CA2265135C - Insulated concrete wall - Google Patents
Insulated concrete wall Download PDFInfo
- Publication number
- CA2265135C CA2265135C CA 2265135 CA2265135A CA2265135C CA 2265135 C CA2265135 C CA 2265135C CA 2265135 CA2265135 CA 2265135 CA 2265135 A CA2265135 A CA 2265135A CA 2265135 C CA2265135 C CA 2265135C
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- concrete
- wall
- securing
- pouring
- insulation
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Abstract
The present invention relates to poured concerete walls and, more particularly, to poured concrete walls including a layer of thermal insulation for reducing heat transfer in which the insulation layer is secured to the concrete wall at the time of pouring the concrete.
Description
' CA 02265135 2005-07-21 INSULATED CONCRETE WALL
FIELD OF THE INVENTION
The present invention relates to poured concrete walls and, more particularly, to poured concrete walls including a layer of thermal insulation for reducing toeat transfer in which the insulation layer is secured to the concrete wall at the time of pouring the concrete.
BACKGROUND
Concrete walls are commonly formed by pouring concrete between inner and outer forms and, after hardening, insulation materials for reducing the therm~~l R value may be added to the concrete walls. In order to do so, frame members may be applied to the concrete walk such as by using pneumatic guns and concrete nails, arid then the insulating material may be secured to the frame members. Alternatively, the insulation may be secured t_o the concrete wall by concrete nails. Such multi-step S assembly procedures are both time consuming and costly.
Thus, there has long been a need for a system and a method whereby poured concrete walls may be formed and insulated at the same time in one step.
SUMMARY
The present invention provides an apparatus and method for securing an insulation layer in place while the concrete is poured between conventional forms, and for continuing to secure the insulation layer to the poured concrete wall after the forms have been removed.
I~ BRIEf DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a poured concrete wall with a thermal insulation layer secured thereto;
FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. l;
0 FIG. 3 is an en7_arged side-elevational v_i..ew of once tie strip;
FIG. 4 is a top plan view of a wedge which is inserted into the tie strip;
FIG. 5 is an enlarged, side elevational view of ore form of support element for securing the insulation layer to the concrete wall prior to, during, and after the concrete is poured;
FIG. 6 is a front plan view of the support element taken along line 6-6 of FIG. 5;
FIG. 7 is a top plan view of the support element taken along line 7-7 of FIG. 5;
FIG. 8 is an elevational view of a plurality of insulation panels secured to the concrete wall by a plurality of support elements;
FIG. 9 is a vertical cross-sectional view of a portion of the concrete wall showing an alternative position of the insulation layer; and FIG. 10 is a horizontal cross-sectional view of tlne concrete wall taken along view line 10-10 of FIG. 9.
DETAILED DESCRIPTION
Referring first to FIG. 1, numeral 10 designates a concrete wall which has been poured between first and second conventional forms 12 and 19. E'orms 12, 14 are held together by metal strips or ties 16 as in conventional practice. however, as stnown most clearly io FIG. 3, each of ties 16 includes a non-conventional slot 17 for a purpose hereinafter described. Numeral 18 represents a conventional footing for supporting the wall, and numeral 20 represents a plurality of conventional reinforcing bars ("rebar") which extend horizontally through the poured concrete to add strencli.la to the wall.
The structure described thus far is typical of the manner of forming poured concrete walls. After the concrete hardens, forms 12 and 14 are removed and the concrete wall is complete. If insulation is to be added, frame members (not shown) must be secured to the wall, or sheets or rolls of insulation must be secured by pneumatic nailing guns. As previously stated, this double-step procedure is both tame consuming and costly.
In the present invention, layers or panels of insulation 22 are secured in place before the concrete is poured between forms 12, 14. The means for securing the insulation in place during the pouring of the concrete comprise clips or wedges 23 and anchors or connectors 24.
Clips or wedges 23, hereinafter wedges, are shown in detail in FIGS. 2 and 4. Each wedge comprises a molded piece of plastic, such as polypropylene, which is in tl~e form of a double-ended V-shape with an open hole 26 in the central region. As such, the wedges are flexible ar~~i resilient so that they rnay be squeezed together in the center portion and inserted into slots 17 of ties 16.
Upon insertion, the center portions of the wedges expmod such that grooves 28 lock in ties 16 and the wedges extend horizontally. As shown most clearly in F'IG. 2, approximately one-half of each wedge becomes embedded .in the insulation panel, and the other half becomes embeil~~led in the poured concrete. As a result, the insulation panels become locked to fixed ties 16 so that the lightweight panels cannot "float" upwardly when the concrete is poured.
