JP2003529691A - Insulated wall structure - Google Patents

Abstract

(57) Abstract: Insulated wall forms that are held in place and include exterior wall coverings, such as plaster or brick appearance, interior wall coverings, such as gypsum board, or both exterior and interior wall coverings, are cured. Simplifies wall construction using conductive materials, such as concrete, and reduces the steps required to install the final wall.

Description

Detailed Description of the Invention

The present invention relates to members and systems used in the construction of permanent curable material walls in building construction. The present invention relates in particular to members and systems that are held in place after a hardenable material such as concrete used to form a wall has hardened. The present invention more particularly relates to members and systems in which at least one, and preferably both, of the inner and outer surfaces of the wall form part of the member.

In North America, concrete wall assembly usually requires many steps.
First, the mold walls that form the cavities or gaps are assembled. Second, pour concrete into this cavity or gap. Third, harden the concrete sufficiently so that the formwork walls can be removed. Fourth, remove the formwork wall.

In residential construction, concrete base walls and other concrete walls are constructed using the methods described above. After building the concrete wall, the upper part of the concrete wall,
Timber frames are assembled on the sides or both as needed. The usual next step is to insert insulation between the wood frame members. After this, the interior and exterior of the wall are finished.

The above steps are time consuming, inefficient, costly and wasteful, especially on the materials and labor used to process and remove formwork walls. As is common in particularly cold climates, when insulating all walls, including the base wall, it is necessary to remove the formwork walls and then assemble and insulate the wood formwork walls, which is a building Delay the construction process.

Other methods, which have been practiced for several years, especially in Europe, combine many construction steps by using foam insulation materials to form permanent formwork walls. The foam insulation material is fixed in place, no additional insulation is needed, and finishing materials may be applied to the interior and exterior walls if desired. This method is used for both the base wall and the above ground wall.

US Pat. No. 5,657,600 discloses a building component including first and second high density foam panels spaced parallel to each other. At least two connecting members span the gap between the panels and are molded into the panels to tie the panels together. Each connecting member has a pair of elongate end plates abutting and vertically disposed on the outer surface of the foam panel. The connecting member has an X shape and is formed of a plastic material such as high density flame retardant polyethylene, flame retardant polypropylene, or polystyrene.

US Pat. No. 4,730,422 discloses an insulating, non-removable type of concrete wall forming structure, device and system. In a modular synthetic foam concrete concrete structure, many pairs of modular concrete impermeable panels are stacked on top of each other and joined end to end. This pair of panels includes vertically arranged rows of Ts into which the T ends of synthetic plastic fit to fit. The outer surface of the slotted portion has embossed markings to allow the panel to be screwed into synthetic plastic to be secured, and other exterior wall finish covers to be secured to the panel or wall portion.

US Pat. No. 4,889,310 discloses a concrete forming system that includes a number of opposed first and second polystyrene foam panels bonded in opposed, parallel, and spaced relationship. The foam panel has tie slots arranged vertically along the top and bottom edges. The plastic ties match the tie slots and hold the foam panel in a separate configuration. Each tie end has a formed T-shaped inner and outer paddle member which conforms to the inner and outer panel surfaces, respectively. Tie ends should be removed if one or both foam tie panels are removed
After the concrete hardens, it is destroyed and removed. The ties may be modular, including spacer straps and tie ends that can be lengthened or shortened if desired to vary the spacing between foam tie panels.

US Pat. No. 5,107,648 describes a tie for assembling a pair of spaced form panels, such as foam panels. The tie allows at least one to be compressed through the foam panel without cutting the tie slot.
It has two beveled ends. The tie also has an integrally formed end plate opposite the beveled end. As the beveled ends pass through both spaced foam panels, spacers are inserted between the panels to hold the correct alignment and gusset plates are provided on the beveled ends to hold the panels in place.

