WO2010047919A1 - Locking tie and insulating concrete form - Google Patents

Abstract

The present invention is directed to locking tie members for insulating concrete forms that include a mid-section portion and two flanges. The mid-section portion includes a plurality of pour holes spaced vertically. The flanges extend along the vertical length of an edge of the mid-section and include a male locking portion and a female locking portion. The male locking portions and the female locking portions are adapted to secure a first locking tie to a second locking tie. The locking tie is used to assemble insulating concrete forms that include two or more first panel members, two or more second panel members, and two or more of locking tie members. The first panel and second panel members include two or more slots in an inner side extending vertically therethrough.

Description

LOCKING TIE AND INSULATING CONCRETE FORM

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to a locking tie, insulating concrete forms and systems that utilize the locking tie and insulating concrete walls and structures that include the insulating concrete forms and locking ties.

2. Description of the Prior Art

Concrete walls in building construction are most often produced by first setting up two parallel form walls and pouring concrete into the space between the forms. After the concrete hardens, the builder then removes the forms, leaving the cured concrete wall.

This prior art technique has drawbacks. Formation of the concrete walls is inefficient because of the time required to erect the forms, wait until the concrete cures, and take down the forms. This prior art technique, therefore, is an expensive, labor-intensive process. Accordingly, techniques have developed for forming modular concrete walls, which use a foam insulating material. The modular form walls are set up parallel to each other and connecting components hold the two form walls in place relative to each other while concrete is poured there between. The form walls, however, remain in place after the concrete cures. That is, the form walls, which are constructed of foam insulating material, often from expandable polystyrene (EPS), are a permanent part of the building after the concrete cures. The concrete walls made using this technique can be stacked on top of each other many stories high to form all of a building's walls. In addition to the efficiency gained by retaining the form walls as part of the permanent structure, the materials of the form walls often provide adequate insulation for the building.

Although the prior art includes many proposed variations to achieve improvements with this technique, drawbacks still exist for each design. The connecting components used in the prior art to hold the walls are constructed of (1) plastic foam, (2) high density plastic, or (3) a metal bridge, which is a non-structural support, i.e., once the concrete cures, the connecting components serve no function. Even so, these members provide thermal and sound insulation functions and have long been accepted by the building industry.

Typical ties used in an ICF do not span the entire height of the form, nor do they lock together. Rather, the ties are used solely to support an individual form in which they are placed and the various individual forms are stacked on top of each other. A particular problem that is encountered is "lifting," which is caused when concrete is poured into the forms.

Typically, when concrete is poured into the forms, they will separate at the horizontal seams due to the forces generated by placing wet concrete between the ICF walls, which leads to concrete escaping from the form walls, commonly referred to as "blowout". Seam lifting, concrete leakage and blowout problems have been addressed in the past by including intricate foam locking ends to try and secure the ICF seams; however, the locking ends are difficult to mold and are often damaged in transit, limiting their effectiveness. Additionally, the lack of vertical support in prior art stacked ICF structures results in "pillowing", a deformation in the ICF wall that occurs in the various unsupported sections.

A number of such insulating concrete forms made all or in part from molded EPS are known in the art, as disclosed, for example, in U.S. Patent Nos. 5,333,429; 5,390,459; 5,566,518; 5,568,710; 5,657,600; 5,709,060; 5,787,665; 5,822,940; 5,845,449; 5,887,401 ; 6,098,367; 6,167,624; 6,170,220; 6,235,367; 6,314,697; 6,318,040; 6,336,301 ; 6,363,683; 6,438,918; 6,526,713; 6,588,168; 6,647,686 and 6,820,384; and in U.S. Patent Application Publication Nos. 2002/0116889 and 2003/0005659. However, ICF's made according to these disclosures are prone to form deformation, blowout, concrete leakage, and/or pillowing due to pressure exerted by poured concrete.

Thus, there is a need in the art for composite pre-formed insulated concrete forms that are relatively inexpensive, easy to assemble and install and that are not prone to lifting, blowout, pillowing, and/or separation.

SUMMARY OF THE INVENTION The present invention provides a locking tie member that includes a mid-section portion, a first flange and a second flange. The mid-section portion includes a plurality of pour holes spaced along its length vertically. The first flange extends along the vertical length of a first edge of the midsection and includes a male locking portion at a first end and a female locking portion at a second end. The second flange extends along the vertical length of a second edge of the mid-section and includes a male locking portion at a first end and a female locking portion at a second end. The male locking portions and the female locking portions are adapted to secure a first locking tie to a second locking tie. The present invention also provides an insulating concrete form that includes two or more first panel members, two or more second panel members, and two or more of the locking tie members described above. The first panel members include two or more first slots in an inner side extending vertically therethrough and the second panel members include two or more second slots in an inner side extending vertically therethrough. The first flange of the locking tie member securably extends within the first slot of at least two first panel members and the second flange of the locking tie member securably extends within the second slot of at least two second panel members. The panel members are made of an expanded polymer matrix. A mold chamber is defined by the space between the inner side of the first panels and the inner side of the second panels.

The present invention further provides insulated concrete walls and buildings that include the above-described insulating concrete form.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation view of a locking tie member according to the invention; FIG. 2 is a side elevation view of a locking tie member according to the invention;

FIG. 3 is a top plan view of a locking tie member according to the invention; FIG. 4 is a perspective view of a locking tie member according to the invention;

FIG. 5 is a front elevation view of insulating concrete forms according to the invention;

FIG. 6 is a top plan view an insulating concrete form according to the invention; and

FIG. 7 is a perspective view insulating concrete forms according to the invention.

DETAILED DESCRIPTION OF THE INVENTION For the purpose of the description hereinafter, the terms "upper",

"lower", "inner", "outer", "right", "left", "vertical", "horizontal", "top", "bottom", and derivatives thereof, shall relate to the invention as oriented in the drawing Figures. However, it is to be understood that the invention may assume alternate variations and step sequences except where expressly specified to the contrary. It is also to be understood that the specific devices and processes, illustrated in the attached drawings and described in the following specification, is an exemplary embodiment of the present invention. Hence, specific dimensions and other physical characteristics related to the embodiment disclosed herein are not to be considered as limiting the invention. In describing the embodiments of the present invention, reference will be made herein to the drawings in which like numerals refer to like features of the invention.

Other than where otherwise indicated, all numbers or expressions referring to quantities, distances, or measurements, etc. used in the specification and claims are to be understood as modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties, which the present invention desires to obtain. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective measurement methods.

Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10; that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. Because the disclosed numerical ranges are continuous, they include every value between the minimum and maximum values. Unless expressly indicated otherwise, the various numerical ranges specified in this application are approximations.

As used herein, the term "expandable polymer matrix" refers to a polymeric material in particulate or bead form that is impregnated with a blowing agent such that when the particulates and/or beads are placed in a mold and heat is applied thereto, evaporation of the blowing agent (as described below) effects the formation of a cellular structure and/or an expanding cellular structure in the particulates and/or beads and the outer surfaces of the particulates and/or beads fuse together to form a continuous mass of polymeric material conforming to the shape of the mold.