In addition to ties 16 and wedges 23, the present invention provides anchors or connectors 29 as shown in FIGS. 1 and 5-7. Preferably, connector elements 24 are in the form of a web portion 32 having openings 34 so tluat=
the poured concrete passes through and fills the openings as shown in E'IG. 1. Thus, as the concrete hardens, connectors 29 become bound and locked in the concrete.
As further shown most clearly in FIGS. 1 and 5-7, each connector 24 includes an enlarged head portion 36 which extends laterally and vertically at a right angaE.~
relative to the web portion. Thus, when the web portion of each connector passes through a slot 38 in t1e insulation panel as shown in FIGS. 1 and 8, the panel i.s retained by head portion 36 while the web portion is retained in and by the concrete. In the preferred embodiment, it will be understood that the area of the insulation surrounding slot 38 may be recessed or counter-sunk such that the exposed surface of the connector head is flush with the surface of the insulation. 1-Iowever, the thickness of the head portion is only in the order of 1/4 inch or less such that counter-sinking is not necessary.
Also in i-he preferred embodiment, stiffening side bars or ribs 37 may be added as most clearly shown in FIGS. 5 and 7, and the stiffening ribs may be provided with barbs 39 for engaging in insulation layer 22. ~ll~;ce, the upper and lower portions of connectors 24 may be provided witt barbs 41 which further engage and hold tlm insulation panel in place. In addition, in order to accommodate walls of either 6 or 8 inches in thickness, the horizontal length of connectors 24 may be manufactured of a uniform 8 inch length, and with groc» es 42 as shown in FIG. 5 near the tip of the connector suc:fo that the tip may be easily broken off for 6 inch walls.
In the foregoing description, connectors 24 may toe held in place during the concrete pouring by virtue of a tight frictional fit between the web portion 32 and slot.
38 of the insulation panel and the frictional engagerncut of barbs 39 and 41. however, a substantially greater securing of the connectors may be effected by providing one or more notches, grooves or hook portions 40 as sWnwn in FIGS. 1 and 5. These hook portions may be engaged k.~y rebar 20 so as to positively lock connectors 24 in place before, during and after the concrete is poured, Connectors 24 may be composed of any rigid materiel, but they are preferably composed of molded plastic suol~
as for example, polypropylene or polyethylene. Such materials may be easily molded, are of low thermal conductivity and are low cost. Most importantly, they provide an excellent medium for receiving nails, screws, staples or other means through heads 36 for securing tlm later installation of additive wall materials such as plaster board, paneling or other finishing layers.
Insulation layer 22 may be composed of any commercially available material of low thermal conductivity, but is preferably composed of rigid panels of expanded or extruded polystyrene. In addition to the thermal insulation value of such panels, their inherent properties provide a vapor barrier and their thermal properties are not deteriorated by moisture.
From the foregoing description of one preferr.:ed embodiment it will be apparent that numerous variatior~_;
in the details will be readily apparent to those skilJ_c~l in the art. For example, as shown in FIGS. 9 - 10, i.nsu7.ation layer 2?_.' may be positioned within the interior of concrete wall 10 during the pouring of the concrete. This is of particular benefit in the pouring of concrete walls for corrunerci.al-type buildings where no additional finishing of the interior wall is to be provided for after the pouring. In this situation, ties 16' are provided with two slots 17 and 17' and, as shown in FIG. 10, two wedges 23 and 23' are engaged in these slots such that approximately half of each wedge is embedded in foam insulation 22' and the other half becomes embedded in the poured concrete. In au y event, wedges 23 and 23', and ties 16' with double slots 17, L7' positively engage the insulation layer 22' and hold it securely, and against floating or otherwise moving upwardly or sideways during the pouring of the concrete.
This embodiment produces an insulated wall of the same R
value as previously described, but with the insulation layer contained within the concrete wall despite the very substantial buoyant forces which are encountered in tloe pouring of the concrete.
Accordingly, it will be understood that the foregoing description is purely illustrative of the principles of the invention, and that the invention is not intended to be limited other than as expressly set forth in the clairns interpreted under the doctrine of equivalents.
FIELD OF THE INVENTION
The present invention relates to poured concrete walls and, more particularly, to poured concrete walls including a layer of thermal insulation for reducing toeat transfer in which the insulation layer is secured to the concrete wall at the time of pouring the concrete.