US Pat. No. 5,107,648 discloses an insulating wall structure using tongue-and-groove foam plates that are held apart by a spacer rod assembly. The spacer rod assembly includes an outer support plate having rod receiving segments that pass through the foam plate, an inner support plate that slides over the rod receiving segments, spacer rods that fit the rod receiving segments of both plates, and spacers within each rod receiving segment. Includes a lock pin that holds the end of the rod in place. The spacer rod may take various forms, from cylindrical (both solid and hollow) to externally threaded shaped bodies other than cylindrical. In the latter configuration, the rod receiving segment is internally threaded. The outer support plate functions as a coating material such as plasterboard or plaster.

The present invention includes a first panel segment, a second panel segment, and a number of connectors, each of the first panel segment and the second panel segment being a flat structure. Panel segment and a second panel segment are spaced apart from each other to form a cavity, the first panel segment is aligned parallel to the second panel segment, and each of the connectors has a first end. And a second end remote from the first end, the first end being removably coupled to the first panel segment and the second end being the second end. Removably coupled to the panel segment, a number of connectors hold the first and second panel segments apart and in parallel, allowing the wall formwork to cure Insulating wall formwork forming a cavity for receiving possible filling materials.

FIG. 1 shows a wall panel segment 20 used as part of a wall formwork 10 (shown in FIG. 3).
Shows a part of. The panel segment 20 is a laminated structure including an inner layer 21 and an outer layer. The inner layer 21 has an inner surface 22 and a spaced parallel outer surface 23. The inner layer 21 is formed with a large number of traversing passages 24 that connect the inner surface 22 and the outer surface 23 with a fluid. The outer layer 25 has an inner surface 26 and a spaced parallel outer surface 28. A large number of slots 27 are formed in the outer layer 25. Outer surface 2 of inner layer 21
3 and the inner surface 26 of the outer layer 25 are in contact with each other. Such contact is preferably made with an adhesive material (not shown) disposed between the surfaces 23 and 26. The slot 27 (preferably T-shaped) is in fluid communication with the passage 24 of the inner layer 21. The combination of slots 27 and passages 24 form multiple channels to receive the connector ends (shown in Figures 2 and 3).

The channels in the wall panel segment 20, also referred to as the first panel segment, preferably have elongated openings in the inner layer 21 (preferably the foam layer) and the outer layer 2.
5 includes a cavity. The opening and the cavity are in fluid communication with each other. The cavity and the opening each have a predetermined width. The width of the cavity is preferably larger than the width of the opening. Such channels readily accept connectors such as connector 30 shown in FIG.

FIG. 2 shows a partial cross section of the wall panel segment 20 with a partial cross section of the connector 30. The connector 30 has a first end 31 and a second end 35 (shown in FIG. 3) separated by a center shaft 33. Shaft 33 near ends 31 and 35
The middle part of the is externally threaded. FIG. 2 shows a threaded segment 32 near the end 31. The threaded segment 34 (not shown) is near the end 35 (shown in FIG. 3). The internally threaded compression fitting 36 is threadedly engaged to the externally threaded shaft portions 32 and 34 (not shown) to connect the connector 30 to the wall panel segments 20 and 40 (see FIG. 3). Hold) in a fixed position with respect to

Although not shown in FIGS. 2 and 3, the wall panel segments 20 and 40 are preferably seals disposed between a connector end, such as the first end 31 of the connector 30, and a compression fitting or nut 36. The sealing means further includes means for contacting and sealing both the inner foam layer 21 of the panel segment 20 or the inner foam layer 41 of the panel segment 40 and the compression nut 36.

Those skilled in the art know that various combinations of externally threaded shaft segments 32 and 34 and internally threaded compression fittings 36 will accomplish the same purpose. . Illustratively, the collar includes one or more protrusions from which the collar slides, engages a ring on the shaft, and the collar with locking means slides and locks. Those skilled in the art also recognize that the compression fitting 36, etc., need not be solid or continuous. In fact, for ease of installation, the fitting preferably has a slot, such as a threaded portion inside fitting 36, that connects between the outer end of the fitting and the central opening of the fitting. This slot allows the fitting to slide onto the central shaft 33 of the connector 33 at the assembly site.