As used herein, the term "polymer" is meant to encompass, without limitation, homopolymers, copolymers and graft copolymers. As used herein, the terms "(meth)acrylic" and "(meth)acrylate" are meant to include both acrylic and methacrylic acid derivatives, such as, the corresponding alkyl esters often referred to as acrylates and (meth)acrylates, which the term "(meth)acrylate" is meant to encompass. The present invention provides a locking tie that is capable of securing the components of an insulating concrete form (ICF) together in order to increase the overall strength of the wall as well as to create an uninterrupted vertical nailing strip from the top to the bottom of a resultant insulated concrete structure. The present locking tie is able to interlock with other ties placed above or below. The ability to lock the ties together provides a number of benefits. As an example, the resistance to "lifting" generated from pouring concrete into the forms is decreased. Typically, when concrete is poured into ICFs, they will want to separate at the horizontal seams due to the forces generated by placing wet concrete between the ICF walls. In the present invention, the locked tie will minimize or prevent the forms from separating while concrete is being poured into the form.

Another exemplary benefit is that the locked tie as described herein creates an uninterrupted nailing strip from the top to the bottom of the ICF. A further exemplary benefit obtained by using the present locking tie is the decreased reliance on intricate foam locking ends, which are difficult to mold, are easily damaged during transport and handling, and provide limited support . Failure of these foam locking ends can result in lifting, concrete leakage and/or blowout. Using the present interlockable tie allows for a much less complex form locking system, making the form easier to mold and the option of using less foam.

An additional exemplary benefit of the present locking tie is that it can span the entire height of an ICF, which reduces the amount of "pillowing" that may occur through unsupported sections of an ICF using prior art ties.

As shown in FIGS. 1-4, locking tie member 10 includes a midsection portion 12, first flange 14 and second flange 16. Mid-section portion 12 includes a plurality of pour holes 18 spaced along its length vertically. First flange 14 extends along the vertical length of first edge 20 of mid-section 12 and includes male locking portion 22 at first end 24 and female locking portion 26 at second end 28. Second flange 16 extends along the vertical length of second edge 30 of mid-section 12 and includes male locking portion 32 at first end 34 and female locking portion 36 at second end 38. Male locking portions 22 and 32 and female locking portions 26 and 36 are adapted to secure a first locking tie to a second locking tie.

The vertical length of locking tie 10, measured from first end 24 to second end 28, is at least 24 inches (61 cm), in some cases, at least 30 inches (76 cm) and, in other cases, at least 36 inches (91 cm) and, in particular embodiments, can be up to 120 inches (305 cm), in some cases up to 96 inches (244 cm) and, in other cases, up to 84 inches (213 cm). The vertical length of locking tie 10 is typically sufficient to securably extending within the first slot of at least two panel members as described below. The vertical length of locking tie 10 can be any value or range between any of the values recited above.

In embodiments of the invention, locking tie 10 can be made of metal, construction grade plastics, composite materials, ceramics, and the like.

Suitable construction grade plastics include, but are not limited to reinforced thermoplastics, thermoset resins, and reinforced thermoset resins. Thermoplastics include polymers and polymer foams made up of materials that can be repeatedly softened by heating and hardened again on cooling. Suitable thermoplastic polymers include, but are not limited to homopolymers and copolymers of styrene, homopolymers and copolymers of C₂ to C_2O olefins, C₄ to C₂₀ dienes, polyesters, polyamides, homopolymers and copolymers of C₂ to C₂₀ (meth)acrylate esters, polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides, polyurethanes, and combinations thereof.

Suitable thermoset resins are resins that when heated to their cure point, undergo a chemical cross-linking reaction causing them to solidify and hold their shape rigidly, even at elevated temperatures. Suitable thermoset resins include, but are not limited to alkyd resins, epoxy resins, diallyl phthalate resins, melamine resins, phenolic resins, polyester resins, urethane resins, and urea, which can be crosslinked by reaction, as non- limiting examples, with diols, triols, polyols, and/or formaldehyde. Reinforcing materials and/or fillers that can be incorporated into the thermoplastics and/or thermoset resins include, but are not limited to carbon fibers, aramid fibers, glass fibers, metal fibers, woven fabric or structures of the mentioned fibers, fiberglass, carbon black, graphite, clays, calcium carbonate, titanium dioxide, woven fabric or structures of the above-referenced fibers, and combinations thereof.

A non-limiting example of construction grade plastics are thermosetting polyester or vinyl ester resin systems reinforced with fiberglass that meet the requirements of required test methods known in the art, non-limiting examples being ASTM D790, ASTM D695, ASTM D3039 and ASTM D638.

The thermoplastics and thermoset resins can optionally include other additives, as a non-limiting example ultraviolet (UV) stabilizers, heat stabilizers, flame retardants, structural enhancements, biocides, and combinations thereof. Suitable metals include, but are not limited to, aluminum, steel, stainless steel, tungsten, molybdenum, iron and alloys and combinations of such metals. In a particular embodiment of the invention, the metal bars, studs, joists and/or members are made of a light gauge metal.

Pour holes 18 are generally defined by first edge 20, second edge 30, and web sections 40. The width, measured from top edge 42 to bottom edge 44 of web section 40 can vary along the length from first edge 20 to second edge 30 but is sufficient to maintain stability in the ICF structures described herein. As such, depending on the shape of pour holes 18, at its smallest dimension, web section 40 can be at least 0.5 inches (1.25 cm), in some cases at least 0.75 inches (1.9 cm) and in other cases at least 1 inch (2.5 cm) and in embodiments of the invention can be up to 6 inches (15 cm), in some cases up to 4 inches (10 cm) and in other cases up to 3 inches (7.5 cm). The smallest dimension of web section 40 can be any value or range between any of the values recited above.

In many embodiments of the invention, pour holes 18 have a shape selected from round, oval, elliptical, square, rectangular, triangular, hexagonal and octagonal. Further, the cross-sectional area of pour holes 18 can be at least about 4 in² (26 cm²), in some cases at least about 6 in² (39 cm²), and in other cases at least about 9 in² (58 cm²) and can be up to about 36 in² (232 cm²), in some cases up to 25 in² (161 cm²), and in other cases up to about 20 in² (129 cm²). The cross-sectional area of pour holes 18 can be any of the values or range between any of the values recited above.

As can be appreciated by those skilled in the art, the shape and size of each of the various pour holes 18 in locking tie 10 can vary depending on desired design properties. In embodiments of the invention, the thickness of locking tie 10 will depend on the particular materials of construction and is sufficient to maintain the stability in the ICF structures described herein. As such, the thickness of locking tie 10, measured from first side 46 to second side 48 can be at least 0.1 inches (0.25 cm), in some cases at least 0.2 inches (0.5 cm) and in other cases at least 0.25 inches (0.6 cm) and can be up to 1.5 inches (3.8 cm), in some cases up to 1 inch (2.5 cm) and in other cases up to 0.75 inches (1.9 cm). The thickness of locking tie 10 can be any value or range between any of the values recited above.

The length of locking tie 10, as measured from first end 50 to second end 52, is consistent with the designed width of the form in an ICF according to the invention. As such, the length of locking tie 10 can be at least 3 inches (7.5 cm), in some cases at least 4 inches (10 cm) and in some cases at least 5 inches (12.7 cm) and can be up to 24 inches (63.5 cm), in some cases up to 20 inches (51 cm), in other cases up to 16 inches (40.5 cm) and in some instances up to 12 inches (30.5 cm). The length of locking tie 10 can be any value or range between any of the values recited above. The dimensions of first flange 14 and second flange 16 coincide with the dimensions of the slots in the ICF panels as described herein to allow locking tie 10 to be securably attached to the respective panels. The thickness 54 or 56 of first flange 14 or second flange 16 respectively can be at least 0.1 inches (0.25 cm), in some cases at least 0.2 inches (0.5 cm) and in other cases at least 0.25 inches (0.6 cm) and can be up to 1 inch (2.5 cm), in some cases up to 0.75 inch (1.9 cm) and in other cases up to 0.5 inches (1.25 cm). The thickness of first flange 14 or second flange 16 can be any value or range between any of the values recited above.