BACKGROUND
Concrete walls are commonly formed by pouring concrete between inner and outer forms and, after hardening, insulation materials for reducing the therm~~l R value may be added to the concrete walls. In order to do so, frame members may be applied to the concrete walk such as by using pneumatic guns and concrete nails, arid then the insulating material may be secured to the frame members. Alternatively, the insulation may be secured t_o the concrete wall by concrete nails. Such multi-step S assembly procedures are both time consuming and costly.
Thus, there has long been a need for a system and a method whereby poured concrete walls may be formed and insulated at the same time in one step.
SUMMARY
The present invention provides an apparatus and method for securing an insulation layer in place while the concrete is poured between conventional forms, and for continuing to secure the insulation layer to the poured concrete wall after the forms have been removed.
I~ BRIEf DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a poured concrete wall with a thermal insulation layer secured thereto;
FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. l;
0 FIG. 3 is an en7_arged side-elevational v_i..ew of once tie strip;
FIG. 4 is a top plan view of a wedge which is inserted into the tie strip;
FIG. 5 is an enlarged, side elevational view of ore form of support element for securing the insulation layer to the concrete wall prior to, during, and after the concrete is poured;
FIG. 6 is a front plan view of the support element taken along line 6-6 of FIG. 5;
FIG. 7 is a top plan view of the support element taken along line 7-7 of FIG. 5;
FIG. 8 is an elevational view of a plurality of insulation panels secured to the concrete wall by a plurality of support elements;
FIG. 9 is a vertical cross-sectional view of a portion of the concrete wall showing an alternative position of the insulation layer; and FIG. 10 is a horizontal cross-sectional view of tlne concrete wall taken along view line 10-10 of FIG. 9.
DETAILED DESCRIPTION
Referring first to FIG. 1, numeral 10 designates a concrete wall which has been poured between first and second conventional forms 12 and 19. E'orms 12, 14 are held together by metal strips or ties 16 as in conventional practice. however, as stnown most clearly io FIG. 3, each of ties 16 includes a non-conventional slot 17 for a purpose hereinafter described. Numeral 18 represents a conventional footing for supporting the wall, and numeral 20 represents a plurality of conventional reinforcing bars ("rebar") which extend horizontally through the poured concrete to add strencli.la to the wall.
The structure described thus far is typical of the manner of forming poured concrete walls. After the concrete hardens, forms 12 and 14 are removed and the concrete wall is complete. If insulation is to be added, frame members (not shown) must be secured to the wall, or sheets or rolls of insulation must be secured by pneumatic nailing guns. As previously stated, this double-step procedure is both tame consuming and costly.
In the present invention, layers or panels of insulation 22 are secured in place before the concrete is poured between forms 12, 14. The means for securing the insulation in place during the pouring of the concrete comprise clips or wedges 23 and anchors or connectors 24.
Clips or wedges 23, hereinafter wedges, are shown in detail in FIGS. 2 and 4. Each wedge comprises a molded piece of plastic, such as polypropylene, which is in tl~e form of a double-ended V-shape with an open hole 26 in the central region. As such, the wedges are flexible ar~~i resilient so that they rnay be squeezed together in the center portion and inserted into slots 17 of ties 16.
Upon insertion, the center portions of the wedges expmod such that grooves 28 lock in ties 16 and the wedges extend horizontally. As shown most clearly in F'IG. 2, approximately one-half of each wedge becomes embedded .in the insulation panel, and the other half becomes embeil~~led in the poured concrete. As a result, the insulation panels become locked to fixed ties 16 so that the lightweight panels cannot "float" upwardly when the concrete is poured.
In addition to ties 16 and wedges 23, the present invention provides anchors or connectors 29 as shown in FIGS. 1 and 5-7. Preferably, connector elements 24 are in the form of a web portion 32 having openings 34 so tluat=
the poured concrete passes through and fills the openings as shown in E'IG. 1. Thus, as the concrete hardens, connectors 29 become bound and locked in the concrete.
As further shown most clearly in FIGS. 1 and 5-7, each connector 24 includes an enlarged head portion 36 which extends laterally and vertically at a right angaE.~
relative to the web portion. Thus, when the web portion of each connector passes through a slot 38 in t1e insulation panel as shown in FIGS. 1 and 8, the panel i.s retained by head portion 36 while the web portion is retained in and by the concrete. In the preferred embodiment, it will be understood that the area of the insulation surrounding slot 38 may be recessed or counter-sunk such that the exposed surface of the connector head is flush with the surface of the insulation. 1-Iowever, the thickness of the head portion is only in the order of 1/4 inch or less such that counter-sinking is not necessary.