FIG. 3 shows a wall formwork. The formwork 10 includes a wall segment 20, a wall panel segment 40 and a number of connected connectors 30. Wall panel segment 40 is preferably a mirror image of wall segment 20 that secures the material from which outer layers 25 and 45 are formed. Accordingly, the wall panel segment 40 is a laminated structure including the inner layer 41 and the outer layer 45. The inner layer 41 has an inner surface 42 and a parallel outer surface 43 spaced therefrom. Both the inner surface 42 and the outer surface 43 are connected to the inner layer 41 by a fluid,
A large number of passageways 44 are provided to traverse. The outer layer 45 has an inner surface 46 and a parallel outer surface 48 spaced therefrom. The outer layer 45 is provided with a number of slots 47. The outer surface 43 of the inner layer 41 and the inner surface 46 of the outer layer 45 are in contact with each other. Such contact is provided by an adhesive layer (not shown) located between surfaces 43 and 46. Slots 47 (preferably T-shaped) are channels 44 in inner layer 41.
And fluid communication. Similar to the combination of slot 27 and passage 24 shown in FIG. 1, the combination of slot 47 and passage 44 has connector ends (shown in FIGS. 2 and 3).
Gives you a number of channels to accept.

The channels in the wall panel, also called the second panel segment, preferably include an elongated opening in the inner layer 41, preferably the foam layer, and a cavity in the outer layer 45. Similar to layers 21 and 25, the openings and cavities are in fluid communication with each other, each having a predetermined width, preferably the width of the cavities is greater than the width of the openings. This channel is preferably a connector such as the connector shown in FIGS.
Accept the connector end.

A connector, such as connector 30, is preferably located in many connector assemblies. Each connector assembly more preferably includes a grid such that each connector is spaced apart and aligned parallel to at least one other connector. This arrangement is preferably maintained by at least one connector link between each two adjacent connectors in the connector assembly.
As shown in FIG. 3, the multiple connectors 30 are connected to each other by multiple links 32. FIG. 3 shows two links 32 between each pair of connectors 30. Two links 32 per pair of connectors give satisfactory results in terms of simplicity and uniformity of spacing, but more or fewer links may be used without departing from the scope of the invention. In fact, this link may be eliminated if desired. This link 32 may be flexible in terms of storage and handling prior to using the wall formwork 10. The link 32 may be rigid to provide additional stability prior to inserting the curable material into the cavity formed by the inner surfaces 22 (FIG. 1) and 42 of the panel segments 20 and 40.

The ends 31 and 35 of the connector may be of various shapes without departing from the scope of the invention. This shape requires a sliding fit with at least a portion of slots 27 (FIG. 2) and 47 of panel segments 20 and 40. This shape desirably provides friction, but slides over the surfaces of slots 27 and 47. This shape includes, for example, squares, rectangles, parallelograms, trapezoids, polygons (eg hexagons and octagons), circles and ovals. This shape preferably has at least the same thickness as the width of slots 27 and 47, but more preferably
It has a thickness slightly larger than the width to give excellent friction.

Particularly preferred connectors are design patents 383,373, US Pat. No. 4,706,429,
A foldable connector as disclosed in U.S. Pat. No. 4,730,422 and U.S. Pat. No. 4,885,888. By using such a connector, the heat insulating wall formwork of the present invention can be constructed and the connector can be folded into a flat configuration for shipping. The connector can be easily unfolded and set for use.

