CA2204558A1 - Energy efficient light weight, container-form system - Google Patents

Abstract

In one basic form, the invention discloses a system with associated methods of providing a flexible and economical modular system for use as a container-form for building structures from typically light weight expandable foam, such as expandable polystyrene foam. The invention includes molding a component portion with spacers, then fabricating a module by coupling the various portions, such as wall components, to a variable spacing, yet with sufficient strength to withstand the rigors of such applications as the pouring of concrete structural walls. The module may cooperate with other modules to form a modular form. This spacing may be accomplished by either molding, trimming, removing or otherwise providing a certain length to the spacers in an area of the spacers nominated a variable length removable section. The spacers may also have a tapered centering configuration to assist in located reinforcing materials. The invention also describes the use of the container-form systems with structural walls to form, for instance, preformed walls, an insulated firewall system, a structural wall with a fitting formed integral with the wall, and other like uses and applications. The walls may even be semi-prefinished and may include attaching a foam form for insulation. Thus, a preformed insulating structural wall with finish surfaces could be made in a facility, hauled to a job site, quickly erected, and with minimal finishing, the walls completed. The finish surfaces could be connected to either the wall component, the structural wall member, or both and may be on one or both sides.

Description

~ENERGY 3:~FICIENT, LIG~tT WEIGI~T, CONTAINER-FORM SYSTl:M

This applir~tion claims the benefit of U.S. Provisional Application No.60/020,858, filed June 28, 1996.

The field ofthis invention relates to energy Pffi~Pnt light weight, container-form systems and methods for using such systems to hold or to form various m~tPri~le such as conventional and/or v ~ .OIl~ of sand, gravel, roc~, concrete. More specifically, it relates to light weight, cnnt~inPr-form systems for concrete wall building structures.

L BACKGROUND
The desire for a suitable light weight form for s~uc~ures has been known in various intllls~ries formanyyears. Aba_icconceptirlvolves~l~P,~ toproduceamaterialthatissubst~nti~llyplastic foam, and transform it into forms of various sizes and shapes that may be easily erected, display a S high degree of energy efflciency, exhibit the strength and rigidity to hold or form a material, such as concrete~ while w;ll~ g the ~ttent~nt weight and pressures and ...~i..l~;.~l..g a subst~nti~lly flat, straight, and level surface on both sides of the form with the ability to accept various finishes such as drywall (gypsum board), and siding or stucco. Such a product may offer several advantages over convention~l forms now in use. For example, a product ~ltili7ing light weight foam may be more 10 eco~1o.~- c~l to m~mlf~lre than a product using wood or ~lllmim~m as in a convçntion~l form. Also, there may be much less expense to the m~n-lf~ -rer as well as to the user (such as a builder), regarding injuries to wulkel~ caused by the weight of the co~lY~..Lional m~t~ri~l~ in use. Other economical factors may be the speed of erection of a light weight product and the inc~ tin~ varue that may be realized by leaving the foam forrn in place, after filling, as part of the wall structure.
Also, by leaving the forms in place, the time involved in removing the conventional forms from a completed or solidified structure may be reduced or elimin~ted-~ltholl~h this basic concept seems quite simple, in realitv it is not readily achievable by using currently available foam forms. To the collL.~uy, it is ~ttf .n~7ed by a variety of challenges and problems that have been prevalent during several decades that the light weight product has been in use with perhaps little improvement or solutions to the problems. This is a surprising aspect, considering the prevailing dpm~n~ and in many areas the trend toward requiring by statute and code, energy efficient wall structures. Although others have attempted such a co~ h,dlion, the solution has not been provided until this invention to combine features and to satisfy the requirements of the above desirable form product. This fact may be due to the te~çhing away from the present invention by the various styles of light weight forms using low density materials, one piece molds, and other fabricated forms that do not embody the concepts of the present invention.

1~ One of the most significant problems faced by those in these industries is that the foam components in the various current light weight products generally may not be sl.fficiently strong enough to with~t~nd the weight and pressures that are present with the use of materials such as co~ le. The,~r("t;, the user may experience failures of the product in a phenomenon referred to a~
"Blow-Outs," in which the form experiences partial loss of the contents, while being filled with materials, such as concrete, through fissures and breaks in the foam components, reslllting in signific~nt loss of time due to repairs. These Blow-Outs in light weight form systems may result~in signific~nt losses of the desired pe-rol~ ce aspects, loss of in~ ting value of the product, failure to achieve a s b~L~lLially flat, straight, and level surface on at le~st one side of the form sllffi~i~nt to receive a finish surface such as drywall (gypsum panels), siding or stucco, the possibi~ity of the final cost for the resulting structure being, higher than the conventional systems, and loss of other economic benefits. A second common problem experienced by those in these industries is the absence of a g system and techniques sufficient to ,..~ i" the foam members in these products in proper perspective relative to one another, to prevent the parting of the seams between these foam members which allows leakage of the contents, such as concrete, and causes "fioating" of the forms. Again, 10 this results in lost time and failure of the current foam form products to achieve the desired superior p~. r~ e and econornics over conventional form products. Because these problems appa~ ,Lly have not been entirely solved by prior products, the general attitude of the industry may have been focused toward more conventional forms such a plywood, steel, ~ minum, and so forth.

The m~mlf~ct~lre of light weight form systems commonly entails the use of polymeric 15 materials, such as Expandable Poly~ly~ene Foam (EPS), as the primary or basic material of choice, as is recognized by those in the art. Obviously, other m~tt~ri~lc could be used. For example and without limit~tic~n, expandable polyethylene, e~p~n~l~ble polyp,o~ylene, and other copolymers may be used (more generally referred to as ~ nd~ble foam in the claims). In combination with a variety of other materials and techniques, polymeric materials, such as EPS, may achieve many desired 20 aspects, namely: (1) Light weight, (2) High in.~ tinsg value, (3) Strength and rigidity, (4) Moldability into various sizes and shapes, and (5) Total ec~nomic~ However, in practice, the use of EPS has not been entirely suçc~fill due to the difficulties in actually producing a structurally sound product ~or the above: purposes.

The industry involved in the processing of EPS from raw material into usable products is known as the Foam Plastics, or Moldable Foam Plastics Industry. Two sections of this industry take 5 part in the m~mlf~ re of light weight foarn systems. "Board Molders" use metal molds and a steam process to ~.~r~l.n (typicallyby ~ .l,..g and fusion, known to those in the art) EPS raw material into foarn boards or billets, co. I ll l " l~ly in dpn~iti~s of 0.75 pounds per cubic foot to about 1.2~ pounds per cubic foot (pcf). The boards or billets may be molded into various sizes, such as about 50" wide by 26" thic}c by 190" or more in length. The boards or billets may be ~rimmPd and cut into various 10 sizes and sold to others who may fabricate the various foarns into products, such as light weight form systems. Both entities comrnonly cut and adhesively attach foam board to m~nllf~ctllre the basic board shapes into other products. Also, they may use other various materials such as hard plastics or metal to clamp or fasten foam boards together, instead of using integrally molded spacers, thus contributing to the costs of material and labor expenses. These methods involving cutting and 15 adhesively ~tt~hing are methods used to m~nl~f~ct~lre some of the light weight form systems. These are called "f~bric~ted systems." Since fabricated systems commonly use foam board cut from a board or billet, that material is from the inside of a much larger molded piece, and has no outer skin and may be less resistant to wear.

The other section of the Foam Plastics Industry involved in the m~mlf~ re of light weight 20 form systems, is the "Shape Molder." Shape Molders generally use metal molds and a steam process to L~ r~,. ,., EPS raw material (commonly a smaller pellet or bead size than the board molder) into molded shapes of various sizes and commonly in densities of 1.25 pcf to 8.0 pcf or even beyond.
Molders of EPS light weight form systems may commonly mold an entire module in one piece, comprising both sides of a wall for in~t~n5e However, this process has inherent diffic~ ies in S obtaining a sufficiently sized and structurally appropriate module for the use in form systems. For in~t~nc~ the modules may be short and require more rows of modules, talcing time and e~fort.
~r1flitinn~11y, because ofthe laclc of strength in many forms, multiple height layers may have difficulty w;~ t~ the stress and may require several stages of construction to build a structure such as a wall to a giYen height, adding additional time and expense. The molded forms commonly use metal 10 or plastics inserts in the mold, so the foam part forms around the inserts to help hold the form together and to hold the desired space between the form walls in which to pour material such as concrete. However, in use, it appears that sometimes these embedded inserts may rip through the foam form and cause a Blow-Out. Additionally, many foam forms attempt to use more foam to str~n th~n the module, but because the foam is generally left in place in this industry, the final 1~ reslllting structure includes sometimes more foarn than concrete and results in a weaker overall structure, such as a supporting wall.

Of the two systems mentioned above, (1) the totally fabricated systern, or (2) the totally molded system, both are commonly used in the m~mlf~ctllre of light weight form systems. Neither appears to have solved the problems commonly experienced by those in the building in~ tries that 20 are the primary market for these products. Fabricated systems may face much higher costs from using higher densities of foam board to achieve more strength to address the Blow-Out problems. Other problems, such as less fusion, may develop in the process of molding hi ,her densities of EPS foam in very large board molds that the board molders economically tend to use, as those in the art recognize. On ~he other hand, Shape Molded systems commonly mold the double wall form co~ onents in one piece by inserting various metal or hard plastic parts into the mold and mol~lin~
5 the foam material around the metal or plastic. This system may experience laclc of filling the mold properly because ofthe EPS m~tPri~l having to travel around the metal or plastic inserts in the mold.
.A~l~lition~lly, because the process of moklin~ the modules may be interrupted to insert the inserts, the process is more time con~ lming and may be less economical than desired.

While the broad concepts of this invention may seem straightforward in hin~ ht, it is 10 noteworthy that in appro,~ ely three dec~dçc, it does not appear that anyone has put the colllbil.alions of methods and devices together in this manner to make an economical, fiexible, and structurally sound module or modular system, especially for light weight systems using EPS.

The present invention discloses systems and techniques that may overcome many if not all of the previous problems in a practical fashion. It satisfies a long felt but llnc~fi~fied need (even though 15 the needed impl~m~nting arts and elements had long been available) in the market to achieve the economical and pelroll.,ance needs of the end users. Those in the art appreciated that a problem existed but appalelllly were unable to see the solution. Substantial attempts were made by those skilled in the art to fill the need, but they were unable to cope with the difficulties extant because of failure to understand the problem. Some of those skilled in the art actually may have taught away 20 from the technical direction in which the p~t~-ntee went by providing various structural support systems and densities not in keeping with those disclosed in this application.