Male locking portions 22 and 32 are adapted to securably fit and/or snap into female locking portions 26 and 36 respectively to connect two locking ties 10 to one another and thus secure one portion of an ICF to another. Thus, the shape of the opening that makes up female locking portions 26 and 36 is generally the same shape as male locking portions 22 and 32. The shape of male locking portions 22 and 32 and the opening that makes up female locking portions 26 and 36 can be one or more of circular, oval, elliptical, triangular, hexagonal and octagonal.

In embodiments of the invention, second ends 28 and 38 and female locking portions 26 and 36 include legs 60 and 62 that are adapted to move independently to allow female locking portions 26 and 36 to slide around and/or over the perimeter of male locking portions 22 and 32 to effect a secure snap fit to hold two locking ties 10 together.

As indicated above, locking ties 10 are used to construct ICF systems. As shown in FIGS. 5-7, ICF system 100 includes a plurality of mold units 112 for forming a wall by receiving concrete therein. Mold units 112 include first panel member 114, second panel member 116, locking ties 10 and mold chamber 101.

First panel member 114 includes first outer panel side 118 including a first wall surface area extending generally vertically thereon; first inner panel side 120 positioned oppositely from said first outer panel side; and a plurality of first slots 122 in first inner panel side 120 extending vertically therethrough. Second panel member 116 includes second outer panel side 124 including second wall surface area extending generally vertically thereon and facing oppositely from first panel member 114. Second inner panel side 126 is positioned oppositely from second outer panel side 124 and facing first inner panel side 120 of first panel member 112. A plurality of second slots 128 in second inner panel side 126 extends vertically therethrough.

Locking ties 10 are detachable and securable with respect to first panel member 114 and said second panel member 116 and extend the length vertically therebetween to maintain a spatial distance therebetween for defining a mold chamber 101 therebetween.

In embodiments of the invention, mold units 100 can be assembled by placing panels 114 and 116 parallel to each other and sliding flanges 14 and 16 of locking ties 10 into slots 122 and 128 respectively. In embodiments of the invention, first slot 122 and second slot 128 can have a T-shaped cross-sectional shape.

Locking ties 10 are subsequently slid into slots 122 and 128 of additional panels 114 and 116 to secure the panels and units together to form a secure ICF. In the present invention, first panel member 114 and second panel member 116 can have a horizontal length of at least about 12 inches (30.5 cm), in some cases at least about 18 inches (16 cm) and in other cases at least about 24 inches (61 cm) and the length of the panel members can be up to about thirty feet (9.1 m), in some cases up to about twenty five feet (1.6 m), in other cases up to about twenty feet (6.1 m), in some instances up to about 15 feet (4.6 m), in other instances up to about 10 feet (3 m), in some situations up to about 5 feet (1.5 m) and in other situations up to about 3 feet (0.9 m). The length of first panel member 114 and second panel member 116 can be any of the values or range between any of the values recited above.

In the present invention, first panel member 114 and second panel member 116 can have a vertical height of at least about six inches (15 cm), in some cases at least about 10 inches (25 cm) and in other cases at least about 15 inches (38 cm) and can be up to about 10 feet (3 m), in some cases up to about 5 feet (1.5 m) and in other cases up to about 3 feet (0.9 m). The vertical height of first panel member 114 and second panel member 116 can be any of the values or range between any of the values recited above.

Mold units 100 can have a width, measured from first outer panel side 118 to second outer panel side 124 of from about 4, in some cases at least about 5, in other cases at least about 6 inches and can be up to about 30, in some cases up to about 24, and in other cases up to about 16 inches. The width is determined by the design for an overall insulated concrete wall. The width can be any value or range between any of the values recited above.

Typically, in the present concrete wall forming system, the first panel member 114 and second panel member 116 are made of an expanded polymer matrix. The expanded polymer matrix is typically molded from expandable thermoplastic particles. These expandable thermoplastic particles are made from any suitable thermoplastic homopolymer or copolymer. Particularly suitable for use are homopolymers derived from vinyl aromatic monomers including styrene, isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene, tert-butylstyrene, and the like, as well as copolymers prepared by the copolymerization of at least one vinyl aromatic monomer as described above with one or more other monomers, non-limiting examples being divinylbenzene, conjugated dienes (non-limiting examples being butadiene, isoprene, 1 ,3- and 2,4- hexadiene), alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinyl aromatic monomer is present in at least 50% by weight of the copolymer. In an embodiment of the invention, styrenic polymers are used, particularly polystyrene. However, other suitable polymers can be used, such as polyolefins (e.g., polyethylene, polypropylene), polycarbonates, polyphenylene oxides, and mixtures thereof.

In a particular embodiment of the invention, the expandable thermoplastic particles are expandable polystyrene (EPS) particles. These particles can be in the form of beads, granules, or other particles convenient for the expansion and molding operations. Particles polymerized in an aqueous suspension process are essentially spherical and are useful for molding the mold units and/or forms described herein below. These particles can be screened so that their size ranges from about 0.008 inches (0.2 mm) to about 0.16 inches (4 mm).

In an embodiment of the invention, resin beads (unexpanded) containing any of the polymers or polymer compositions described herein have a particle size of at least 0.2 mm, in some situations at least 0.33 mm, in some cases at least 0.35 mm, in other cases at least 0.4 mm, in some instances at least 0.45 mm and in other instances at least 0.5 mm. Also, the resin beads can have a particle size of up to about 4 mm, in some situations up to about 3.5 mm, in other situations up to about 3 mm, in some instances up to 2 mm, in other instances up to 2.5 mm, in some cases up to 2.25 mm, in other cases up to 2 mm, in some situations up to 1.5 mm and in other situations up to 1 mm. The resin beads used in this embodiment can be any value or can range between any of the values recited above.

The average particle size and size distribution of the expandable resin beads or pre-expanded resin beads can be determined using low angle light scattering, which can provide a weight average value. As a non-limiting example, a Model LA-910 Laser Diffraction Particle Size Analyzer available from Horiba Ltd., Kyoto, Japan can be used