FIG. 4 shows another preferred embodiment of the panel segment designated 20 '. Panel segment 20 'differs from panel segment 20 in which outer layer 25 has slots 27 in that outer layer 25' has no slots. Like the segment 20, the segment 20 'is a laminated structure including an inner layer 21' and an outer layer 25 '.
The inner layer 21 'has an inner surface 22' and a spaced parallel outer surface 23 '. Inner layer 2
1'also has a number of passages 24 'that fluidly connect the inner surface 22' and the outer surface 23 '. The passage 24 'preferably has a T-shape provided by the combination of the passage 24 and the slot 27 of the panel 20. FIG. 4 shows the outer surface 23 'of the inner layer 21'.
The passages 24 'are shown as traversing, but are in fluid communication with a) located in the inner layer 21 ", b) traversing only the inner layer 22', and c) only the inner surface 22 '. May be arranged towards the inner surface 22 '.
6'and spaced parallel outer surfaces 28 '. Outer surface 23 'of inner layer 21'
And the inner surface 26 'of the outer layer 25' is in contact with each other. Similar to panel 20,
This contact is preferably made with an adhesive material (not shown) located between the surfaces 23 'and 26'.

The T-shaped passages 27 and 24 ′ may be formed by any suitable means. For example, a router or other similar device may be used to cut the passage after contacting the inner layer 21 'and the outer layer 25' with each other. A more preferable method is the inner layer 21.
A strip of'narrow (for outer layer 25 ') is used. The outer surface 23 'of the inner layer 21' is longitudinally on each side to form a T-shaped passage 24 'when the two strips of the inner layer 21' are arranged in close proximity but not in physical contact. Forming a step or shoulder.

The outer panel 40 is preferably modified similarly to the inner panel 20 to form an outer panel 40 ′ (not shown). Similarly, another preferred wall formwork 10 '
Includes an inner panel 20 'and an outer panel 40' instead of the inner panel 20 and the outer panel 40. Of course, the panels may be mixed, for example inner panel 20 and outer panel 40 ', two inner panels 20, 20', or a combination of one panel 20 and one panel 20 ', or two outer panels 40, 40'. , Or a combination of one panel 40 and one panel 40 'may be provided.

The inner panels 20 and 20 ′ are a laminated structure that includes at least two layers, an inner layer that includes an insulating foam material and an outer layer that includes an interior facing material. Interior surface materials are gypsum board, decorative board, wood, mirror board, brick, fiber board, vinyl board,
Or other materials that provide acceptable aesthetics, functionality, or both.

The outer panels 40 and 40 ′ are a laminated structure that includes at least two layers, an inner layer that includes an insulating foam material and an outer layer that includes an exterior surface material. The exterior surface material is selected from wood, brick, plaster, concrete blocks, cement board laminates, fiberboard, vinyl siding, wood laminates, brick veneers, or other materials that provide acceptable functionality and optionally aesthetics.

The insulating foam material may be any cellular insulating material that is sufficiently rigid to substantially maintain its shape during construction and use of the wall formwork. Preferably, the insulating foam panel is a cellular polymer foam. It is formed from a thermosetting or thermoplastic polymer. Suitable polymers are polyethylene (low density polyethylene (LDPE), linear low density polyethylene (LLDPE), high density polyethylene (
HDPE) and substantially linear ethylene interpolymers), polypropylene, polyurethanes, polyisocyanurates, ethylene vinyl acetate copolymers, polyvinyl chloride, phenol formaldehyde resins, ethylene styrene interpolymers, and alkenyl aromatic polymers and copolymers. styrene,
Alpha methyl styrene, ethyl styrene, vinyl benzene, vinyl toluene,
Including those derived from alkenyl aromatic compounds such as chlorostyrene and bromostyrene). The preferred alkenyl aromatic polymer is polystyrene. Minor amounts of monoethylenically unsaturated compounds such as C _2-6 alkyl acids and esters, ionomer derivatives, and C _4-6 dienes may also be copolymerized with the alkenyl aromatic compound. Examples of copolymerizable compounds include acrylic acid, methacrylic acid, ethacrylic acid, maleic acid, itaconic acid, and acrylonitrile. Mixtures of two or more of the above or mixtures of the above with other polymers or resins are also suitable. Rigid polyurethane, polystyrene, polyisocyanurate and phenolic foams are preferred, polystyrene and polyisocyanurate foams being particularly preferred. This foam may be used as it is, or the outer surface may be mechanically modified. Mechanical modification includes filing, scratching, flattening or other actions that change the outer surface from its foamed state.