IL SU~MARY OF INVENTION
The present invention inch~des a variety of molded and fabricated components that may be used in dif~renl combinations, depending upon the particular application to be addressed. In one basic form, ~he invention diccloses a system with associated methods of providing a flexible and economical module and modular system for use with container-form systems, structures, and me~hods. The invention focuses on mnldin~ a portion, typically one half, of a module with spacers, then fabricating the module by coupling the various portions, such as wall components, together to a given spacing. This spacing may be accomplished by either molding, l,i"""i"~, removing or 10 otherwise providing a certain length to the spacers in an area of the spacers nomin~ted a variable length removable section. The invention also describes the use of the container-form systems with structural walls which rnay form ~l~r ,-llled waUs. The present invention and the use of the forms may also be used to produce an jnc~ ted firewall system, a structural wall with a formed fitting integral with the wall, and other like uses and applications. The walls could even be prefinished. Thus, a 15 preformed ins~ tinp structural wall already semi-finished with finish surfaces could be made in a facility, hauled to a job site, quickly erected, and with minim~l finiching, the walls completed. The semi-finish s..rf~cPs could be conn~cted to either the wall component, the structural wall member, or both and may be on one or both sides. They could be connected by nailing, gluing or otherwise adhesively ~ rhing, screwing or using other threaded ~len~l~, or otherwise f~ctening to the desired 20 surface. The invention may also include allowing for a varying thickness wall and use of a variable wall thi~n~s transition component. Spacers may have a cr~.~P~ ;llg configuration. The structure such as a wall may include fitting components, such as corners, tees, 4-way crosses, and may be integral to the form to more readily produce a building structure. The present invention may also assist in curing the concrete or other solidifying materials by providing an in~ tin~ barrier. This inclll~ting effect may result in less use of curing admixtures, more uniformity of structural properties of the materials, and stronger material.

The present invention focuses upon solving the associated problems based on the observation that the light weight forrn systems presently experience a high percentage of Blow-Outs, resulting in their failure to meet the requirements of the market. In addition and in contrast to other designs in the .I.a.h~L~lace~ the present invention allows a combination of a contiguous structure (such as 10 conc-~le), accescible and relatively easy flow during the structure forming process, a stronger final structure from more material in the r~ tin~ structure, a more uniformly distributed support system, and a more uniformly dimensioned structure (such as a wall). The invention encompasses both appa-~L~Is and methods to achieve the res -ltin~ structure.

Generally, this invention may include light weight systems, and, speciiEically, may include 1~ expandable foam such as Expandable Polystyrene Foam (EPS). Different shapes, materials, and confi~lrations are possible and fill the need for an economic~l and practical solution to light weight form products. This m~teri~l also may be a "modified grade" polymeric material, such as EPS, which has fire resistant properties, known to those in the art.

The term "container-form" is meant to include those devices that could serve as a container for m~t~l such as loose fill dir~ sand, and so forth or even liquids or those devices that could serve as a form for use while producing a structure, such as a concrete wall or other solidified structure.
Naturally, the device could serve in both capacities.

Another aspect of the invention is that it provides for a container-form system in which the 5 components are assembled, or otherwise combined, and held in proper perspective, relative to one another, by use of a f~etPning system that, with properly fused and formed EPS foam components, is sllfficiently strong and rigid enough to achieve in many cases subst~nti~lly flat, straight and level sides. ~flrlition~lly~ it may be generally sllffi~i~nt to receive finiehee, such as drywall (gypsum board), siding, and stucco. Wlth other aspects, such as a tongue and groove or lap joint design that provides 10 for greater speed in the erection of the cc ~ -form system, it reduces or may even e1imin~te many of the problems experienced by others.

Another goal of this invention is to go further in addressing applications and new mar~ets where the previously used form systems are not able to respond. One object of this invention is to allow for molded decorative shapes and designs on one or both sides of the foam components, not 15 presently available in these industries, such as deco~alive l~n-l$c~ring using retainer and garden walls and other buiIding structures. For "~ r~ in the l~nrlec~ring marlcet, where decorative retainer and garden walls are commonly used, the present invention may respond by molding decorative shapes and designs, for i~ cP~, on the inside surfaces ofthe foam components ofthe form modules, so that the designs are L,~r~ d to the outside s~ cP,s ofthe formed solidifying material, such as concrete.
20 Afcer removal of the foam modules, the designs displayed on the concrete surfaces may be finiehed by using m~tPri~lc such as paint, plaster, or stucco. Alternatively, the material, such as concrete, may be tinted or colored or otherwise treated before forming.

IIL BRIEF DESC~IPTION OF T~IE DRAWINGS
Figure 1 is a drawing ~ s~ the side view of one basic concept of a wall component of 5 the cont~inçr-form prior to assembly.

Figure la is a drawing represtontin~ an assembled view of at least two wall components into a module.

Figure 2 is a drawing repr~s~nting the side view of the parts of a f~qt~nin~ system before assembly.

Figure 3 is a drawing representin~ the ~ic~qsPmhled components of one basic concept of a corner module viewed from a top view.

Figure 4 is a drawing representing the rliq~cs~mbled components of one basic concept of a "Tee" module viewed from a top view.

Figure 5 is a drawing repr~s~ntin~ the top view of a variety of assembled modules that may 15 be used in the container-form system.

Figure 6 is a d~dw~lg reyl~c~ the side view of sixteen assembled wall modules displaying a possible molded design on two of the modules.

Figure 7 is a drawing ~ r5~ g the side view of a formed concrete wall structure a~er the container-~orm has been removed, displaying a possible design left in the concrete surface.

Figure 8 is a perspec~ive drawing repr~nting a fully assembled wall module of one basic concept of the foam container-form system.

Figure 9 is a perspective drawing leples~ g one basic concept of a fully assembled foam fitting component, such as a corner component.

Figure 9a is a top view of a fitting component at an angle.

Figure 9b is a top view of a fitting component, such as a tee with varying wall thicknesses.

Figure 10 is a pel~e.;~ e drawing repres~nting one basic concept of a partially erected container-form system comprising multiple wall modules and fitting modules in a stacked array.

Figure lOa is a perspective drawing lepl ~s~ g the addition of walkways supported by the lS container-form system.

Figure 11 is a drawing representin~ a side view of a variable wall thiclcness transition co~ onent.

Figure 12 is a drawing le~lesr~ a perspective view of a formed wall sttucture with the forms removed.

Figure 13 is a top view of a pre~ormed wall member with a connected wall module, an ad~oining member, finish surfaces, and a lap joint, and a lap joint securing element.

Figure 14 is a side view of a possible arrangement to make a plerollned wall member.

Figure 15 shows a perspective view of a positioning element for the wall member.

Figure 16 shows a side view of a fire rated tie between wall components.

Figure 17 shows a top view of Figure 16 of a fire rated tie.

IV. DETAILED DESCRIPTION OF TEE PREFERRED EMBODIMENTS
As can be easily understood, the basic concepts of the present invention may be embodied in avariety of ways. It involves Soth methods and devices to accomplish the applopliate method. In this applic~tion the methods are ~ losed as part of the results shown to be achieved by the various 15 devices described and as steps that are inherent to utilization. They are simply the natural result of ~ltili7in~ the devices as intPntled and described. In addition, while some devices are disclosed,~it would be understood that these not only accomplish certain methods but also can be varied in many ways. Lllpol L~llly, as to the foregoing, all these facets should be understood to be encompassed by this disclosure.

As mPnti()ne(l earlier, the present invention includes a variçty of components that may be used in ~ el~llL co..,l.;, i~l.one dep~n-ling on the application that needs to be addressed. The invention is deeignrd plilnalily to take advantage of shape molding of a particular and novel design and combine and modify it as needed for a variety of shapes, sizes, and orientations, as will be explained in more detail as the figures are described. This invention is intçn~ed to encompass a wide variet,v of uses 10 besides con.,l~lt; wall formation and b~eement walls, such as sand or gravel filled to act as barricades or retainers as in place of s~ndbags, as well as retainer walls in l~n~lsc~rin~ applications, generally referred to as "building wall structures" herein. F.lem~nte, functions, and procedures that ~ictin~lieh the present irlvention will be noted where applopliate.

Figure 1 shows a cross section ofthe principal parts ofthe modular system, com~ g a wall component (1), spacers (2), recesses (3), openings (4), and lip (5). The lip (5) can be a tongue and groove or lap joint arrangement to fasten around the perimeter of the modules (la) and assist in securing the rnodules (la). In practice, the system in~ des molding one side of the module (la), i.e., the wall component (1), producing appropriate sized spacers (2) at a given length (by molding, cutting, Ll;..~ g, red--cing or other applopliate methods) for a given desired or predeterrnined 20 thir~nr~c of ~ccPmhled module (la), as shown in Figure la. This length variation typically may occur in a variable length removable section (''a) that may vary in length as a result of the adjusting or otherwise removing of a portion, depending on the application. The spacers (2) may be att~rtled to the for n. In ~he preferred embodiment, the spacers generally may be molded integrally with the same or similar material as the majority ofthe form. This may be in contrast to other systems, which may S use separate components or tli~.cimil~r components because of the low density of the foam typicaliy used. The present invention appears to have s lffi~nt structural integnty to use the same light weight material as the majority ofthe form for the spacers and still be able to filn~tion in conjunction with the joining system of Fig 2 described below. As shown, these may be generally cone shaped and may assist in the flow of material placed in the form, such as concrete, sand or other fill material, or for 10 other adv~nt~çs, although other shapes are possible. Additionally, the spacers may act as supports or may separate the molded components at a predetermined spacing.

W~hile generally the module (la) could be pre~s~mbled, the module could be assembled in the field. The module can be of standard sizes and shapes. For inct~ne~, for a straight wall module, a typical rnnd~ r inside ~imPn~ion could be sufficient to produce appl o~l.lately a S" thick 4S " long, 15 and 24" wide s~ucture. This thir~nPeC could vary and for most ofthe p,ese.-Lly envisioned structures, a minimllm wall could be app~ ;".;3~1y four inches. A typical maximum wall could be applux;...~ly 10 inches although the thicl~ness could vary less or more depending on the application and market desires. Because ofthe unique co...l~ l;nn offeatures that enable this invention to be shape molded, this invention can exceed generally available form widths in the Ill~k~:L~lace (such as 16" wide), 20 which may save time and effort in assembling and constructing a building structure.

