would never be acceptable, considering that their use involves more labor and many tools. In order to use such finishes the entire building must be furred with wood strips made for the purpose, which is an additional step that is costly in labor and material and is inadequate in that a thin strip of untreated wood could hardly be expected to last long enough to provide the continuous holding power needed to support high quality siding designed and finished to last 50 years. If the attachment member is not integrated into the forming system, so as to save steps, and itself engineered to last as long as the walls are expected to last, then such a method should be abandoned.
A main advantage of ICF construction is that many traditional phases of construction are incorporated into a single step, i.e., foundation, insulation, framing, sheathing, and air barriers, that to build with the prior art ICF construction systems that do not allow tradespeople to use their choice of fastener is to invite their disapproval and ultimately slows the acceptance of ICF construction in general.
2. It has been found that the attachment flange in the prior art ICF construction usually did not extend fully from the top to the bottom of the form unit, the unit being 16″ tall. The flanges stopped 1″ from both the top and bottom, thereby leaving a space of 2″ where nothing could be attached. Although not all the prior art form units have this defect to this degree, none have one continuous attachment member extending from floor to ceiling, as provided for in the present invention.
3. Most molded units are manufactured in a central location which mandates long distance shipping costs to transport material around the country. In addition, block type forms are large and the space that will ultimately be filled with concrete takes up space, thereby limiting the amount of units that can be shipped per truck. This affects the total wall square footage that can be installed per truckload shipped.
4. The tendency of molded stackable units to float during the placement of concrete has been well documented and witnessed by most construction professionals with experience in the field. Wiring, taping, or otherwise fastening subsequent courses of ICF units to one another solves this problem although, in doing so, adds a step to the process. Floating occurs when concrete rapidly fills the void and the velocity of the rising material causes the very lightweight units to float upward. Once units float apart, it is very difficult, if not impossible, to properly position them again, which is a condition that can seriously affect the overall quality of the installation.
SUMMARY OF THE INVENTION
The prior art has been primarily the work of persons with backgrounds in the construction of walls built with concrete masonry units, hence, the propensity of block type systems. These prior art systems focus primarily upon the formation of a concrete wall which is the aspect that provides the building with its structural integrity. The present invention departs from this focus by introducing the concept of a lightweight structural frame that is primarily concerned with the attachment of materials to the wall after the concrete has been poured.
The present invention is the work of a carpenter who is familiar with the needs of those who follow the foundation installation. Present day carpentry makes use of dimensional lumber as its primary building component. There are various lengths and widths of material with which to work, and except for “the plans”, there are no set methods that must be followed to achieve the desired end. In this light, carpenters have much freedom and utilize very simple building components. These simple components, i.e., “boards”, can be cut in very complex ways and used to create very unique and complex structures.
The present invention is very similar to the “board”. It is, in fact, a hollow board. It is to wall studs what engineered wood I-joists are to dimensional lumberjoists. It can be made to various lengths and widths, installed vertically or horizontally for walls, and used as joists for floors. It is a new primary framing component. To enhance its simplicity and adaptability to all the variety of construction needs, the present invention has two main components in its assembly. The first is a wire reinforcement truss that can be made of various gauges of wire where the larger the gauge, the stronger the truss. The second component is the attachment stud which can also be made of various materials such as wood, metal, and polymeric composites, and in various sizes and shapes.
The present invention is then used to frame the shape of the desired structure with few limitations. It provides the framework for rigid foam panels that are shaped specifically to fit the framework. The panels provide foam-to-foam closure on the interior of both inner and outer wall panels. The present invention is also positioned to accept a wide variety ofpolymeric foam, and may utilize technological advancements in foam or other insulative rigid panels.
One embodiment of the present invention provides wooden studs held a specific distance apart by a galvanized welded wire reinforcement truss. Each stud is grooved in its center a specific depth and width to receive the preformed wire truss which is forced into the groove. Prior to insertion, an adhesive is applied into the groove. After insertion, mechanical fasteners are installed at precise points along the stud so as to preclude the withdrawal of the wire until the adhesive has had sufficient time to set and permanently bond the wire truss to the wooden stud. The present invention also provides for the use o
Armstrong Westerman Hattori McLeland & Naughton LLP
Friedman Carl D.
Wilkens Kevin D.
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