Suitable alkenyl aromatic polymers include those derived from alkenyl aromatic compounds such as styrene, alphamethylstyrene, ethylstyrene, vinylbenzene, vinyltoluene, chlorostyrene, and bromostyrene. The preferred alkenyl aromatic polymer is polystyrene. A small amount of monoethylenically unsaturated compound,
For example, C _2-6 alkyl acids and esters, ionomer derivatives, and C _4-6 dienes may also be copolymerized with the alkenyl aromatic compound. Examples of copolymerizable compounds are acrylic acid, methacrylic acid, ethacrylic acid, maleic acid, itaconic acid, acrylonitrile, maleic anhydride, methyl acrylate, ethyl acrylate, isobutyl acrylate, n-butyl acrylate, methyl methacrylate, vinyl acetate and Contains butadiene. The preferred foam is substantially (95 percent or more), most preferably completely polystyrene.

The insulating foam material can be prepared by any conventional method, extrusion foaming being preferred.

Slots 27 and 47 of wall panel segments 20 and 40 or slots 24 ′ and 44 of wall panel segments 20 ′ and 40 ′ to facilitate processing of wall forms 10 and 10 ′ and reduce assembly time. A lubricant may be placed on the surfaces of the connector ends 31 and 35 that contact the '(not shown). Suitable lubricants include mineral oils, synthetic oils and fluorocarbons.

The wall forms 10 and 10 ′ have cavities designed to accept load bearing materials, preferably hardenable materials such as concrete, fiber reinforced concrete or reinforced concrete. If desired, the cavity may further include a cavity liner. When used, the cavity liner is in close proximity and in physical contact with at least a portion of the inner surface of the selected combination of inner and outer panels 20, 20 ', 40 and 40'. The inner and outer surfaces are 22, 22 ', 42 and 42' (not shown), respectively. The cavity liner may be a polyolefin such as polypropylene, low density polyethylene,
Includes films of thermoplastic polymers which are high density polyethylene or linear low density polyethylene, polyamides, alkenyl aromatic polymers such as polystyrene, polyvinyl chloride, polycarbonate, acrylic polymers, or polyesters. The film may be unstretched, uniaxially stretched, or biaxially stretched. The film may include one or more conventional additives such as fillers, pigments, colorants, antioxidants, UV stabilizers, flame retardants, and processing aids.

Load bearing materials that provide suitable strength and hardness may be used. In order to make the wall structure inexpensive and simple, the load bearing capacity may be, for example, wood, stone, earth, sand or metal. They are advantageously in particulate form so that they can be easily poured into the formwork assembly. However, the present invention is suitable for pouring and curing load bearing materials after assembling a system of wall panels, insulating foam panels and panel connectors. Thus, various forms of cement such as Portland cement, aluminum cement and hydrated cement are suitable, as well as curable clays such as dry bricks, mortar, and curable mixtures of clay and cement. Concrete that is an aggregate of materials such as gravel, pebbles, sand, crushed stone, slag, or ash in a hardening matrix of cement or mortar such as Portland, aluminum or hydrated cement in terms of cost and properties Is preferably used. Generally, concrete or agglomerates useful in load bearing building walls are suitable for the present invention.

[Brief description of drawings]

[Figure 1]   It is a top view of a part of panel segment.

[Fig. 2]   It is a top view of a part shown in FIG. 1 with a part of connector.

FIG. 3 is a cross-sectional view of an insulating wall frame including two facing panel segments and multiple connectors of the type shown in FIG.

[Figure 4]   It is a partial top view of a part of panel segment.