In the ~ ;d embodiment, the wall component (1) is molded of EPS foam. Molded EPScolll} ollents are used to create cQnt~inPr-form modules of standard sizes and shapes. These modules may then be easily erected to create the desired light weight container-form system. This EPS foam pl~r~bly can be about 3.0 pcf, but other d~,ncitie~, both lighter and heavier, can be made. Generally, 5 the strength and rigidity of the molded material tend to increase as the density increases. This is known to those in the art and has been tested by such producers of EPS as ARCO Chemical Co.,.p~,~. However, from such tests by ARCO and others, it appears that the inc~llAting value of the molded material increases as the density increases only to about 3.54.0 pcf (after expansion), after which the in~llAtin~; p~ r~ e curve begins dropping. According to these tests, further increases 10 in density result in a lower in~lllAting value. On the other hand, the material cost at higher den~ities may be much higher so economics may alter the desirable density. Thus, a balance between the strength, in~lllAtin~ value, and economics in the plefelled embodiment may be obtained. It is envisioned that about 3.0 pcf density may be sufficient to achieve the goals of the present invention, although lighter and heavier densities may be used. Without limitation, a range could include 15 apploximd~ely 2.0-8.0 pc~ Obviously, the EPS would preferably be properly fused and m~mlf~ctllred. Likewise, it could exhibit the structural inte~ity associated with proper fusion, such as the results shown in such reference guides as ARCO Chemical's Family of Foarns Properties and Performance Reference Guide and ARCO's brochures on F~pAnfled Polystyrene Properties, which are incorporated herein by reference, and other similar references lcnown to those in the art. Many 20 light weight foam form products currently on the market exhibit a variety of densities less than 1.8 pcfbecause oftheir mAn~fActl-ring and process constraints. Because the plt;~ll~d embodiment of the present invention has less ofthose constraints and uses apploxi~.~AIPly 3.0 pcfmaterial, it may satisfy a goal to provide energy efficiency.

Abenefit to this insulative quality, and particularly this level of insulative quality, may affect the curing ofthe solidifying matesial. It is well known, that some solidifying material such as concrete increase in llltim~te strength by slow curing in the drying process. For instance, concrete allowed 5 to cure over a 7 day period may exhibit .~ignifi( ~nt increases in l-ltim~te strength co~ aled to simply air cured in a 1-2 days, where the moisture is evaporated quiclcer. After appro~ ely 28 days the conc~ may exhibit the majority ofthe strength, but with an initial slower cure, the ultim~te strength may be higher than without the initial slower cure. Especially in some areas having hot temperatures in the sl~mmP~r, some~imps steps are specifically taken to slow down the curing and retain moisture 10 longer to allow this increase in strength. Somptimp~ sheets of plastic are spread over the surface and sometimes water is sprayed over the surface to create a mist. In other in~t~nc~c, a ~hPmic~l is sprayed over the surface to retain the moisture in the concrete for this initial period and sometimes chernical ~ res are added to the solidifying material's composition to accomplish this goal.

The present invention, with its high insulative and water resistant qualities, may also assist in 1~ this curing. First, there may be a moisture barrier through the use of this foam. Thus, the foam may act as the moisture barrier described above and could reduce the effort and expense to create a separate moisture barrier. Secondly, there may be a thermal barrier. The insulative qualities may retain the heat in the concrete curing as well as may stabilize the temperature from any temperature variations. Even if the top of the structure such as a wall was exposed, this may be a relatively small 20 percentage of a typical height wall. Thus, the majority of the structure could be more easily cured using this light weight form design.

Further, it is believed that one method of making the molded material, such as EPS, ~LIollger is to insert other matrix producing particles, such as fibers or pellets into the raw m~tPri~l prior to m~n~lf~ ring. Generally, fibers could be defined as having a length ~iPnifir~ntly greater than the S width or ~ m~t~r. For instance, fibers might be randomly oriented, loose bulk fibers to be added in the steps of making the foam. Generally, this could contrast to large bloclcs of material such as plastic or even screen mesh. Such matrix producing particles could have a much longer length than width. Mixing or otherwise inserting such matrix particles could occur for inct~nce prior to l~ittl~lit~g and fusion of the EPS. This is in contrast to mol(~ing the EPS with large bloc~cs of material 10 simply added to the foam. Another aspect of this material used for the form is that a modified grade of EPS may be sPtecte~l to i~sure the higher degree of available fire retardant char~ete~i~ics, as those in the art would understand. Typically, in moltling EPS and other products, the molding process produces a wear le~ outer skin integral with the molded EPS. Thus, a substantially completed mnkling (with perhaps some adj-l~tment~ such as spacer length) might offer a more useful and wear 15 resistant surface that may not exist with cut or fabricated materials. In this invention, such a wear resistant outer surface may be useful for the various applications that the described container-form components are envisioned to encompass.

While EPS foarn has been disc~lssed other suitable material may be used. The present invention and methods that may be disclosed or claimed would include other suitable material that 20 could fulfill the purposes of the invention.

Re~erring to ~ig. la, the spacers (2) may be aligned to enable leil~lcing material (9), such as bars, to be inserted in the module (la) prior to pouring concrete or other suitable material. The shape ofthe spacers (2) may allow for C'~ el;tl~ ofthe lei~ ;ing material (9). afthe spacers, are separated by a tie, then the tie or spacer or both may allow for centering of the lei~,cl"g material S (9).) Likewise, the spacers (2) may be aligned vertically to allow for pl~ç~m~nt of vertical leil~lcill bars. The shape of the supports and their distribution may enh~nce the concrete flow and fill for a more cont~ ous and ~7L~ungcr concrete or fill wall and typically requires less steel or other supporting members in the struc~ure.

In as ,elllbly, the wall compollell~s may be aligned so that generally spacers (2), a~er trimming 10 to length if nt~c~cs~ry, abut each other, as shown in Fig la. Holding element (6) may be ~ hed to a tie (8) and a stress element (7) placed over the tie (8) and then inserted through opening (4) into recess (3) through wall component (1) and spacer (2) into an adjacent abutting wall component to the other side wherein another stress element (7) and holding element (6) may be placed to secure the assembly (this being one embodiment of a more general "joining system"). The holding element 1~ (6) may be a threaded nut, the stress element (7) may be a washer or other generally enlarged area element to reduce any stress from a f~ nin~ system, and the tie (8) may be a threaded pin to engage the holding el~ment (6). The tie may be a fire rated material, ~ c~ssed in more detail below. By proper sizing of recess (3), the holding element (6) and associated elements may be flush, or even, with the surface of the wall component (1). Additionally, the broader concept of a f~ct~nin~ system 20 can include any other means that would place the wall components together. This could in~.tl~d~, for instance, plastics ties. It could also include adhesively joining the structures. It could also include casting or moklin~ a material into the form to secure the wall components together through opening (4). It could include a frarne structure of various materials to secure the wall components, and even assembled modules in an array, together. While not shown, the present invention is meant to encompass those variations as would Se obvious, such as Pxt~nrling the spacers on a first wall S co~ ol1e"L directly to a second wall con-ponel,~ not having spacers, or even a second wall component having spacers but not aligned with the first spacers and therefore not abutting the first spacers from the first wall component.

While the broad concepts of this invention may seem straighlro-w~,l in hinrlci~ht it is noteworthy that in al,p,oxil.,ately three dec~(les, it does not appear that anyone has put the 10 colllbinal:ions of methods and devices together in this manner to make an econ~lmic~l flexible, and structurally sound module or modular system, especially for light weight systems using EPS.

Also corners, Tee's, angles, reducers, and so forth (more generally referred to as a "fitting"
herein) may be assembled from molded components in the same basic manner as the wall, sometimçs inclll-ling variations in a mold or simply through additional molds. Fig. 3 shows a corner 15 configuration of a fiKing. Corner component (10) may be similar to wall component (1) in design, excepting an angular aspect. Typically, this angle may be 90 degrees, although other angles are certainly possible. The spacers (2) ofthe corner (10) may be aligned with the spacers (2) on the wall component (1) and secured together as described above. As an example, a mold may produce a corner component. The spacers (2) may be sized to produce a size corner of 11 1/4" total wall 20 thichlP~c (8 1/4" of c~)ncl~le plus 3" offoam walls). Using the same mold, the wall thi~ness can be d or adjusted to any other size by wire-cutting or otherwise re-lu~in~ the length of the spacers (2). Alternatively, one branch of the corner can be a different ~imrn~ n than the other branch.
Similarly~ other configurations can be made using the same molds, such as Tee's, reducers, 4-way crosses, and so forth. For columns or curves, a mold can be made to make halves lilce a u-shaped 5 or other curved shapes.

NOL~;:W~J~LIY and of particular interest is the fle~bility ofthis invention in allowing varying wall thicicness, denoted by ~limpncions "a" and "b" in Figure 3. By simply varying the length of spacers (2) along dimlonsions "a" and "b," multiple wall thir~nesses can be accommodated. The wall components (1) in the l~lo~ y of intersection (11) could be trimmed to an ap~ liate length to 10 abut each other (or insert an intervening piece) and still align the spacers (2) from each wall compollent (1) and may be secured by arly common means, such as adhesively joining them at the intersection (1 1).

Fig. 4 shows a Tee confi~lration of a fitting. In the example, it could comprise two corner components (10) and at least one wall component (1). The structure is similar as described above 15 and could offer the flexibility in varying wall thi~l~ness between rlim~ncions "a" and "b" as described in Fig. 3.

Fig. S shows a u), . .1);"~ n of several options as could be typical in a structure created with the fl~ihility ofthe invention. Section I cc,.,~i.",~ a curved inside radius wall component (12) secured to a curved outside radius wall component (13). The spacers (2) may abut each other at a given n~e to form a given wall thicl~n~ss and may be secured in a similar manner as shown in Fig. ~a.
Section ~[ shows a similar structure as shown in Fig. la. Section II may be secured to Section I (and other sec~ion~ in sirnilar fashion) by any of commonly used techniques, such as adhesively ~ rhing~
threadably ~tt~ching and so forth. Section m shows a Tee section and may comprise two corner 5 components (10) in combination with at least one wall component (1). Obviously, a "cross"
i.~Lel~e~;Lion could be created instead of a Tee illLt:l~e.;Lion, as those in the art would readily recognize The "branch" ofthe Tee, denoted as Section IV may have a ~iimrn~ion "b" that may be d~el~llL from the ~lim~n~ion "a" as shown in this example of Fig. 5. Section V is similar to Fig. 3 described above and may include a corner component (10) used with at least one wall component (1). Obviously, an 10 outside corner component could be created to substitute for the multiple wall components (1) to secure directly to the corner component (10).