Also in i-he preferred embodiment, stiffening side bars or ribs 37 may be added as most clearly shown in FIGS. 5 and 7, and the stiffening ribs may be provided with barbs 39 for engaging in insulation layer 22. ~ll~;ce, the upper and lower portions of connectors 24 may be provided witt barbs 41 which further engage and hold tlm insulation panel in place. In addition, in order to accommodate walls of either 6 or 8 inches in thickness, the horizontal length of connectors 24 may be manufactured of a uniform 8 inch length, and with groc» es 42 as shown in FIG. 5 near the tip of the connector suc:fo that the tip may be easily broken off for 6 inch walls.
In the foregoing description, connectors 24 may toe held in place during the concrete pouring by virtue of a tight frictional fit between the web portion 32 and slot.
38 of the insulation panel and the frictional engagerncut of barbs 39 and 41. however, a substantially greater securing of the connectors may be effected by providing one or more notches, grooves or hook portions 40 as sWnwn in FIGS. 1 and 5. These hook portions may be engaged k.~y rebar 20 so as to positively lock connectors 24 in place before, during and after the concrete is poured, Connectors 24 may be composed of any rigid materiel, but they are preferably composed of molded plastic suol~
as for example, polypropylene or polyethylene. Such materials may be easily molded, are of low thermal conductivity and are low cost. Most importantly, they provide an excellent medium for receiving nails, screws, staples or other means through heads 36 for securing tlm later installation of additive wall materials such as plaster board, paneling or other finishing layers.
Insulation layer 22 may be composed of any commercially available material of low thermal conductivity, but is preferably composed of rigid panels of expanded or extruded polystyrene. In addition to the thermal insulation value of such panels, their inherent properties provide a vapor barrier and their thermal properties are not deteriorated by moisture.
From the foregoing description of one preferr.:ed embodiment it will be apparent that numerous variatior~_;
in the details will be readily apparent to those skilJ_c~l in the art. For example, as shown in FIGS. 9 - 10, i.nsu7.ation layer 2?_.' may be positioned within the interior of concrete wall 10 during the pouring of the concrete. This is of particular benefit in the pouring of concrete walls for corrunerci.al-type buildings where no additional finishing of the interior wall is to be provided for after the pouring. In this situation, ties 16' are provided with two slots 17 and 17' and, as shown in FIG. 10, two wedges 23 and 23' are engaged in these slots such that approximately half of each wedge is embedded in foam insulation 22' and the other half becomes embedded in the poured concrete. In au y event, wedges 23 and 23', and ties 16' with double slots 17, L7' positively engage the insulation layer 22' and hold it securely, and against floating or otherwise moving upwardly or sideways during the pouring of the concrete.
This embodiment produces an insulated wall of the same R
value as previously described, but with the insulation layer contained within the concrete wall despite the very substantial buoyant forces which are encountered in tloe pouring of the concrete.
Accordingly, it will be understood that the foregoing description is purely illustrative of the principles of the invention, and that the invention is not intended to be limited other than as expressly set forth in the clairns interpreted under the doctrine of equivalents.
Claims (13)
1. A system for thermally insulating a wall of poured concrete comprising:
a) first and second wall forms horizontally spaced apart;
b) at least two tie strips spaced vertically apart and having ends connected to said first and second wall forms;
c) each of said tie strips having at least one slot;
d) wedge means extending through said slot of each tie strip; and e) said slots and wedge means being located between said first and second wall forms for securing a layer of thermal insulation between said first and second wall forms during the pouring of the concrete.
a) first and second wall forms horizontally spaced apart;
b) at least two tie strips spaced vertically apart and having ends connected to said first and second wall forms;
c) each of said tie strips having at least one slot;
d) wedge means extending through said slot of each tie strip; and e) said slots and wedge means being located between said first and second wall forms for securing a layer of thermal insulation between said first and second wall forms during the pouring of the concrete.
2. The system of Claim z wherein said wedge means have a hollow central portion whereby said wedge means fractionally engage said tie strips in said slots.