As used herein, the terms "expandable thermoplastic particles" or "expandable resin beads" refers to a polymeric material in particulate or bead form that is impregnated with a blowing agent such that when the particulates and/or beads are placed in a mold or expansion device and heat is applied thereto, evaporation of the blowing agent (as described below) effects the formation of a cellular structure and/or an expanding cellular structure in the particulates and/or beads. When expanded in a mold, the outer surfaces of the particulates and/or beads fuse together to form a continuous mass of polymeric material conforming to the shape of the mold. As used herein, the terms "pre-expanded thermoplastic particles", "pre-expanded resin beads", or "prepuff" refers to expandable resin beads that have been expanded, but not to their maximum expansion factor and whose outer surfaces have not fused. As used herein, the term "expansion factor" refers to the volume a given weight of resin bead occupies, typically expressed as cc/g. Pre-expanded resin beads can be further expanded in a mold where the outer surfaces of the pre-expanded resin beads fuse together to form a continuous mass of polymeric material conforming to the shape of the mold. The expandable thermoplastic particles can be impregnated using any conventional method with a suitable blowing agent. As a non-limiting example, the impregnation can be achieved by adding the blowing agent to the aqueous suspension during the polymerization of the polymer, or alternatively by re-suspending the polymer particles in an aqueous medium and then incorporating the blowing agent as taught in U.S. Pat. No. 2,983,692. Any gaseous material or material which will produce gases on heating can be used as the blowing agent. Conventional blowing agents include aliphatic hydrocarbons containing 4 to 6 carbon atoms in the molecule, such as butanes, pentanes, hexanes, and the halogenated hydrocarbons, e.g., CFCs and HCFCs, which boil at a temperature below the softening point of the polymer chosen. Mixtures of these aliphatic hydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbon blowing agents or water can be used as the sole blowing agent as taught in U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents, water-retaining agents are used. The weight percentage of water for use as the blowing agent can range from 1 to 20%. The texts of U.S. Pat. Nos. 6,127,439; 6,160,027 and 6,242,540 are incorporated herein by reference. The impregnated thermoplastic particles are generally pre- expanded to a density of at least 0.5 Ib/ft³, in some cases at least 0.75 Ib/ft³, in other cases at least 1.0 Ib/ft³, in some situations at least 1.25 Ib/ft³, in other situations at least 1.5 Ib/ft³, and in some instances at least about 1.75 Ib/ft³. Also, the density of the impregnated pre-expanded particles can be up to 12 Ib/ft³, in some cases up to 10 Ib/ft³, and in other cases up to 5 Ib/ft³. When the density is too low, the panels may deform when concrete is poured into the mold units. When the density is too high, the economics of using the present mold units may become unfavorable. The density of the impregnated pre-expanded particles, as well as the density of first panel member 114 and second panel member 116, can be any value or range between any of the values recited above. The pre- expansion step is conventionally carried out by heating the impregnated beads via any conventional heating medium, such as steam, hot air, hot water, or radiant heat. One generally accepted method for accomplishing the pre-expansion of impregnated thermoplastic particles is taught in U.S. Pat. No. 3,023,175.

The impregnated thermoplastic particles can be foamed cellular polymer particles as taught in U.S. Patent Application Publication No. 2002/0117769, the teachings of which are incorporated herein by reference. The foamed cellular particles can be polystyrene that are pre- expanded and contain a volatile blowing agent at a level of less than 14 wt %, in some situations less than 8 wt %, in some cases ranging from about 2 wt % to about 7 wt %, and in other cases ranging from about 2.5 wt % to about 6.5 wt % based on the weight of the polymer.

The thermoplastic particles, according to the invention, can include an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers. Non-limiting examples of such interpolymers are disclosed in U.S. Patent Nos. 4,303,756, 4,303,757 and 6,908,949, the relevant portions of which are herein incorporated by reference. A non-limiting example of interpolymers that can be used in the present invention include those available under the trade name ARCEL^®, available from NOVA Chemicals Inc., Pittsburgh, PA and PIOCELAN^®, available from Sekisui Plastics Co., Ltd., Tokyo, Japan.

The expanded polymer matrix can include customary ingredients and additives, such as pigments, dyes, colorants, plasticizers, mold release agents, stabilizers, ultraviolet light absorbers, mold prevention agents, antioxidants, flame-retardants and so on. Typical pigments include, without limitation, inorganic pigments such as carbon black, graphite, expandable graphite, zinc oxide, titanium dioxide, and iron oxide, as well as organic pigments such as quinacridone reds and violets and copper phthalocyanine blues and greens.

In a particular embodiment of the invention, the pigment is carbon black, a non-limiting example of such a material being EPS SILVER^®, available from NOVA Chemicals Inc.

In another particular embodiment of the invention the pigment is graphite, a non-limiting example of such a material being NEOPOR^®, available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein,

Germany.

Non-limiting examples of suitable flame retardants that can be used in the invention include phosphoric esters, such as triphenyl phosphate; bromine compounds, such as decabromobiphenyl, pentabromotoluene, brominated epoxy resin, hexabromocyclododecane, pentabromophenyl allyl ether, tris dibromo-propylphosphate, bis allyl ether of tetrabromo-bis- phenol A, octabromodiphenyl oxide, decabromodiphenyl oxide, halogenated hydrocarbyl phosphate or phosphonate esters and trisdibromopropyl antimonite; chlorine compounds such as chloroparaffins, mixed halogen compounds such as pentabromo monochloro cyclohexane; nitrogen-containing phosphorus compounds such as melamine derivatives; alumina trihydrates hydroxylamine esters; antimony compounds such as antimony trioxide; boron compounds; and zinc compounds. When used, the flame retardants are present at from about 0.6 to about 7% by weight based on the weight of the expandable polymer matrix.

The pre-expanded particles or "pre-puff" are usually heated in a closed mold to form the present mold units. Slots 122 and 128 can be molded into panels 114 and 116 or in some embodiments slots 122 and

128 can be cut into panels 114 and 116 with, as non-limiting examples, a knife or a hot wire cutter. In another embodiment of the invention, the mold units can have a male "tongue" edge and a female "groove" edge that facilitates a "tongue and groove" union of two matching mold units. In other embodiments of the invention, the mold units can have overlapping lip ends adapted to join matching mold units together. As another example, the first panel member and the second panel member can each have a male end that includes a tongue edge and a female end that includes a female groove edge that facilitates a tongue and groove union between corresponding members. Thus, the present concrete wall forming system can include a plurality of mold units arranged sequentially to form the wall forming system.

In embodiments of the invention, a finish surface can be attached to one or more of first outer panel side 118 and/or second outer panel side 124. As non-limiting examples, the finish surface can be selected from wood, rigid plastics, wood paneling, concrete panels, cement panels, drywall, sheetrock, particle board, rigid plastic panels, a metal lath, and combinations thereof.

In embodiments of the invention, a water impervious fabric can be placed over at least a portion of outward facing surfaces of outer panel sides 118 and/or 124 of ICF system 100. As used herein, "outward facing surface" refers to the portion of the surface of an ICF system 100 that will be exposed to the earth and weather outside of a planned insulated concrete wall or building. Typically, a top edge of the water impervious fabric will extend above grade when the wall or building is completed. Typically, the water impervious fabric is a layered fabric that includes channels, capillaries, and/or dimples that provide for seepage and/or drainage of moisture. The materials of construction for the water impervious fabric are typically pressure resistant, rot-proof, and resistant to saline solutions, inorganic acids, alkalis, and liquids such as alcohols, organic acids, esters, ketones, and similar substances and are typically not damaged or affected by minerals, humic acid, or bacterial decomposition in the earth and is resistant to bacteria, fungi and/or microorganism attack it. In many embodiments, the water impervious fabric is constructed using thermoplastics, non-limiting examples of which include polyethylene and polypropylene.

According to the present invention, an insulated concrete wall can be formed by pouring concrete into molding chamber 101. The concrete is then allowed to set and harden in the molding chamber.

Any suitable type of concrete can be used to make the concrete walls and concrete wall systems described herein. The specific type of concrete will depend on the desired and designed properties of the concrete walls and concrete wall systems. In embodiments of the invention, the concrete includes one or more hydraulic cement compositions selected from Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, and slag cements.

In an embodiment of the invention, the concrete includes a hydraulic cement composition. The hydraulic cement composition can be present at a level of at least 3, in certain situations at least 5, in some cases at least 7.5, and in other cases at least 9 volume percent and can be present at levels up to 40, in some cases up to 35, in other cases up to 32.5, and in some instances up to 30 volume percent of the cement mixture. The concrete can include the hydraulic cement composition at any of the above-stated levels or at levels ranging between any of levels stated above.