Fig. 6 shows an assembly of modules in which two of the modules may have drsign~ The designs can be created on the inside ofthe wall components (1) so that if desired the wall component (1) may be se~ Led from the completed or solidified structure, leaving an m~lt;s~ion in the material 15 such as concrete, as is shown in Fig. 7. Alternatively, these designs can be created on the outside of the wall components (1) and may be decorative as formed, if for in~t~nce the modules were left in place. Figure 6 also shows the modular arrangement where even large construction may be accomplished using multiple modules. Lips (described in Figs. 1-5), for in~nce~ may assist in ~lignin~ and securing an adjoining module or wall member.

Fig. 8 shows another view of the module (la) shown in Fig. la. The thir~nPss of wall component (1) may be ap~luxi~ Lely 1 ~/2t~ thick but could be more or less depending ofthe loads and stresses involved. Also, shown in Fig. 8 is lip (5) which may alternate from an inside orientation on top to an outside orientation on bot~om of the wall component (10), to engage s~ccesciv~ or st~ P,d modules. (Naturally, when an odd length wall component is needed, a lip can be cut even 5 on the site of construction.) As tliccn~ed earlier, the spacers may also fi~nctiQn as a support for the structure. In one embodiment as shown in Fig. 8, the spacers (2) are arranged with ~3~ spacer orientation. In that orientation, one example ofthe spacing could be applu~~ ely 12-13 inches between the spacers in a row (shown as dimen~ion "c"), ap~,ux.lllately 7-8 inches between rows (shown as dim~n~ion "d"), apploxi.~ P,Iy 4-5 inches to the closest spacer from an edge (shown as 10 rlimPrl~ion "f'), and apl)lu~ ely 11-12 inches tû a first spacer in a middle row from an edge (shûwn as ~limPn~ion "e"). Obviously, other orientations and other spacings are available depending on the load conditions, strength and thiclcness of the fûrm, and other criteria. One key is that the support systems be structurally strong enough to ",~i"~ the integrit,v of the form during the pouring or filling process and thereafter if the forms remain in position.

Also, the spacers(2) may have a conical shape with a larger ~ Le~ dimension of appl uXIll ~ ly 3 inches at its base and a smaller d ~ lcr dimension near the end of applu~ ely 2 inches, and may more generally be referred to as tapered. ~Thus, "tapered" for the purposes of the present invention could relate to circular, elliptical, pyramidal, and so forth. ~lt~rn~tively, the space could simply be a non-tapering shape, such a rect~n~ r or circular. Obviously, other shapes could 20 be ap~ l,ale, depending on the needs and the ~alkell~lace. Thus, in this in~t~nce with 11 spacers with a 3" base col"paled to the standard size module of 24" by 48", the pe.cell~age area (and in this .,e a correspondingly similar volume percentage) of the wall surface of the wall component or similar sit~ted components occupied by the spacers could be applu~ lalely 8%. There would appear to be a balance between insulative qualities ûfthe fûam and the structural strength ûf the filled material such as cûncrete. Thus, a range ûf up to a~ tely 20% might be suitable, with a presently ~ relled area ûf a~prûxill~aLely 8% per side of wall component where the spacers are located.

The l~p may be ilnpol l~-~ (or some other adjoining element) to assist the forms from moving with respect to each other during the pour and while wi~ in~ the l~les~ules. Naturally, the thi~rness ofthe wall of the container-form, the dist~nce between the spacers along the wall surface, 10 the lips and the density ofthe material used to make the container-form, and the pressure exerted by the particular material used to make the structure inside the container-form could be altered in ulller~us ways in pelr~ g ~ lly the same function in subst~nti~lly the same way to achieve subst~nti~lly the same result. Such stress c~1c~ tions could be done, once the basic concepts are PYp1~inPrl in accû-dallc with the present invention, by even a typical civil en~ine~ring college student 15 usingrl-~,..P~.;..gtextbooksonstrengthofm~tPri~1c Forinct~nçP,thedistanceofthespacerscould be increased if the wall thickness were increased, the lips could be decreased if the ~ist~nce of the spacers were decreased, and the wall thickness might be decreased if less plt;ssule from lighter alelial were exerted on the container-form. The above configuration simply describes a plerelled embodiment. This spacing of the spacers in colllb;l~aLion with the material described above appears 20 to have sufflcient strength to withstand the ple~ les of at least a six foot pour of concrete (and even higher) performed in substantially a single operation (where the pressures exhibit from the unsolidified concrete would be gr~ale~L at the bottom of the form).

Fig. 9 shows a fitting component such as a corner arr~n~enn~nt similar to Fig. 3 in perspe~tive view to show other aspects ofthe present invention. Although the corner is shown at applo~"dLely 90 degrees any angle can be produced and used and as such the term "corner" in~t~des any angle.
5 The corner component (10) may include an inside piece (lOa) and an outside piece (lOd). The inside piec~ itself may consist of a first portion (lOb) angled toward a first direction and a second portion (lOc) angled toward a second direction di~l~ren~ than the first direction. As stated, this angle may be any angle. The outside piece (lOd) may also have a first portion (lOe) and second portion (lOf).
These portions may be angled in similar directions as the first and second portions of the inside piece 10 or, alternatively, could be angled in ~ ellL directions (generally causing non UniLUIlll wall th;cl~nPc~Pc) as the market needs may dictate. The ends ofthe first and second portions ofthe outside piece typically may be aligned along an alignm~nt plane (lOg) with the ends ofthe first and second pûrtions ofthe inside piece, as shown in Fig. 9. Naturally, lip (5) may be in~ ded at any of the joints to assist in supporting the joint relative to the mating aC~iacpnt structure or component.

The comer component (and more generally applicable to other fitting components) may be made sep~Lely and co~ ed to another component such as a wall component. In other inct~nc~c, the fitting component may be made integral with the other component. This may have an advantage of lessPnin~ the quantity of joints.

Fig. 9a shows one arrangement of making a comer component (10) to bum an angle. The angle of the first and second portions as shown is dine~ than a 90 degree angle, but naturally could include such an angle. The inside and outside pieces could be made (such as molded) at the desired angle sirnilar to Fig. 9. (Naturally, curves can be formed in similar manners.) However, in some situations, it may be advantageous to use other (perhaps yl~fo~llled) components and adjust the angle 5 by the following method or subst~nti~lly similar method. The inside piece (lOa) could be severed ~t some point, generally at the line of departure (lOj). The first portion (lOb) and second portion (lOc) could be aligned to some desired angle. An inside wedge (lOh) could be inserted into the space caused by the turî~ing of the first and second portions. The wedge could be connected in any appropriate manner, such as f~ctçning, gluing, att~hin~ with pins, and so forth. A similar 10 a,.~lge.-lent could be made on the outside piece (lOd) with an outside wedge (lOi). Alternatively, the outside piece may not need a wedge. For inct~n~ in the example shown in Fig. 9a, the structure formed by the container-form system could be formed on the inside surfaces of the outside piece (lOd) and might not have a missing portion on the inside surface to affect the formed structure. Also, the inside piece (lOa) c~uld be severed at some appropliaLe angle so that the first and second portions 15 might be joined without an inside wedge (lOh). Typically, one could align a first portion of the outside piece with the projected i,ll~l~e~Lion ofthe first and second portion ofthe inside piece, along the line of de~ule (lOj). A second portion of the outside piece could be aligned in the other direction to the line of departure. The first and second portions could be secured together to form a unit. If a dilI~ wall thi. l~ness were desired in di~el en~ directions from one portion to the other 20 portion, adj--stm~nts could be made and ~lignm~nt~ altered. The outside piece could be secured to the inside piece by a variety of ~lçm~nt$ and in the example of Fig. 9a by at least two aitelllaLiv~;s.
The first portion ofthe inside piece could be secured to the first portion ofthe outside piece by use of a spacer (2). The first portions may for inct~nce use a spacer (2b) e~cten~lin~ between the inside and outside pieces. Alternatively, as shown between the second portions, a pair of spacers abuttin~ each other at the ends of each spacer (2c) may be used to space the ~ t~nce as well as be used to join the inside and outside pieces together similar to the embo-lim~nf~ of Fig. la and Fig.3.

Figure 9b shows a tee arrangement (another fitting component) which in some ways may resemble the corner a,l~ng~ lent of Fig. 9. In this arrangement, generally two inside pieces, each having a iirst portion (lOb) and second portion (lOc), may be oriented at di~ic;ll~ angles. Generally, the ends would align with an outside piece (lOd) so as to make joining to a(ljacPnt form modules more uniform. For in~nc~, a first end (lOk) of one of the inside pieces might align with a first end lQ (101) ofthe outside piece and a first end (lOk) ofthe other inside piece might align with a second end (lOm) ofthe outside piece. Also, the wall thiçkness could be varied, denoted by dim~n~ions "a" and "b", shown in Fig. 3, and the directions changed from one piece to the other, as is also shown in Figure 3. ~lthough spacers are not shown, typically, the inside and outside pieces could be secured relative to each other with the use of spacers and other applupliate securing means. Naturally, these concepts could apply to other fittings, such as crosses, which ec~nti~lly may be con~ red as two "tees. "

An assembly of modules is more clearly shown in Fig. 10 in which a representative example of erected wall modules and corner modules in the stacked configuration may be seen. This aspect may allow even more flexibility to this system in allowing multiple layer fonns to produce the completed structure in less time and with less effort. For in~t~nce, if a wall was being poured of concrete, an 8 feet high waU might be poured in one "pour." In ~ig. 10, if one used the above d~ ed 24" by 48" modules, the heights ofthe waU from leflc to right would thus be 8 feet, 6 feet, 4 feet, and 2 feet. Other co~ er~ ;al embodiments have difficulty pouring even a wall 4 feet high coneiet.-ntly without creating "Blow Outs" ~lieclle~ed above.