─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Young, W. Scott             48674, MI, Michigan, United States             Drand Haskin Drive 3708

Claims (18)

[Claims] 1. A heat insulating wall formwork comprising a first panel segment, a second panel segment and a number of connectors, wherein the first panel segment and the second panel segment are flat structures. The first panel segment and the second panel segment are spaced apart from each other to form a cavity, the first panel segment is disposed parallel to the second panel segment, and each of the connectors is A second end having a first end and a second end remote from the first end, the first end being removably coupled to the first panel segment; Is removably coupled to the second panel segment and a number of connectors hold the first panel segment and the second panel segment apart and in parallel, and the wall formwork An insulating wall formwork that forms a cavity that receives a curable filling material. 2. The first panel segment is a laminated structure including at least two layers, an inner layer and an outer layer, wherein the inner layer comprises a heat insulating foam material and the outer layer comprises an exterior surface material. Item 2. The heat insulation wall formwork according to item 1. 3. The exterior surface material is wood, brick, stucco, concrete block, cement board laminate, fibreboard, vinyl siding, wood laminate, brick veneer, or provides acceptable functionality, preferably aesthetics. The heat insulating wall formwork according to claim 2, which is selected from the materials of 4. The second panel segment is a laminated structure including at least two layers, an inner layer and an outer layer, wherein the inner layer comprises a heat insulating foam material and the outer layer comprises an interior surface material. Item 2. The heat insulation wall formwork according to item 1. 5. The interior surface material is selected from gypsum board, decorative board, wood, mirror board material, brick, fiberboard, vinyl board, or other material that provides acceptable aesthetics and functionality. Insulated wall formwork as described. 6. The curable filter material is concrete, fiber reinforced concrete, reinforced concrete, portland cement, alumina cement, hydraulic cement, curable clay, or a curable mixture of cement and clay.
The heat insulation wall formwork according to claim 1. 7. The insulated wall formwork of claim 2, wherein each of the first panel segments has multiple grooves, the grooves receiving connector ends. 8. The groove in the first panel segment includes an elongated opening in the inner foam layer and a cavity in the outer layer, the opening and the cavity being in fluid communication with each other, the cavity. Each of the tee and the opening has a predetermined width,
The heat insulating wall formwork according to claim 7, wherein the width of the cavity is larger than the width of the opening. 9. The insulated wall formwork of claim 4, wherein each of the second panel segments has a number of grooves that receive the connector ends. 10. The groove in the second panel segment includes an elongated opening in the inner foam layer and a cavity in the outer layer, the opening and the cavity being in fluid communication with each other, the cavity The heat insulating wall formwork according to claim 9, wherein each of the tee and the opening has a predetermined width, and the width of the cavity is larger than the width of the opening. 11. The heat insulating wall according to claim 1, wherein at least one of the connectors is externally threaded at a position close to each connector end, and at least a part of the thread projects into the cavity. Formwork. 12. A large number of connectors are externally threaded, and at least one of the connectors is internally threaded to mate with a connector portion externally threaded. The insulated wall formwork of claim 11, including a compression nut to removably retain the connector in a fixed position relative to the first and second panel segments. 13. The insulated wall formwork of claim 12, further comprising sealing means disposed between the connector and the compression nut, the sealing means contacting both the inner foam layer of the panel segment and the compression nut. . 14. The connectors are arranged in a number of connector assemblies, each connector assembly including a grid, each connector being spaced apart from and parallel to at least one other connector, the arrangement comprising two connectors within the connector assembly. The insulated wall formwork of claim 1, maintained by at least one connector link between each adjacent connector. 15. The insulating wall formwork of claim 1, further comprising a cavity liner. 16. The cavity liner is adjacent to and in physical contact with at least a surface portion of the first panel segment, or is adjacent to and in physical contact with at least a surface portion of the second panel segment. The heat insulation wall formwork according to claim 15. 17. The insulated wall formwork of claim 15, wherein the cavity liner comprises a thermoplastic polymer film, the polymer selected from polyethylene, polyvinyl chloride, polypropylene, and polyester. 18. The insulated wall formwork of claim 1, wherein at least one connector end further comprises a lubricating material, the lubricating material being in physical contact with at least a surface portion of the connector end.