In an embodiment of the invention, the concrete mixture can optionally include other aggregates and adjuvants known in the art including but not limited to sand, additional aggregate, plasticizers and/or fibers. Suitable fibers include, but are not limited to glass fibers, metal fibers, silicon carbide, aramid fibers, polyester, carbon fibers, composite fibers, fiberglass, metal and combinations thereof as well as fabric containing the above-mentioned fibers, and fabric containing combinations of the above-mentioned fibers.

Non-limiting examples of fibers that can be used in the invention include MeC-GRID^® and C-GRID^® available from TechFab, LLC, Anderson, SC, KEVLAR^® available from E.I. du Pont de Nemours and Company, Wilmington, DE, TWARON^® available from Teijin Twaron B.V., Arnheim, the Netherlands, SPECTRA^® available from Honeywell International Inc., Morristown, NJ, DACRON^® available from Invista North America S.A.R.L. Corp. Wilmington, DE, and VECTRAN^® available from Hoechst Celanese Corp., New York, NY. The fibers can be used in a mesh structure, intertwined, interwoven, and oriented in any desirable direction.

In a particular embodiment of the invention, fibers can make up at least 0.1 , in some cases at least 0.5, in other cases at least 1 , and in some instances at least 2 volume percent of the concrete composition. Further, fibers can provide up to 10, in some cases up to 8, in other cases up to 7, and in some instances up to 5 volume percent of the concrete composition. The amount of fibers is adjusted to provide desired properties to the concrete composition. The amount of fibers can be any value or range between any of the values recited above.

Further to this embodiment, the additional aggregate can include, but is not limited to, one or more materials selected from common aggregates such as sand, stone, and gravel. Common lightweight aggregates can include glass, expanded slate and clay; insulating aggregates such as pumice, perlite, vermiculite, scoria, and diatomite; light-weight aggregate such as expanded shale, expanded slate, expanded clay, expanded slag, pelletized aggregate, tuff, and macrolite; and masonry aggregate such as expanded shale, clay, slate, coal cinders, pumice, scoria, and pelletized aggregate. When included, the other aggregates and adjuvants are present in the concrete mixture at a level of at least 0.5, in some cases at least 1 , in other cases at least 2.5, in some instances at least 5 and in other instances at least 10 volume percent of the concrete mixture. Also, the other aggregates and adjuvants can be present at a level of up to 95, in some cases up to 90, in other cases up to 85, in some instances up to 65 and in other instances up to 60 volume percent of the concrete mixture. The other aggregates and adjuvants can be present in the concrete mixture at any of the levels indicated above or can range between any of the levels indicated above.

In embodiments of the invention, supplementary cementitious materials can optionally be included in the concrete compositions. As used herein, the terms "supplementary cementitious material" or

"pozzolan" refer to a siliceous or siliceous and aluminous material, which in itself possesses little or no cementitious value, but which will in finely divided form and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties. Non-limiting examples of supplementary cementitious materials or pozzolans include fly ash (C and F), silica fume, micronized silica, volcanic ashes, calcined clay, metakaolin clay and ground granulated blast furnace slag. When supplementary cementitious materials are used, they can be included at a level of up to 30, in some situations up to 20, in other situations up to 10, in some cases up to 8, in other cases up to 7, in some instances up to 5 and in other instances up to 3 volume percent of the concrete composition.

In embodiments of the invention, the concrete compositions can contain one or more additives, non-limiting examples of such being anti- foam agents, water-proofing agents, dispersing agents, set-accelerators, set-retarders, plasticizing agents, superplasticizing agents, freezing point decreasing agents, adhesiveness-improving agents, and colorants. The additives are typically present at less than one percent by weight with respect to total weight of the composition, but can be present at from 0.1 to 3 weight percent.

Suitable dispersing agents or plasticizers that can be used in the invention include, but are not limited to hexametaphosphate, tripolyphosphate, polynaphthalene sulphonate, sulphonated polyamine and combinations thereof. Suitable plasticizing agents that can be used in the invention include, but are not limited to polyhydroxycarboxylic acids or salts thereof, polycarboxylates or salts thereof; lignosulfonates, polyethylene glycols, and combinations thereof. Suitable superplasticizing agents that can be used in the invention include, but are not limited to alkaline or earth alkaline metal salts of lignin sulfonates; lignosulfonates, alkaline or earth alkaline metal salts of highly condensed naphthalene sulfonic acid/formaldehyde condensates; polynaphthalene sulfonates, alkaline or earth alkaline metal salts of one or more polycarboxylates (such as poly(meth)acrylates and the polycarboxylate comb copolymers described in U.S. Patent No. 6,800,129, the relevant portions of which are herein incorporated by reference); alkaline or earth alkaline metal salts of melamine/formaldehyde/sulfite condensates; sulfonic acid esters; carbohydrate esters; and combinations thereof.

Suitable set-accelerators that can be used in the invention include, but are not limited to soluble chloride salts (such as calcium chloride), triethanolamine, paraformaldehyde, soluble formate salts (such as calcium formate), sodium hydroxide, potassium hydroxide, sodium carbonate, sodium sulfate, 12CaO-7AI₂O₃, sodium sulfate, aluminum sulfate, iron sulfate, the alkali metal nitrate/sulfonated aromatic hydrocarbon aliphatic aldehyde condensates disclosed in U.S. Patent No. 4,026,723, the water soluble surfactant accelerators disclosed in U.S. Patent No. 4,298,394, the methylol derivatives of amino acids accelerators disclosed in U.S. Patent No. 5,211 ,751 , and the mixtures of thiocyanic acid salts, alkanolamines, and nitric acid salts disclosed in U.S. Patent No. Re. 35,194, the relevant portions of which are herein incorporated by reference, and combinations thereof. Suitable set-retarders that can be used in the invention include, but are not limited to lignosulfonates, hydroxycarboxylic acids (such as gluconic acid, citric acid, tartaric acid, maleic acid, salicylic acid, glucoheptonic acid, arabonic acid, and inorganic or organic salts thereof such as sodium, potassium, calcium, magnesium, ammonium and triethanolamine salt), cardonic acid, sugars, modified sugars, phosphates, borates, silico-fluorides, calcium bromate, calcium sulfate, sodium sulfate, monosaccharides such as glucose, fructose, galactose, saccharose, xylose, apiose, ribose and invert sugar, oligosaccharides such as disaccharides and trisaccharides, such oligosaccharides as dextrin, polysaccharides such as dextran, and other saccharides such as molasses containing these; sugar alcohols such as sorbitol; magnesium silicofluoride; phosphoric acid and salts thereof, or borate esters; aminocarboxylic acids and salts thereof; alkali-soluble proteins; humic acid; tannic acid; phenols; polyhydric alcohols such as glycerol; phosphonic acids and derivatives thereof, such as aminotri(methylene- phosphonic acid), 1-hydroxyethylidene-1 ,1-diphosphonic acid, ethylene- diaminetetra(methylenephosphonic acid), diethylenetriaminepenta- (methylenephosphonic acid), and alkali metal or alkaline earth metal salts thereof, and combinations of the set- retarders indicated above.