S One of the advantages of the present invention is the flexibility of the material yet with sufflcient ~lellglll to wi~ the stresses of pouring at least a six feet high concrete wall, for ce, in one pour (i.e. s~lbst~nti~lly continuously), particularly at the bottom of the form where the stresses are typically highest. In many inet~ncee, the prerelled embodiment has withstood the pressure g~dled by at least a eight foot, ten foot, or twelve foot pour. (The two foot incl~,l.e~lLs are simply because one ofthe ~ "--olle ofthe components is two feet in the ple~lled embo-lim~nt Naturally, odd or various other heights would be in~ çd as well.) Experience has shown that if for in~t~nce a section of the wall components need ~d~lition~l bracing, the material appears flexible enough that additional bracing may simply be used to straighten out the bends. This may be accomplished by securing a board, such as nailing a "2 x 4" board to the expandable foam for in.~t~nC~, then bracing the board. Should an intenrled curve be applop~ e, the material in the prefel~ed embodiment may actually be bent to form a curve with applop.;~Le bracing.

The pie~l.ed embodiment appears to even have enough structural strength that wallcways may be added to the sides ofthe wall components. An example is more particularly seen in Fig. 10a.
If an eight foot high wall was desired, a typical place to position a first level might be appl v~ ely five feet high. Obviously, a second level or other levels could be added as well. The walkways could be ~u~ulled, for inst~nce~ by a board nailed to the foam wall component and supported with some angled bracing to some appro~liate location such as the ground.

Generally, the wall components may leave the factory assembled into modules On the job site, the particular configuration of modules may be erected using the pr~cs~mhled modules.
However, the wall components could be assembled on the job site into modules, as con-lition~ may occur. The modules may be erected, using either a stacked or staggered (offset with respect to a lower layer) configuration, and can remain snugly in place, using the lip (S) design shown in Fig. 1, Fig. la, orFig. 8, for i~ e~ Also, as shown in the layout of Fig. 10, in the pref~ d embodiment with a size of 48" by 24", a~plo~llaLely eleven spacers (2) could be used. The confi~lration shown 10 in Fig. 8 shows the spacers in a 4-34 staggered orientation in three rows, ~l~hollgh naturally other configurations are possible. Besides providing a space between the wall components, an ~,drlition~l function of the spacers may include distributing the loads and stresses in securing the wall components together and, therefore, may function to support the wall components.

Fig. 11 shows yet another variation of the wall modules. A variable wall thickness tr~ncitioll 15 component (14) may be sized to allow for a variation in the thickness of the wall by rerluring or expanding and may be used with wall component (1) as shown or fitting components or other components to assist in making a transition to a different thickness wall or to another variable wall thi~ c~ ~ansition component. In practice, this feature may allow the same or similar components molded from the same or similar mold to be used in a variety of applic~ions with a variety of spa~ing~
20 to produce a variety of wall thi~lrnPss and other variations. (Naturally, this variation and other aspects ~licc -sse~l with the wall modules throughout this patent could be applicable to fitting components and other components as well.) LT1 some embo~1im~nt~, it may be preferable to leave the foam module ~tt~ch~d to the wall structure to provide insulative qualities. This is shown in Fig. 13. It might be possible to provide 5 prero,l"ed wall pieces (15) (such as pre-stressed concrete walls or firewalls) that could be erected on the site, which could include the light weight container-fo~n modules (la and lb) akeady connected. For inst~nce~ the walls could be app.ox;."~ely eight feet by twelve feet in rlim~n~;on ~ some in.~t~n~e~, it may be preferable to include an adjoining member. While the adjoining member could include a variety of structures known to those in the art, one example is shown in Fig. 13, shown as a lap joint (16) having a lap joint member (17a). The lap joint member (17a) could co~ ,olld to another lap joint member (17b) in another adjoining wall piece. To hold the lap joint members together a lap joint securing element (18) could be used, such as a bolt (19a) inserted for instance into two aligned threaded holes (19b). Such a securing element could occur at a plurality of spaced positions around the structure to secure it f~nly. Obviously, any suitable securing ~IPmf.nt 1~ could be used, such a piece of steel on each wall piece which could be welded and so forth or the lap joint could simply be positioned and perhaps sealed and supported with external supports to ~
the position or seal. If the foam module was incl~ded as part of the preformed wall piece, then a pr~ ed embodiment might be to allow an opening (20) to insert the lap joint securing ~lemPnt Then, the opening could be in~ te-l with, for example, a portion of similar material as contained in 20 the co~ iner-formmodules.

If the distance between the light weight modules was a certain fire rated minim~lm and the material in between the modules was acceptable for fire rating purposes, the wall could be used as a firewall By "firewall" in this application, it is meant to include specifically more than just the use of a fire resistant polymeric foam such as the modified grade of EPS, described above. In this S applic~ion such a firewall rating is meant l:o include at least a time rating of two hours, such as could be found in a five inch thick concrete wall. (Naturally, a firewall could be used with a variety of configurations disclosed in this patent.) Also shown in Fig. 13 are a first finish surface (22) and a second finish surface (23). For the purposes of the present invention, the term "finish" in~ des completed surfaces or semi-completed 10 surfaces such as semi-pr~finiched surfaces. On some instances, it may be preferable to attach or oLllel wise connect a finish surface to said wall or wall pieces. In the example shown in Fig. 13, the finish surfaces may be connected to the molded container-form. In that in.ct~nt~Ç, the molded col ,~ e~--form would generally remain connected to the wall and the finish surface be conn~oGted to the form on either side or both sides. If the walls were preformed, the finish surface could be 15 connected prior to ere~tion at for in~t~nce the building site. Then, after connection of the wall pieces, the openi,~g (20) could be filled with a portion of sirnilar material as contained in the co~ er-form modules described above and then an insert (22a) of the finish surface could be added to connect to the finish surface (22). Likewise, insert (23a) could be conn~ctecl to finish surface (23) in l~ce manner. As example (and others certainly are foreseeable and practical), the finish surface could 20 gypsum wall board such as sheetrock while painting or wallpapering could be completed later after the structure is erected as a whole (or even previous to the erection of the structure as a whole with perhaps touchup ofthe finish surface in specific areas). Thus, a ~lerolllled inq~ ting structural wall already semi-fini~hed with finish surfaces could be made in a facility, hauled to a job site, quickly erected, and with minim~l fini.ching, the walls completed.

~L mal~ng a pr~ lled wall, especially a firewall, the light weight foam of the wall and fittir,g S components may be restricted in their ~loxlh~ y to another opposite and corresponding component.
For i,.~ cç, the spacers might need to be spaced apart as is shown in Figure 14 c~ c;d to Figs.
la, 5, and others previously ~iscussecl To assist in spacing the ct nt~inPr-form components, an arr~n~emPnt such as shown in Fig. 4 may be usefill. The cont~inpr-form components could be spaced at some appropriate dict~nce One component (la) might be placed against a wall (24) or solid structure and might be relatively immobile. Another corresponding component (lb) might be ?,tt~r~h~1 or placed ~djacent another walL structure, or even a movable support (25). (The versatility ofthe movable support might assist in making a variety ofthi~l~n~sçs ofthe p,~ "ed wall (15).) The p,~rul"led wall could be molded of suitable material, depending on the needs of the applic~tion Generally, this may be some solidifying material, such as an aggregate material lilce concrete. It may be a light weight concrete such as disclosed in U.S. Patent No. 5,580,378. If a fire rated firewall is desired, the thiçl~ness would presumably need to meet various regll~tions. In some in~t~nt~, the forms could be taken off (such as might be appropriate for designs in the face of the wall). In other i..~l;.~ce~, the forms might remain connected to the wall (such as might be a~p,opliate for additional in~ tion from the form).

In some instances, as is shown in Fig. 15, it may be desirable to allow a positioning el~m~nt (28) ofthe wall (15) to correspond with some other mating positioning element (2~) such as might be made in a structural footing (26). The positioning element might assist in ~ nin~ a plurality of walls or wall components, or might assist in ~ an ~fi~nm~nt, or otherwise increase the stability.
Naturally, the positioning e!em~nt could be made into other parts of the wall or the container forms S as might be a~p~ Le, as would be understood by those in the art.

As mentioned above, the invention may include a firewall, which may be prefolll,ed and moved to a site or may be produced on site. The firewall may be configured so that the spacers (2) shown in Fig. la rnight not touch. This may be because in the p,efelled embodiment the spacers may be made from some light weight construction-form material and may not be fire rated. (Obviously, 10 the spacers could in another embodiment be made from fire rated material and might resemble the configuration more like Fig. la.) ~ some ~ Pe the firewall may be made similar to the configuration and method such as described above relative to Fig. 14. ~ other inet~ncee it may be more appropriate for on site cor~etruction. A method may include ~Itili~ing a wall component form ae a first form, positioning the 15 wall co~ ollent form at a predetermined spacing from a second form, msel Ling a fire rated tie in the sp~ng This aspect is shown in Figs. 16 and 17. The fire rated tie (29) may be inserted into a slot (30). The slot (30) may be formed or cut into the wall component (la) or the other wall colllpollent (lb) or both as shown.

The fire rated tie may be made of any fire rated material. By "fire rated material, " it is meant in this patent to include m~tPri~lc recognized by the various governm~nt~l authorities as approved~to produce a firewall. One source of such mAt~ n~l may be a product known as "Wonderwall"lM, which may be described at a fire resistant concrete board typicaily l/2" thicl~ and in sheets. A fire rated tie may be cut at various lengths and widths. In a preferred embodiment, for instance as is shown in Fig.
5 17, to produce a six inch fire rated wall, an eight inch thick wall at its widest dimension (32), might be al~p,vplia~e. This would allow the spacers (2), to be sized to app~ux;...AIely one inch long on each side, the slots (30) could be ap~ruxi..~ ely 2 l/2 lûng" and the fire rated ties could be app-ox;..~ely the sum ofthe two slots and the desired wall thir1~nec~ (in this example, 11 inches long). A width of the fire rated tie could be al~pro~ Ately t~o inches. Other spacers could be used in conjunction or 10 se~Le from the spacer (2). Although not shown, these could include a pin between the spacers (2~, which pin could I~Ai-llAil~ a separation spacing ~lict~n~e between the wall components (or fitting components or other components). The pin could have a washer or threaded engagement with the wall modules to assist in . . .~ the predetermined spacing distance. (Naturally, the spacers may be separated as the above discussion shows and used in non fire rated embodiments as well.) Such 15 adj-letm~nte of the thickness may reflect the ability to vary the wall thickness between the same or similar modules by adjusting the sp~c-in~ tliec ~eeed elsewhere in the patent. The fire rated tie (29) (or other ties) may be secured in the wall component in some fashion as would be known to those in the ar~. This could in~ d~, for instance, adhesively att~hin~ the fire rated tie (29) to the wall component. Not shown but certainly inçhlded from this description could be an embodiment that 20 might utilize for inet~nce a single slot, no spacers (2), a premolded fire rated tie, and other aspects as could be known to those with skill in the art using the basic explanation disclosed in this patent.