3. The system of Claim 2 wherein said wedge means are composed of plastic.
4. A system for increasing the insulating R value of a wall of poured concrete comprising:
a) first and second wall means for holding poured concrete; said first and second wall means being horizontally spaced apart;
b) horizontally extending tie strip means, connected to said first and second wall means, for securing said wall means in horizontally spaced relationship to each other;
c) hole means in said tie strip means, said hole means being positioned in said tie strip means at a position between said first and second wall means;
and d) securement means for securing a vertically extending layer of insulation in place between said first and second wall means, said securement means extending horizontally through said hole means in said tie strip means for engaging both said insulation layer and said poured concrete.
a) first and second wall means for holding poured concrete; said first and second wall means being horizontally spaced apart;
b) horizontally extending tie strip means, connected to said first and second wall means, for securing said wall means in horizontally spaced relationship to each other;
c) hole means in said tie strip means, said hole means being positioned in said tie strip means at a position between said first and second wall means;
and d) securement means for securing a vertically extending layer of insulation in place between said first and second wall means, said securement means extending horizontally through said hole means in said tie strip means for engaging both said insulation layer and said poured concrete.
5. The system of Claim 4 wherein said hole means comprise first and second holes extending through said tie strip means, and wherein said securement means comprise first and second securing means extending horizontally through said first and second hole means for engaging said vertically extending layer of insulation in place between said first and second wall means during pouring of said poured concrete wall.
6. The system of Claim 5 wherein said first and second holes comprise horizontally extending slots in said tie strips means.
7. The system of Claim 5 wherein said securement means comprise first and second securing means for frictionally engaging opposite sides of said insulation layer for preventing said insulation layer from rising during the pouring of the concrete.
8. The system of Claim 7 wherein said first and second securing means comprise flexible wedge means for engaging both said insulation layer and said poured concrete.
9. The system of Claim 8 wherein each of said first and second securing means comprise flexible plastic wedges of a size and shape to snap into and be secured by said slots in said tie strip means.
10. A tie strip for securing first and second form walls during the pouring of a concrete wall between said form walls comprising:
a) elongated strip means having first and second ends for securing said first and second form walls in horizontally spaced relationship during and after the pouring of concrete therebetween; and
a) elongated strip means having first and second ends for securing said first and second form walls in horizontally spaced relationship during and after the pouring of concrete therebetween; and
11 b) said elongated strip means including at least one horizontally extending slot means of a size and shape for receiving and retaining at least one flexible wedge means for engaging and securing a vertically extending layer of insulation during the pouring of the concrete, and wherein c) said elongated strip means includes two horizontally extending slots of a size and shape for receiving and retaining two flexible wedge means positioned on opposite sides of laid vertical insulation layer.
11. A tie strip for securing first and second form walls during the pouring of a concrete wall between said form walls comprising:
a) elongated strip means having first and second ends for securing said first and second form walls in horizontally spaced relationship during and after the pouring of concrete therebetween; and b) said elongated strip means including at least one horizontally extending slot means of a size and shape fox receiving and retaining at least one flexible wedge means fox engaging and securing a vertically extending layer of insulation during the pouring of the concrete, and wherein c) said flexible wedge means comprise wedges having a hollow central portion, and said wedges are of a size and shape so as to be inserted into and
11. A tie strip for securing first and second form walls during the pouring of a concrete wall between said form walls comprising:
a) elongated strip means having first and second ends for securing said first and second form walls in horizontally spaced relationship during and after the pouring of concrete therebetween; and b) said elongated strip means including at least one horizontally extending slot means of a size and shape fox receiving and retaining at least one flexible wedge means fox engaging and securing a vertically extending layer of insulation during the pouring of the concrete, and wherein c) said flexible wedge means comprise wedges having a hollow central portion, and said wedges are of a size and shape so as to be inserted into and
12 frictionally retained by said horizontally extending slot means.
13
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/065,285 | 1998-04-23 | ||
| US09/065,285 US6079176A (en) | 1997-09-29 | 1998-04-23 | Insulated concrete wall |
| US09/243,382 US6351918B1 (en) | 1997-09-29 | 1999-02-01 | Insulated concrete wall |
| US09/243,382 | 1999-02-01 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2265135A1 CA2265135A1 (en) | 1999-10-23 |
| CA2265135C true CA2265135C (en) | 2006-05-30 |
Family
ID=29714515
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2265135 Expired - Fee Related CA2265135C (en) | 1998-04-23 | 1999-03-10 | Insulated concrete wall |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2265135C (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102012219931A1 (en) | 2012-10-31 | 2014-04-30 | Doka Industrie Gmbh | Wall formwork system used for manufacturing wall section used in building, has holding unit which is attached to vertical system supporting rail, for holding isolation panels at side surface of supporting rails |
| CN117803189A (en) * | 2023-12-29 | 2024-04-02 | 中国核工业华兴建设有限公司 | Construction method of particulate matter supported vertical curved surface template |
-
1999
- 1999-03-10 CA CA 2265135 patent/CA2265135C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2265135A1 (en) | 1999-10-23 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20170310 |