Suitable defoaming agents that can be used in the invention include, but are not limited to silicone-based defoaming agents (such as dimethylpolysiloxane, dimethylsilicone oil, silicone paste, silicone emulsions, organic group-modified polysiloxanes (polyorganosiloxanes such as dimethylpolysiloxane), fluorosilicone oils, etc.), alkyl phosphates (such as tributyl phosphate, sodium octylphosphate, etc.), mineral oil- based defoaming agents (such as kerosene, liquid paraffin, etc.), fat- or oil-based defoaming agents (such as animal or vegetable oils, sesame oil, castor oil, alkylene oxide adducts derived there from, etc.), fatty acid- based defoaming agents (such as oleic acid, stearic acid, and alkylene oxide adducts derived there from, etc.), fatty acid ester-based defoaming agents (such as glycerol monoricinolate, alkenylsuccinic acid derivatives, sorbitol monolaurate, sorbitol trioleate, natural waxes, etc.), oxyalkylene type defoaming agents, alcohol-based defoaming agents: octyl alcohol, hexadecyl alcohol, acetylene alcohols, glycols, etc.), amide-based defoaming agents (such as acrylate polyamines, etc.), metal salt-based defoaming agents (such as aluminum stearate, calcium oleate, etc.) and combinations of the above-described defoaming agents. Suitable freezing point decreasing agents that can be used in the invention include, but are not limited to ethyl alcohol, calcium chloride, potassium chloride, and combinations thereof. Suitable adhesiveness-improving agents that can be used in the invention include, but are not limited to polyvinyl acetate, styrene- butadiene, homopolymers and copolymers of (meth)acrylate esters, and combinations thereof. Suitable water-repellent or water-proofing agents that can be used in the invention include, but are not limited to fatty acids (such as stearic acid or oleic acid), lower alkyl fatty acid esters (such as butyl stearate), fatty acid salts (such as calcium or aluminum stearate), silicones, wax emulsions, hydrocarbon resins, bitumen, fats and oils, silicones, paraffins, asphalt, waxes, and combinations thereof. Although not used in many embodiments of the invention, when used, suitable air-entraining agents include, but are not limited to vinsol resins, sodium abietate, fatty acids and salts thereof, tensides, alkyl-aryl-sulfonates, phenol ethoxylates, lignosulfonates, and mixtures thereof. In some embodiments of the invention, the concrete is light-weight concrete. As used herein, the term "light weight concrete" refers to concrete where light-weight aggregate is included in a cementitious mixture. Exemplary light weight concrete compositions that can be used in the present invention are disclosed in U.S. Patent Nos. 3,021 ,291 , 3,214,393, 3,257,338, 3,272,765, 5,622,556, 5,725,652, 5,580,378, and 6,851 ,235, JP 9 071 449, WO 98 02 397, WO 00/61519, and WO 01/66485 the relevant portions of which are incorporated herein by reference.

In particular embodiments of the present invention, the lightweight concrete (LWC) composition includes a concrete mixture and polymer particles, a non-limiting example of which is disclosed in U.S. Patent Application Publication 2006/0225618 A1 , the relevant disclosure of which is hereby incorporated by reference. In many instances the size, composition, structure, and physical properties of expanded polymer particles, and in some instances their resin bead precursors, can greatly affect the physical properties of LWC used in the invention. Of particular note is the relationship between bead size and expanded polymer particle density on the physical properties of the resulting LWC wall. The polymer particles, which can optionally be expanded polymer particles, are present in the LWC composition at a level of at least 10, in some instances at least 15, in other instances at least 20, in particular situations up to 25, in some cases at least 30, and in other cases at least 35 volume percent and up to 90, in some cases up to 85, in other cases up to 78, in some instances up to 75, in other instance up to 65, in particular instances up to 60, in some cases up to 50, and in other cases up to 40 volume percent based on the total volume of the LWC composition. The amount of polymer particles will vary depending on the particular physical properties desired in a finished LWC wall. The amount of polymer particles in the LWC composition can be any value or can range between any of the values recited above.

The polymer particles can include any particles derived from any suitable expandable thermoplastic material. The actual polymer particles are selected based on the particular physical properties desired in a finished LWC wall. As a non-limiting example, the polymer particles, which can optionally be expanded polymer particles, can include one or more polymers selected from homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates; polyesters; polyamides; natural rubbers; synthetic rubbers; and combinations thereof.

In an embodiment of the invention, the polymer particles include thermoplastic homopolymers or copolymers selected from homopolymers derived from vinyl aromatic monomers including styrene, isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene, tert- butylstyrene, and the like, as well as copolymers prepared by the copolymerization of at least one vinyl aromatic monomer as described above with one or more other monomers, non-limiting examples being divinylbenzene, conjugated dienes (non-limiting examples being butadiene, isoprene, 1 , 3- and 2,4- hexadiene), alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinyl aromatic monomer is present in at least 50% by weight of the copolymer. In an embodiment of the invention, styrenic polymers are used, particularly polystyrene. However, other suitable polymers can be used, such as polyolefins (e.g. polyethylene, polypropylene), polycarbonates, polyphenylene oxides, and mixtures thereof.

In a particular embodiment of the invention, the polymer particles are expandable polystyrene (EPS) particles. These particles can be in the form of beads, granules, or other particles.

In the present invention, particles polymerized in a suspension process, which are essentially spherical resin beads, are useful as polymer particles or for making expanded polymer particles. However, polymers derived from solution and bulk polymerization techniques that are extruded and cut into particle sized resin bead sections can also be used. In an embodiment of the invention, resin beads (unexpanded) to be used in the lightweight concrete containing any of the polymers or polymer compositions described herein have a particle size of at least 0.2 mm, in some situations at least 0.33 mm, in some cases at least 0.35 mm, in other cases at least 0.4 mm, in some instances at least 0.45 mm and in other instances at least 0.5 mm. Also, the resin beads can have a particle size of up to 3 mm, in some instances up to 2 mm, in other instances up to 2.5 mm, in some cases up to 2.25 mm, in other cases up to 2 mm, in some situations up to 1.5 mm and in other situations up to 1 mm. In this embodiment, the physical properties of LWC walls made according to the invention have inconsistent or undesirable physical properties when resin beads having particle sizes outside of the above described ranges are used to make the expanded polymer particles. The resin beads used in this embodiment can be any value or can range between any of the values recited above. The expandable thermoplastic particles or resin beads can optionally be impregnated using any conventional method with a suitable blowing agent. As a non-limiting example, the impregnation can be achieved by adding the blowing agent to the aqueous suspension during the polymerization of the polymer, or alternatively by re-suspending the polymer particles in an aqueous medium and then incorporating the blowing agent as taught in U.S. Pat. No. 2,983,692. Any gaseous material or material which will produce gases on heating can be used as the blowing agent. Conventional blowing agents include aliphatic hydrocarbons containing 4 to 6 carbon atoms in the molecule, such as butanes, pentanes, hexanes, and the halogenated hydrocarbons, e.g. CFCs and HCFCs, which boil at a temperature below the softening point of the polymer chosen. Mixtures of these aliphatic hydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbon blowing agents or water can be used as the sole blowing agent as taught in U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents, water-retaining agents are used. The weight percentage of water for use as the blowing agent can range from 1 to 20%. The texts of U.S. Pat. Nos. 6,127,439; 6,160,027 and 6,242,540 are incorporated herein by reference.