A~er securing the fire rated tie, a typical step might be placing the fire rated material into ~he spacing between the forms and forming a wall member. A fitting (such a corner, tee, or cross) could be formed as part of the firewall. An adjoining member may also be in~ ded to assist in joining an ~rlj~c~nt section of another wall member. An example has been shown and described in Fig. 13. If the m~t~ri~l is of a solidi~ing type, then generally to form a firewall, it would need to solidify and so adequate conditions would be given to allow the solidifying. While some embodiments may not include the form ~ i"~ ~tt~hed to the wall member, other embo~1im~nts could include the forms.
The forms may allow ad~itioll~l insulation to the firewall. Also, the surfaces could include at least one finish surface which may assist in the speed of in~t~ tion and ~~ltim~te fini.chin~: ofthe walls. Still 10 in other embo~imPnt~ bracing could be inrluded and could remain. Such bracing could include timber, backfilled dirt, steel bracing, and so forth.

Naturally, a variety of other shapes and configurations are possible and could be in keepingJ
with the purposes and intents of the present invention. For in~t~nc~, the invention could be used to hold or to form various materials, for example, co.lv~.lLional and/or variations of sand, gravel, rock 15 concrete or synthetic matenals, to create, among other things, wall structures. It could also be used for such purposes as construction, building, concrete, l~n~l~c~ping, decGI~Ling, and irrigation industries, among others.

It may be said that the present invention embodies the "best of both worlds" in that the colllpo~ lL~ may be molded from light weight material, such as 3.0 pcf density EPS foam, modified 20 grade, and then fabricated or ~c~mhled into a variety of shapes to offer ease of assembly and still be structurally able to be used in these application as well as offer insulative qualities if ~tt~rhPd to any building wall structure. The result appears to be an energy ~fficiPnt light weight, container-form system that is easier and faeter to erect, performs better, and may be more econornical than prev:ous light weight form systems.

The foregoing di~clle~ion and claims that may follow describe only the prerell~d embodiments of the present invention. Particularly with respect to the claims, it should be understood that a number of changes may be made without dep~~ g ~om its essence. In this regard, it is intPn~ed that such ~h~n~s--to the extent that they substantially achieve the sarne results in subst~nt;~lly the same way--would still fall within the scope of the present invention.

Although the methods related to the system are being inrl~lded in various detail, only initial claims directed toward some aspects ofthe present invention have been inrlllded Naturally, those claims could have some application to the various other methods and ap,t)al~lus ~l~imed throughout the patent. The disclosure of the system or method context is sufficient to support the full scope of methods and appalaL-ls claims with, for inet~ncP; the concepts such as the variable wall thi~nPse tr~neition co~ ollent, tapered centering spacer, container-form capable or withst~nrlin~ stresses of at least a ten foot concrete single pour, integral tapered support, intelchal-geability modular embodiments, matrix producing particles mixed in the foam, turns for fittings such as corners and tees, in~ ted wall with conn~ted container-form, pl~r,l.ned firewall, integral fitting molded to wall co~ ol~lll, in~ ted firewall, and others that may have been disclosed. While these may be added to explicitly include such details, the existing claims may be construed to encompass each of the other general aspects. Without limitation, the present disclosure should be construed to encompass S~ some ofthose pl~;S~ Led in a system or method context as described above for each ofthe other general aspects. In addition, to the extent of any revisions utilize the essence of the invention, each would naturally fall within the breadth of protection encomp~s~ed by this patent. This is S particularly true for the present invention since its basic concepts and underst~n(lin~ may be broadiy applied.

The reader should be aware that the specific di~c~-ccit-n may not explicitly describe all embodiments possible; many ~ltern~tives are implicit. It also may not fully explain the generic nature of the invention and may not explicitly show how each feature or element can actually represent a 10 broader filnction or of a great variety of ~h~ tive or equivalent elem~nte Again, these are implicitly included in this disclosure. Where the invention is described in device-oriented terminology, each element of the device implicitly performs a function. Apparatus or system claims may not only be in~lllded for the device described, but also method or process claims may be in~ ded to address the functions the invention and each element performs.

Furthermore, equivalent, broader, and more generic terms are implicit in the prior description of each ~lemen~ Such terms can be s lhsti1~lted where desired to make explicitly the implicitly broad coverage to which this invention is entitled. Further, it should be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly inchlde~ in the description. They still fall within the scope of this invention. A broad ~icclosllre 20 encompassing both the explicit embodiment(s) shown, the great variety of implicit alternative embo~l;mPntc and the broad methods or processes and the like are encomp~sed by this ~licclos~lffe~

To the e~tent the m~h~d~ claimed in the present invention are not further (1iCcussecl7 they are natural ou~glowllls ofthe system or apparatus claims. Therefore, no separate and further ~ c~lssions of the methods are deemed necess~ry as they may claim steps that are implicit in the use ar.d S rn~n-lf~h-re of the system or app~ s claims. Furthermore, although the steps may be olgdlfi~ed in a logical fashion, however, other sequences can and do occur. Therefore, any method claims should not be construed to include only the order of the sequence of steps prPsente~l Furthermore, any references mentioned in the application for this patent as well as all references listed in any illrol~lla~ion disclosure originally filed with the application are hereby 10 incorporated by reference in their entirety to the extent such may be deemed ess~nti~l to support the ~n~bl~m~nt of the invention(s). However, to the extent statements might be considered inconsistent with the p~tPntinP of thislthese invention(s), such st~t~m~nt~ are ~ s~ly not to be considered as made by the applicant(s).

Claims (115)

1. A light weight container-form system for building wall structures comprising:
a. at least two light weight container-form modular wall components joined to make a form, said wall components comprising:
i. a wall of molded expandable foam having a molded density of approximately

2.0 to 8.0 pounds per cubic foot;
ii. a plurality of spacers arranged in a staggered fashion on said wall components adapted to space said wall components at a certain predetermined spacing distance from a corresponding opposite wall component wherein at least one of said spacers comprises:
(1) a tapered centering configuration; and (2) a lengthwise opening in said spacer aligned to a face of at least one of said wall components;
b. at least one tie to insert in said opening of at least one spacer and in a corresponding lengthwise opening in another of said spacers and adapted to assist in joining of said wall components;
c. a holding element adapted to hold said tie to at least one of said wall components; and d. a recess in at least one of said wall components adapted to allow said holding element in an assembled state to be recessed into said wall component.
2. A light weight container-form system for building wall structures as described in claim 1 wherein said spacers further comprise a variable length removable section capable of being shortened to size according to said predetermined spacing.

3. A light weight container-form system for building wall structures as described in claim 1 wherein an area occupied by said plurality of spacers compared to an inside surface area created by said wall components does not substantially exceed 20%.

4. A light weight container-form system for building wall structures as described in claim 1 further comprising a building structural foundation comprising a plurality of said building wall structures.

5. A light weight container-form system for building wall structures as described in claim 1 further comprising at least one fitting component adapted to join said wall components at a turn wherein said fitting component comprises molded expandable foam having a molded density of approximately 2.0 to 8.0 pounds per cubic foot

6. A light weight container-form system for building wall structures as described in claim 5 wherein said fitting component comprises a lip adapted to assist in securing said wall components.

7. A light weight container-form system for building wall structures as described in claim 1 further comprising a solidifying material located in said spacing.

8. A light weight container-form system for building wall structures as described in claim 7 wherein said solidifying material comprises fire rated material.

9. A light weight container-form system for building wall structures as described in claim 8 wherein said tie comprises a fire rated tie and wherein said spacing comprises at least a minimum fire rated distance between said spacers.

10. A light weight container-form system for building wall structures as described in claim 7 wherein said solifidying material comprises a premolded wall structure.

11. A light weight container-form system for building wall structures as described in claim 10 further comprising at least one finish surface attached to said premolded wall structure.

12. A light weight container-form system for building wall structures as described in claim 8 wherein said fire rated material comprises a premolded wall structure.

13. A light weight container-form system for building wall structures as described in claim 10 wherein at least one of said modular wall components is connected to said premolded wall structure to form an insulated wall.

14. A light weight container-form system for building wall structures as described in claim 13 wherein said insulated wall comprises at least one finish surface.

15. A light weight container-form system for building wall structures as described in claim 12 wherein at least one of said modular wall components is connected to said premolded wall structure to form an insulated fire rated wall.

16. A light weight container-form system for building wall structures as described in claim 7 wherein said solidifying material comprises a substantially contiguous relationship throughout at least a portion of said container-form.

17. A light weight container-form system for building wall structures as described in claim 1 wherein said spacers are arranged at spacer intervals and wherein said spacers cooperate in conjunction with a wall thickness of said container-form modular wall components and a lip connected to said wall components to withstand a pressure at the bottom of said container-form generated by at least a ten foot high concrete wall single pour.

18. A light weight container-form system for building wall structures as described in claim 1 wherein said container-form comprises at least one surface with a wear resistant outer skin integral with at least one of said wall components.

19. A light weight container-form system for building wall structures as described in claim 1 further comprising a fitting component comprising:
a. at least one inside piece having at least two portions, a first portion angled toward a first direction and terminating at a first end and a second portion angled at a second direction different than said first direction and terminating at a second end; and b. an outside piece removably connected to said inside piece wherein said outside piece has a first end substantially aligned with said first end of said inside piece; and c. a fitting spacing between said inside piece and said outside piece.

20. A light weight container-form system for building wall structures as described in claim 19 wherein said fitting component is connected to said wall component and further comprising a solidifying material in said spacing between said wall and fitting components to form an integral fitting with a wall.

21. A light weight container-form system for building wall structures as described in claim 20 wherein said solifidying material comprises a premolded wall structure.

22. A light weight container-form system for building wall structures as described in claim 1 further comprising a lip on said wall components adapted to engage a corresponding lip on another component to make a modular assembly.

23. A light weight container-form system for building wall structures as described in claim 22 wherein said lip comprises a substantially uniform lip on a plurality of edges of said wall components.

24. A light weight container-form system for building wall structures as described in claim 19 further comprising a lip on said fitting component adapted to engage a corresponding lip on another component to make a modular assembly.

25. A light weight container-form system for building wall structures as described in claim 1 further comprising a variable wall thickness transition component to assist in making a transition to a different thickness wall.

26. A light weight container-form system for building wall structures as described in claim 1 further comprising a quantity of matrix producing particles inserted substantially uniformly throughout said expandable foam material prior to expanding.

27. A light weight container-form system for building wall structures as described in claim 19 wherein said fitting component is integral with said modular wall component.

28. A building comprising:
a. a roof;
b. a living space beneath said roof; and c. at least one wall of said building wherein said wall is as described in claim 1.

29. A light weight container-form system for building wall structures comprising:
a. a plurality of light weight container-form wall components;
b. at least two spacers to separate said components;
c. at least one tie to hold said wall components in relation to each other; and d. a variable wall thickness transition component adapted to assist in making a transition to a different thickness wall with said plurality of components.

30. A light weight container-form system for building wall structures as described in claim 29 wherein said spacers comprise a removable section to adjust said wall thickness.

31. A light weight container-form system for building wall structures as described in claim 29 said tie comprises a fire rated tie and wherein said spacers are separated by a fire rated distance.

32. A light weight container-form system for building wall structures as described in claim 29 further comprising fitting components wherein said variable wall thickness transition component is adapted to assist in making a transition to a different thickness wall with said plurality of components.

33. A light weight container-form system for building wall structures as described in claim 29 further comprising a removable section of said spacers adapted to be variably removed to vary a wall spacing of said wall components wherein said wall components, said spacers, and said removable section of said spacers form a variable wall thickness light weight container-form system by adjustment of said removable section while using same said plurality of molded wall components.

34. A light weight container-form system for building wall structures comprising:
a. at least two light weight container-form components;
b. a first spacer on one of said container-form components and a second spacer on another of said container-form components wherein said spacers are adapted to separate said components at a certain predetermined spacing distance wherein each said spacer comprises:
i. a tapered centering configuration;

ii. a lengthwise opening in said first spacer aligned to a face of at least one of said components;
iii. a variable length removable section of said spacer capable of being shortened to size according to said predetermined spacing and c. at least one tie adapted to insert in said opening of said spacer.

35. A light weight container-form system for building wall structures as described in claim 34 wherein said tie is aligned with a second opening in said second spacer and wherein said second opening is oppositely positioned from said first opening.

36. A light weight container-form system for building wall structures as described in claim 34 wherein said tie comprises a fire rated tie.

37. A light weight container-form system for building wall structures as described in claim 36 wherein said spacers are separated by said fire rated tie at a fire rated distance.

38. A light weight container-form system for building wall structures as described in claim 34 wherein said tie separates a spacer at a distance from an opposite component.

39. A light weight container-form system for building wall structures comprising:
a. a molded wall component of molded expandable foam having a molded density of approximately 2.0 to 8.0 pounds per cubic foot and a wall thickness of at least 1 inch thick;
b. a plurality of spacers connected to said molded wall component and spaced to connect said wall components at a certain predetermined spacing distance wherein said spacers are adapted to allow an encased substance to form a substantially contiguous structure of said substance throughout at least a portion of said wall structure and wherein said spacers are located at spacer intervals along a wall surface of said wall component;
c. a joining system comprising a holding element and a tie adapted to hold at least two wall components in a fixed relationship suitable for forming a structure; and d. a lip on said wall components adapted to engage and secure adjacent wall components wherein said wall components, said plurality of spacers, said joining system, and said lip combine to form a light weight container-form system for building wall structures and wherein spacer intervals in conjunction with said wall thickness and said lip withstand a pressure at the bottom generated by at least a ten foot high concrete pour.

40. A light weight container-form system for building wall structures as described in claim 39 wherein an area occupied by said plurality of spacers compared to a wall surface area of said wall surface does not substantially exceed 20%.

41. A light weight container-form system for building wall structures as described in claim 39 wherein said pressure is generated by at least a twelve feet high concrete pour.

42. A light weight container-form system for building wall structures as described in claim 39 wherein said wall component is adapted to be bent to form a curved wall structure while withstanding said pressure.

43. A light weight container-form system for building wall structures comprising:
a. at least two molded wall components formed of molded material;
b. a plurality of integral tapered support spacers integrally connected to each of said molded wall components and formed of substantially the same molded material as said molded wall components and wherein said integral tapered support spacers are spaced to separate said wall components at a certain predetermined spacing distance andwherein said integral tapered support spacers are adapted to support said wall components substantially independently of any non-similar material supports molded into said wall components; and c. a joining system adapted to hold said wall components in a fixed relationship suitable for forming a structure wherein said molded wall components, said plurality of integral tapered support spacers, and said joining system comprise a light weight container-form system for building wall structures.

44. A light weight container-form system for building wall structures as described in claim 43 wherein said integral tapered support spacers comprise a tapered centering configuration.

45. A light weight container-form system for building wall structures as described in claim 43 wherein said spacers further comprise a variable length removable section capable of being shortened to size according to said predetermined spacing.

46. A variable wall thickness light weight container-form system for building wall structures comprising:
a. a plurality of molded wall components formed of molded material;
b. a plurality of spacers attached to at least one of said molded wall components adapted to space at a predetermined distance at least one of said molded wall componentsfrom another of said wall components, and c. a removable section of said spacers adapted to be variably removed to vary a wall spacing of said molded wall components wherein said molded wall components, said plurality of spacers, and said removable section of said spacers form a variable wall thickness light weight container-form system by adjustment of said removable section while using same said plurality of molded wall components.

47. A variable wall thickness light weight container-form system for building wall structures as described in claim 46 further comprising a tie to connect said molded wall components.

48. A variable wall thickness light weight container-form system for building wall structures as described in claim 46 further comprising solidifying material in said space to form a preformed wall.

49. A variable wall thickness light weight container-form system for building wall structures as described in claim 48 wherein said molded wall components are connected to said preformed wall.

50. A variable wall thickness light weight container-form system for building wall structures as described in claim 49 further comprising at least one finish surface connected to at least one of said molded wall components.

51. A method of forming a variable thickness wall structure using a light weight container-form system comprising the steps of:
a. utilizing a substantially similar form to mold a plurality of wall components to form a structure wherein said wall components comprise a plurality of spacers;
b. matching a first wall component to an opposite corresponding second wall component;
c. adjusting a spacing of said wall components from each other; and d. utilizing the same said plurality of wall components to form a multiple of wall thickness by said step of variably removing said section of said spacers.

52. A method of forming a variable thickness wall structure using a light weight container-form system as described in claim 51 further comprising the step of variably removing a section of said spacers to assist in said step of adjusting said spacing

53 . A method of forming a variable thickness wall structure using a light weight container-form system as described in claim 51 further comprising the step of inserting a tie between said spacers.

54. A method of forming a variable thickness wall structure using a light weight container-form system as described in claim 51 further comprising the step of placing a solidifying material into said spacing and the step of forming a wall member.

55. A light weight container-form system for building wall structures comprising:
a. a first molded wall component formed of light weight molded expandable foam material and adapted to form a wall structure in cooperation with a second wall component;
b. a fitting component comprising:
i. at least one inside piece having at least two portions, a first portion angled toward a first direction and terminating at a first end and a second portion angled at a second direction different than said first direction and terminatingat a second end;

ii. an outside piece removably connected to said inside piece wherein said outside piece has a first end substantially aligned with said first end of said inside piece; and c. at least one spacer adapted to space said inside piece from said outside piece at a predetermined spacing wherein said spacing may be varied between a first spacingformed by said first ends of said inside and outside pieces and a second spacingformed by said second end of said inside piece and a second end of said outside piece.

56. A light weight container-form system for building wall structures as described in claim 55 wherein said fitting comprises a corner fitting and wherein said second end of said outside piece is substantially aligned with said second end of said inside piece.

57. A light weight container-form system for building wall structures as described in claim 55 wherein said fitting comprises a tee fitting and further comprising a plurality of inside pieces each having a first end and wherein said first end of said outside piece is substantially aligned with said first end of at least one inside piece and wherein said outside piece comprises a second end which is substantially aligned with said first end of another inside piece.

58. A method of turning an angle in a fitting component of a light weight container-form system comprising the steps of:
a. utilizing a plurality of light weight container-form wall components to form at least one light weight container-form module;
b. severing at an angle an inside piece of a fitting component having a first portion with a first end and a second portion with a second end;
c. aligning said first and second portions of said inside piece to a desired turning angle;
d. inserting a wedge into any missing portions of said fitting component formed by said step of aligning said first and second portions to said desired angle;
e. securing said wedge into position;
f. utilizing at least one portion of at least one outside wall component to form an outside piece of said fitting component;
g. positioning said outside piece of said fitting component in alignment with said inside piece;
h. adjusting for any wall thickness variations between said outside piece and said inside piece through using spacers;
i. connecting said outside piece to said inside piece by using said spacers to form a fitting module; and j. securing said fitting module to said light weight container-form wall module.

59. A method of turning an angle in a fitting component of a light weight container-form system as described in claim 58 wherein said fitting component comprises a corner component and wherein said step of utilizing at least one portion of at least one outside wall component comprises the step of utilizing at least two portions of said outside wall component to form an outside piece of said corner component comprising the steps of:
a. positioning a first portion of said outside wall component at a projected intersection of said first and second portions of said inside piece;
b. positioning a second portion of an outside wall component at a projected intersection of said first and second portions of said inside piece and aligned in a direction different than said first portion of said outside wall component; and c. securing said first and second portions of said wall components together.

60. A method of turning an angle in a fitting component of a light weight container-form system as described in claim 58 wherein said fitting component comprises a tee component and further comprising the step of utilizing at least two inside pieces each having said first and second ends and wherein said step of positioning said outside piece of said fitting component in alignment comprises the step of aligning a first end of said outside piece with said first end of one of said inside pieces and aligning a second end of said outside piece with said first end of another of said inside pieces.