The impregnated polymer particles or resin beads used in the lightweight concrete are optionally expanded to a bulk density of at least 1.75 Ib/ft³ (0.028 g/cc), in some circumstances at least 2 Ib/ft³ (0.032 g/cc) in other circumstances at least 3 Ib/ft³ (0.048 g/cc) and in particular circumstances at least 3.25 Ib/ft³ (0.052 g/cc) or 3.5 Ib/ft³ (0.056 g/cc). When non-expanded resin beads are used, higher bulk density beads can be used. As such, the bulk density can be as high as 40 Ib/ft³ (0.64 g/cc). In other situations, the polymer particles are at least partially expanded and the bulk density can be up to 35 Ib/ft³ (0.56 g/cc), in some cases up to 30 Ib/ft³ (0.48 g/cc), in other cases up to 25 Ib/ft³ (0.4 g/cc), in some instances up to 20 Ib/ft³ (0.32 g/cc), in other instances up to 15 Ib/ft³ (0.24 g/cc) and in certain circumstances up to 10 Ib/ft³ (0.16 g/cc). The bulk density of the polymer particles can be any value or range between any of the values recited above. The bulk density of the polymer particles, resin beads and/or prepuff particles is determined by weighing a known volume of polymer particles, beads and/or prepuff particles (aged 24 hours at ambient conditions).

The expansion step is conventionally carried out by heating the impregnated beads via any conventional heating medium, such as steam, hot air, hot water, or radiant heat. One generally accepted method for accomplishing the pre-expansion of impregnated thermoplastic particles is taught in U.S. Pat. No. 3,023,175.

The impregnated polymer particles can be foamed cellular polymer particles as taught in U.S. Patent Application Publication No. 2002/0117769, the teachings of which are incorporated herein by reference. The foamed cellular particles can be polystyrene that are expanded and contain a volatile blowing agent at a level of less than 14 wt.%, in some situations less than 8 wt.%, in some cases ranging from about 2 wt.% to about 7 wt.%, and in other cases ranging from about 2.5 wt.% to about 6.5 wt.% based on the weight of the polymer.

An interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers that can be included in the expanded thermoplastic resin or polymer particles according to the invention is disclosed in U.S. Patent Nos. 4,303,756, 4,303,757 and 6,908,949, the relevant portions of which are herein incorporated by reference.

The polymer particles can include customary ingredients and additives, such as flame retardants, pigments, dyes, colorants, plasticizers, mold release agents, stabilizers, ultraviolet light absorbers, mold prevention agents, antioxidants, rodenticides, insect repellants, and so on. Typical pigments include, without limitation, inorganic pigments such as carbon black, graphite, expandable graphite, zinc oxide, titanium dioxide, and iron oxide, as well as organic pigments such as quinacridone reds and violets and copper phthalocyanine blues and greens.

In a particular embodiment of the invention, the pigment is carbon black, a non-limiting example of such a material being EPS SILVER^®, available from NOVA Chemicals Inc.

In another particular embodiment of the invention the pigment is graphite, a non-limiting example of such a material being NEOPOR^®, available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein, Germany.

When materials such as carbon black and/or graphite are included in the polymer particles, improved insulating properties, as exemplified by higher R values for materials containing carbon black or graphite (as determined using ASTM - C518), are provided. As such, the R value of the expanded polymer particles containing carbon black and/or graphite or materials made from such polymer particles are at least 5% higher than observed for particles or resulting walls that do not contain carbon black and/or graphite.

The expanded polymers used in the lightweight concrete can have an average particle size of at least 0.2, in some circumstances at least 0.3, in other circumstances at least 0.5, in some cases at least 0.75, in other cases at least 0.9 and in some instances at least 1 mm and can be up to 8, in some circumstances up to 6, in other circumstances up to 5, in some cases up to 4, in other cases up to 3, and in some instances up to 2.5 mm. When the size of the expanded polymer particles is too small or too large, the physical properties of LWC walls made using the present LWC composition can be undesirable. The average particle size of the expanded polymer particles can be any value and can range between any of the values recited above. The average particle size of the expanded polymer particles can be determined using laser diffraction techniques or by screening according to mesh size using mechanical separation methods well known in the art. In an embodiment of the invention, the polymer particles or expanded polymer particles used in the mold unit panels or in the lightweight concrete can have a minimum average cell wall thickness, which helps to provide desirable physical properties to LWC walls made using the present LWC composition. The average cell wall thickness and inner cellular dimensions can be determined using scanning electron microscopy techniques known in the art. The expanded polymer particles can have an average cell wall thickness of at least 0.15 μm, in some cases at least 0.2 μm and in other cases at least 0.25 μm. Not wishing to be bound to any particular theory, it is believed that a desirable average cell wall thickness results when resin beads having the above-described dimensions are expanded to the above-described densities.

In an embodiment of the invention, the polymer beads are optionally expanded to form the expanded polymer particles such that a desirable cell wall thickness as described above is achieved. Though many variables can impact the wall thickness, it is desirable, in this embodiment, to limit the expansion of the polymer bead so as to achieve a desired wall thickness and resulting expanded polymer particle strength. Optimizing processing steps and blowing agents can expand the polymer beads to a minimum of 1.75 Ib/ft³ (0.028 g/cc). This property of the expanded polymer bulk density, can be described by pcf (Ib/ft³) or by an expansion factor (cc/g).

In order to provide expanded polymer particles with desirable cell wall thickness and strength, the expanded polymer particles are not expanded to their maximum expansion factor; as such an extreme expansion yields particles with undesirably thin cell walls and insufficient strength. Further, the polymer beads can be expanded at least 5%, in some cases at least 10%, and in other cases at least 15% of their maximum expansion factor. However, so as not to cause the cell wall thickness to be too thin, the polymer beads are expanded up to 80%, in some cases up to 75%, in other cases up to 70%, in some instances up to 65%, in other instances up to 60%, in some circumstances up to 55%, and in other circumstances up to 50% of their maximum expansion factor. The polymer beads can be expanded to any degree indicated above or the expansion can range between any of the values recited above. Typically, the polymer beads or prepuff beads do not further expand when formulated into the present concrete compositions and do not further expand while the concrete compositions set, cure and/or harden. The prepuff or expanded polymer particles typically have a cellular structure or honeycomb interior portion and a generally smooth continuous polymeric surface as an outer surface, i.e., a substantially continuous outer layer. The smooth continuous surface can be observed using scanning electron microscope (SEM) techniques at 1000X magnification. SEM observations do not indicate the presence of holes in the outer surface of the prepuff or expanded polymer particles. Cutting sections of the prepuff or expanded polymer particles and taking SEM observations reveals the generally honeycomb structure of the interior of the prepuff or expanded polymer particles.

The polymer particles or expanded polymer particles can have any cross-sectional shape that allows for providing desirable physical properties in LWC walls. In an embodiment of the invention, the expanded polymer particles have a circular, oval or elliptical cross-section shape. In embodiments of the invention, the prepuff or expanded polymer particles have an aspect ratio of 1 , in some cases at least 1 and the aspect ratio can be up to 3, in some cases up to 2 and in other cases up to 1.5. The aspect ratio of the prepuff or expanded polymer particles can be any value or range between any of the values recited above.

In particular embodiments of the invention, the light-weight concrete includes from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.028 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 10 to 50 volume percent of sand and/or other fine aggregate, where the sum of components used does not exceed 100 volume percent.

Light-weight concrete compositions that are particularly useful in the present invention include those disclosed in co-pending U.S. Application Publication No.: 2006/0225618, the relevant portions of the disclosure are incorporated herein by reference.

When lightweight concrete is used in conjunction with the present wall forming system, the density of the mold units can be decreased further or, even greater concrete pour heights can be used at the same mold unit density.

In the present invention, when concrete is poured into mold unit 100 and allowed to set, an insulated concrete wall is formed. The concrete wall includes a solid mass of concrete in the shape of molding chamber 101 with connecting members 16 embedded therein as a result of the concrete flowing through pour holes 36 prior to it setting and hardening.

As those skilled in the art will appreciate, various numbers of courses of mold unit 10 can be used to provide a plurality of mold units 100 and a higher and/or longer insulated concrete wall according to the invention. Also, various insulated concrete wall system layouts can be designed with one or more courses of mold units.

As such, the present invention provides a wall that includes one or more rows of the concrete wall forming systems as described above where concrete is poured into and set in mold chamber 101 in the mold units.

Embodiments of the invention provide a continuous wall that includes the above-described concrete wall forming system, where concrete is poured into and set in mold chamber 101 in mold units 100. Often, in order to add strength to an insulated concrete wall system, concrete reinforcing products are placed within the mold chambers described above. Typically, the concrete reinforcing products are placed in mold chamber 101 prior to pouring concrete into mold chamber 101.

In embodiments of the invention, the concrete reinforcing product can be selected from rebar, fiber reinforced polymer, carbon fibers, aramid fibers, glass fibers, metal fibers and combinations thereof.

As used herein, the term "fiber reinforced polymer" refers to plastics that include, but are not limited to reinforced thermoplastics and reinforced thermoset resins. Thermoplastics include polymers and polymers made up of materials that can be repeatedly softened by heating and hardened again on cooling. Suitable thermoplastic polymers include, but are not limited to homopolymers and copolymers of styrene, homopolymers and copolymers of C₂ to C₂o olefins, C₄ to C₂o dienes, polyesters, polyamides, homopolymers and copolymers of C₂ to C₂₀ (meth)acrylate esters, polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides, polyurethanes, and combinations thereof.

Suitable thermoset resins are resins that when heated to their cure point, undergo a chemical cross-linking reaction causing them to solidify and hold their shape rigidly, even at elevated temperatures. Suitable thermoset resins include, but are not limited to alkyd resins, epoxy resins, diallyl phthalate resins, melamine resins, phenolic resins, polyester resins, urethane resins, and urea, which can be crosslinked by reaction, as non- limiting examples, with diols, triols, polyols, and/or formaldehyde.

Fiber reinforcing materials that can be incorporated into the thermoplastics and/or thermoset resins include, but are not limited to carbon fibers, aramid fibers, glass fibers, metal fibers, woven fabric or structures of the mentioned fibers, and/or fiberglass, and can optionally include one or more fillers, non-limiting examples including carbon black, graphite, clays, calcium carbonate, titanium dioxide, and combinations thereof.

The locking tie of the present invention is able to interlock the plurality of courses of mold units 100 providing a higher and/or longer insulated concrete wall. The ability to lock the courses together provides a number of benefits such as resistance to "lifting", pillowing, blowout and otherwise preventing mold units 100 forms from separating while concrete is being poured into mold form 101. Preventing lifting, blowout, pillowing, and or separation was a particular problem not adequately solved in the prior art.

The present invention has been described with reference to specific details of particular embodiments thereof. It is not intended that such details be regarded as limitations upon the scope of the invention except insofar as and to the extent that they are included in the accompanying claims.

Claims

WHAT IS CLAIMED IS:

1. A locking tie member comprising: a mid-section portion comprising a plurality of pour holes spaced along the length vertically; a first flange extending along the vertical length of a first edge of the mid-section, comprising a male locking portion at a first end and a female locking portion at a second end; and a second flange extending along the vertical length of a second edge of the mid-section, comprising a male locking portion at a first end and a female locking portion at a second end; wherein the male locking portion and female locking portion are adapted to secure a first locking tie to a second locking tie; and wherein the vertical length of the locking tie is at least 24 inches (61 cm).

2. The locking tie member according to Claim 1 comprising a material selected from the group consisting of plastics, metal, construction grade plastics, composite materials, ceramics, and combinations thereof.

3. An insulating concrete form comprising: two or more first panel members comprising two or more first slots in an inner side extending vertically therethrough; two or more second panel members comprising two or more second slots in an inner side extending vertically therethrough; and two or more locking tie members comprising a mid-section portion comprising a plurality of pour holes spaced along the length vertically, a first flange extending along the vertical length of a first edge of the mid-section of the locking tie member and securably extending within the first slot of at least two first panel members, and a second flange extending along the vertical length of a second edge of the mid-section of the locking tie member and securably extending within the second slot of at least two second panel members; wherein the panel members comprise an expanded polymer matrix; and wherein a mold chamber is defined by the space between the inner side of the first panels and the inner side of the second panels.

4. The insulating concrete form according to Claim 3, wherein the expanded polymer matrix comprises one or more polymers selected from the group consisting of homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates; an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers; and combinations thereof.

5. The insulating concrete form according to Claim 4, wherein the polymer matrix comprises carbon black, graphite or a combination thereof.

6. The insulating concrete form according to Claim 3, wherein the first panel member and the second panel member each have a male end comprising a tongue edge and a female end comprising a female groove edge that facilitates a tongue and groove union between corresponding members.

7. The insulating concrete form according to Claim 3, wherein the locking tie member comprises a material selected from the group consisting of plastics, metal, construction grade plastics, composite materials, ceramics, and combinations thereof.

8. An insulated concrete wall comprising the insulating concrete form according to Claim 3 and concrete placed in the mold chamber.

9. The insulated concrete wall according to Claim 8, wherein the concrete comprises one or more cements selected from the group consisting of Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, slag cements and combinations thereof.

10. The insulated concrete wall according to Claim 8, wherein the concrete is light weight concrete.

11. The insulated concrete wall according to Claim 8, wherein the concrete comprises

8 - 20 volume percent cement, 11 - 50 volume percent sand,

10 - 31 volume percent expanded thermoplastic particles, 9 - 40 volume percent coarse aggregate, and 10 - 22 volume percent water; wherein the expanded thermoplastic particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, and an aspect ratio of from 1 to 3.

12. The insulated concrete wall according to Claim 8, wherein rebar is placed in the molding chamber prior to placing the concrete.

13. A building comprising the insulated concrete wall according to Claim 8.

14. A building according to Claim 13, comprising the insulated concrete wall as a foundation.

15. The building according to Claim 14, wherein a water impervious fabric is placed over an outward facing surface.

16. An insulated concrete wall comprising: an insulating concrete form comprising: two or more first panel members comprising two or more first slots in an inner side extending vertically therethrough, two or more second panel members comprising two or more second slots in an inner side extending vertically therethrough, and two or more locking tie members comprising a mid-section portion comprising a plurality of pour holes spaced along the length vertically, a first flange extending along the vertical length of a first edge of the mid-section of the locking tie member and securably extending within the first slot of at least two first panel members, and a second flange extending along the vertical length of a second edge of the mid-section of the locking tie member and securably extending within the second slot of at least two second panel members, wherein the panel members comprise an expanded polymer matrix; and wherein a mold chamber is defined by the space between the inner side of the first panels and the inner side of the second panels; and concrete reinforcing products are placed within the mold chambers; concrete placed within the mold chamber in contact with the concrete reinforcing products and locking tie members, wherein the concrete has set, cured and hardened.

17. The insulated concrete wall according to Claim 16, wherein the concrete is light weight concrete.

18. The insulated concrete wall according to Claim 16, wherein the concrete comprises 8 -20 volume percent cement,

11 - 50 volume percent sand,

10 - 31 volume percent expanded thermoplastic particles, 9 - 40 volume percent coarse aggregate, and 10 - 22 volume percent water; wherein the expanded thermoplastic particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, and an aspect ratio of from 1 to 3.

19. The insulated concrete wall according to Claim 16, wherein the concrete reinforcing products comprise rebar.

20. A building comprising the insulated concrete wall according to Claim 16.