61. A light weight container-form system for building wall structures comprising:
a. at least two light weight container-form modular wall components joined to make a form comprising:
i. insulating molded expandable foam material of a density between approximately 2.0 and 8.0 pounds per cubic foot;
ii. a quantity of matrix producing particles inserted substantially uniformly throughout said expandable foam material prior to expanding;
iii. a wear resistant outer skin integral with said molded expandable foam; and b. a joining system adapted to hold said wall components in a fixed relationship suitable for forming a structure.

62. A light weight container-form system for building wall structures as described in claim 61 wherein said matrix producing particles comprise fibers having a substantially longer length than width.

63. A light weight container-form system for building wall structures as described in claim 62 wherein said fibers comprise randomly oriented loose bulk fibers.

64. A light weight container-form system for building wall structures as described in claim 61 further comprising a solidifying material in a space created between said modular wall components to form a wall member.

65. A light weight container-form system for building wall structures as described in claim 61 further comprising a fitting component connected to said wall components wherein said fitting component comprises molded expandable foam material.

66. An insulated wall structure with at least one connected light weight container-form comprising:
a. a molded light weight container-form comprising:
i. at least two molded light weight container-form wall components;
ii. at least two spacers connected to said wall components wherein said light weight container-form comprises insulating structural material of molded expandable foam of a density between approximately 2.0 and 8.0 pounds percubic foot;
b. a quantity of solidifying material placed in said light weight container-form and connected to said light weight container-form wherein said light weight container-form and said quantity of solidifying material form an insulated wall structure with at least one connected light weight container-form.

67. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein said container-form has sufficient strength to support a gypsum board wall connected to said foam.

68. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein said container-form supports at least one finish surface.

69. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein at least one spacer comprises a tapered centering configuration.

70. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein at least one spacer comprises a variable length removable section capable of being shortened to size according to said predetermined spacing.

71. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein an area occupied by said spacers compared to an inside surface area created by said wall components does not substantially exceed 20%.

72. An insulated wall structure with at least one connected light weight container-form as described in claim 66 further comprising at least one fitting component adapted to join said wall components at a turn wherein said fitting component comprises molded expandable foam having a molded density of approximately 2.0 to 8.0 pounds per cubic foot

73. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein said solidifying material comprises fire rated material.

74. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein said solifidying material comprises a premolded wall structure.

75. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein said spacers are arranged at spacer intervals and wherein said spacers cooperate in conjunction with a wall thickness of said container-form modular wall components and a lip connected to said wall components to withstand a pressure at the bottom of said container-form generated by at least a ten foot high concrete wall single pour.

76. An insulated wall structure with at least one connected light weight container-form as described in claim 66 further comprising a lip on said wall components adapted to engage a corresponding lip on another component to make a modular assembly.

77. An insulated wall structure with at least one connected light weight container-form as described in claim 66 further comprising a quantity of matrix producing particles inserted substantially uniformly throughout said expandable foam material prior to expanding.

78. An insulated wall structure with at least one connected light weight container-form as described in claim 66 further comprising at least one integrally molded fitting of said solidifying material wherein said fitting is selected from the group consisting essentially of corners, tees, crosses, and curved elements.

79. An insulated wall structure with at least one connected light weight container-form as described in claim 66 further comprising an adjoining member to join to an adjacent wall member.

80. An insulated wall structure with at least one connected light weight container-form as described in claim 79 wherein said adjoining member comprises a lap joint adapted to join with an oppositely paired lap joint of said adjacent wall member and further comprising a lap joint securing element adapted to secure said lap joints together.

81. An insulated wall structure with at least one connected light weight container-form as described in claim 80 further comprising insulating light weight foam on at least a portion of one of said inside and outside surfaces with an opening adapted to allow said lap joint securing element access to said lap joint surfaces of said wall members.

82. An insulated wall structure with at least one connected light weight container-form as described in claim 66 wherein said insulated wall structure further comprises at least one finish surface.

83. A molded preformed structural wall member comprising:
a. a quantity of solidifying aggregate material of at least 4 inches thick adapted to be molded into a wall member;
b. an inside surface and an outside surface of said wall member;
c. at least one integrally molded fitting of said solidifying aggregate material wherein said fitting is selected from the group consisting essentially of corners, tees, crosses, and curved elements;
d. an adjoining member to join to an adjacent wall member wherein said solidifying aggregate material, said surfaces, said integrally molded fitting, and said adjoining member are adapted to form a molded preformed structural wall member.

84. A molded preformed structural wall member as described in claim 83 further comprising insulating light weight foam on said inside surface.

85. A molded preformed structural wall member as described in claim 84 further comprising insulating light weight foam on said outside surface.

86. A molded preformed structural wall member as described in claim 83 further comprising insulating light weight foam on said outside surface.

87. A molded preformed structural wall member as described in claim 83 further comprising a positioning element on at least one surface of said wall member.

88. A molded preformed structural wall member as described in claim 83 wherein said adjoining member comprises a lap joint adapted to join with an oppositely paired lap joint of said adjacent wall member and further comprising a lap joint securing element adapted to secure said lap joints together.

89. A molded preformed structural wall member as described in claim 88 further comprising insulating light weight foam on at least a portion of one of said inside and outside surfaces with an opening adapted to allow said lap joint securing element access to said lap joint surfaces of said wall members.

90. A molded preformed structural wall member as described in claim 83 wherein at least one of said inside and outside surfaces comprises a substantially finished surface.

91. A method of molding an integral fitting into an insulating wall member comprising the steps of:
a. utilizing a light weight insulating molded wall component as a first form;
b. positioning said light weight insulating molded first form at a predetermined spacing from a second form wherein said spacing determines a spatial relationship between said forms;
c. placing a quantity of solidifying aggregate material having a thickness of at least 4 inches into said spacing between said forms;
d. forming a wall member;
e. molding a fitting into said wall member with said solidifying aggregate material;
f. providing an adjoining member to join to an adjacent wall member; and g. allowing said solidifying material to solidify.

92. A method of molding an integral fitting into an insulating wall member as described in claim 91 wherein said light weight insulating molded wall component comprises an integrally molded fitting component form and wherein said step of molding a fitting into said wall member comprises the step of utilizing said integrally molded fitting component form.

93. A method of molding an integral fitting into an insulating wall member as described in claim 91 further comprising the step of connecting a separate fitting component form to said light weight insulating molded wall component to form an integrally molded wall member with said fitting.

94. A method of molding an integral fitting into an insulating wall member as described in claim 91 further comprising the step of molding a positioning element into a surface of said wall member.

95. A method of molding an integral fitting into an insulating wall member as described in claim 91 further comprising the step of adding a finish surface to said insulating wall member.

96. A method of forming a preformed firewall comprising the steps of:
a. utilizing a wall component form as a first form;
b. positioning said wall component first form at a predetermined spacing from a second form wherein said spacing determines a spatial relationship between said forms;
c. inserting a fire rated tie in said spacing;
d. securing said fire rated tie in said spacing;
e. placing a fire rated material into said spacing between said forms;
f. providing an adjoining member to join to an adjacent wall member;
g. allowing said fire rated material to solidify; and h. forming a wall member.

97. A method of forming a preformed firewall as described in claim 96 further comprising the step of molding a fitting into said wall member with said fire rated material.

98. A method of forming a preformed firewall as described in claim 96 wherein said step of utilizing said wall component comprises the step of utilizing a wall component preformed from expandable polystyrene foam.

99. A method of forming a preformed firewall as described in claim 96 wherein said step of inserting said fire rated tie comprises the step of inserting said fire rated tie into at least one slot formed into said wall component form.

100. A method of forming a preformed firewall as described in claim 96 wherein said step of placing a fire rated material into said spacing comprises the step of utilizing a solidifying aggregate fire rated material.

101. A method of forming a preformed firewall as described in claim 96 further comprising the step of retaining at least one of said wall component forms to said wall member.

102. A method of forming a preformed firewall as described in claim 101 further comprising the step of connecting a finish surface to at least one of said wall component forms.

103. A method of forming a preformed firewall as described in claim 96 further comprising the step of connecting at least one finish surface to at least one side of said wall member.

104. A fire rated insulated structural firewall comprising:
a. a plurality of light weight insulating container-form wall components separated by a spacing; and b. a fire rated material adapted to form said firewall wherein said fire rated material comprises a solidifying material of at least five inches thick between said spacing wherein said light weight insulating container-form wall components are attached to said fire rated material and said fire material form a fire rated insulated structural firewall.

105. A fire rated insulated structural firewall as described in claim 104 further comprising at least two fire rated ties to separate said components at a fire rated distance between said wall components.

106. A fire rated insulated structural firewall as described in claim 105 wherein at least one of said light weight insulating container-form wall components comprises at least one opening in said components adapted to accept a portion of said fire rated ties.

107. A fire rated insulated structural firewall as described in claim 106 wherein said opening comprises a vertical slot.

108. A fire rated insulated structural firewall as described in claim 104 further comprising a finish surface attached to at least one side of said firewall.

109. A fire rated insulated structural firewall as described in claim 104 wherein said spacing comprises a fire rated distance between said wall components.

110. A method of manufacturing an insulated firewall comprising:
a. utilizing a light weight insulating molded wall component as a first form;
b. positioning said light weight insulating molded first form at a predetermined spacing from a second light weight insulating molded form wherein said spacing determines a spatial relationship between said forms;
c. maintaining said forms at a fire rated distance from each other in said spacing;
d. placing a quantity of solidifying material into said spacing between said forms;
e. allowing said solidifying material to solidify;
f. providing an adjoining member to join to an adjacent wall member;
g. forming a wall member; and h. allowing said at least one of said insulating molded wall component forms to attach to said wall member to form an insulated firewall.

111. A method of manufacturing an insulated firewall as described in claim 110 further comprising the steps of:
a. inserting at least one fire rated tie into said spacing; and b. securing said fire rated tie in said spacing to at least one of said forms.

112. A method of manufacturing an insulated firewall as described in claim 111 wherein said step of inserting said fire rated tie comprises the step of inserting said tie into an opening in said light weight insulating molded wall component

113. A method of manufacturing an insulated firewall as described in claim 112 wherein said step of securing said fire rated tie comprises the step of adhesively attaching said tie to said wall component.

114. A method of manufacturing an insulated firewall as described in claim 110 further comprising the step of bracing at least one of said wall components on an outside surface of said wall component away from said spacing.

115. A method of manufacturing an insulated firewall as described in claim 112 further comprising the step of attaching a finish surface to at least one side of said firewall.