INSULATED CONCRETE FORM AND MOLD FOR MAKING SAME

Abstract

An insulated concrete form has: a first side wall portion; a second side wall portion substantially parallel with said first side wall portion; and a pillar portion extending between said the side wall portions. The pillar portion has: a first tapered section; a second tapered section; and a center section extending between said tapered sections. The first tapered section, the second tapered section and the center section each have an octagonal-shaped longitudinal cross-section. The insulated concrete form may include a plurality of pillar portions extending between the side wall portions, with the plurality of pillar portions being substantially parallel with each other. A wall structure may be formed from a plurality of such insulated concrete forms. A mold for forming an insulated concrete form, has: a first side plate and a second side plate; a slave pallet element supported by a frame and abutting a lower portion of interior sides of the side plates; and a first spine member and a second spine member attached to the side plates. The first side plate and the second side plate, along with the first spine member and the second spine member, may be pulled horizontally outward to clear the mold cavity.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 60/744,303, filed Apr. 5, 2006, the entire disclosure of which is incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an Insulated Concrete Form (ICF) mold allowing for the manufacture of a structurally superior Insulated Concrete Form. The mold allows for multiple sizes, thicknesses, and variable wall thickness within the same block of the ICF while being manufactured as a whole unitary block (achieved by the horizontally opening walls of the mold) as opposed to existing ICF walls being manufactured independently and in halves (or independent walls) and then glued or attached together in other ways as in other ICF's. Additionally, the ICF block has superior lateral, diagonal, and torque load resistance to outside forces because of an engineered multi-sided cell configuration forming a cell grid in the interior of the ICF and consequently the entire wall system. Additionally, the ICF block itself is made from a superior material mix utilizing a formula that not only increases the “R” value of the wall system but make the ICF block stronger and lighter to work with during installation.

2. Background of the Invention

Prior art shows conventional concrete slab style ICF walls tend to crack from corner to corner when impacted by outside forces such as high velocity wind or water from storm surge which can lead to a catastrophic failure. Walls utilizing a “post-and-beam” or “gridwall” interior structural cell pattern having interlocking voids (as opposed to the concrete slab interior style ICF) while filling those voids with structural concrete and reinforced steel bars (“rebar”), are able to sustain impacts with minimal damage being localized to the area around the impact point. However, conventional “post-and-beam” or “gridwall” style ICF structures utilize cylindrical vertical post members and horizontal beam members that are subject to “racking”, “parallelograming”, and torqueing when subjected to the outside such as forces of wind and water. Accordingly, there is a need in the art for an improved “post-and-beam” or “gridwall” structure.

Prior art molds for making insulated concrete forms generate a product having two halves, which must be glued together. This creates a potential for the blocks to split during the concrete filling stage of the installation. Additionally, such prior art molds have limited adjustability, making it difficult to produce blocks of differing desired sizes, e.g., differing heights and widths.

Accordingly, there is a need in the art for a mold that will make integral low-density concrete blocks having a decreased potential for splitting. There is still further a need for a mold that is adjustable in various directions to allow low-density concrete blocks of differing desired sizes to be produced without changing out molds.

Additionally, current formulas used for making cementitious insulated concrete forms are characterized by a relatively high brittleness, low pliability and low strength, a relatively heavy mass, expensive manufacturing costs, and a relatively low “R” value. Similarly, prior art insulated concrete forms have relatively high mass, low strength, and low “R” values, in part because of the material from which they are constructed and in part because of their structural design. “R” value refers to the resistance to temperature change of a material and, in the case of a wall, refers to the resistance to temperature change from one side of the wall to the other side of the wall. Standards for “R” value are written, for example, by Oak Ridge Institute for Science and Education (Knoxville, TN). Accordingly, there is a need in the art for an insulated concrete forms utilizing a composition having low mass, high strength, and high “R” values for use in.

SUMMARY OF THE INVENTION

These needs, and others, are met by the insulated concrete form and mold for making the same of the claimed invention.

According to an aspect of the invention, an insulated concrete form has: a first side wall portion; a second side wall portion substantially parallel with said first side wall portion; and a pillar portion extending between said the side wall portions. The pillar portion has: a first tapered section; a second tapered section; and a center section extending between said tapered sections. The first tapered section, the second tapered section and the center section each have an octagonal-shaped longitudinal cross-section. The first tapered section tapers in from the first side wall at a 45° angle to the center section. The second tapered section tapers in from the second side wall at a 45° angle to the center section. The first tapered section is substantially complementary with said second tapered section. The side wall portions and the pillar portion define a series of voids, and the voids include a leftward-facing vertical flared semi-octagonal void, a rightward-facing vertical flared semi-octagonal void, an upward facing horizontal flared semi-octagonal void, and a downward-facing horizontal flared semi-octagonal void.

More specifically, the insulated concrete form may include a plurality of pillar portions extending between the side wall portions, with each pillar portion having a first tapered section, a second tapered section, and a center section extending between the tapered sections. The first tapered section, the second tapered section and the center section each have an octagonal-shaped longitudinal cross-section. The first tapered section tapers in from the first side wall at a 45° angle to the center section, the second tapered section tapers in from the second side wall at a 45° angle to the center section, and the first tapered section is substantially complementary with said second tapered section. The plurality of center sections are substantially parallel with each other. The side wall portions and the pillar portions define a series of voids. The voids include a leftward-facing vertical flared semi-octagonal void, a rightward-facing vertical flared semi-octagonal void, an upward facing horizontal flared semi-octagonal void, and a downward-facing horizontal flared semi-octagonal void. The leftward-facing vertical flared semi-octagonal void and an adjacent rightward-facing vertical flared semi-octagonal void form a complete vertical flared octagonal void.

The insulated concrete form may be composed of a concrete material comprising cement, a polymer filler and a plant based high-density foaming agent. More specifically, the ratio of cement, to polymer filler to foaming agent, based on weight, may be about 110:11:1-1.125.

According to another aspect of the invention, a wall structure, has a plurality of insulated concrete forms, each form comprising: a first side wall portion; a second side wall portion substantially parallel with said first side wall portion; and pillar portion, as described above, extending between the side wall portions. The plurality of forms are placed adjacent to each other such that the center sections of said forms are substantially parallel with each other and leftward-facing vertical flared semi-octagonal voids and adjacent rightward-facing vertical flared semi-octagonal voids form complete vertical flared octagonal voids; and upward-facing and downward-facing semi-octagonal voids form complete horizontal flared octagonal voids. Thus, the wall structure is arranged in a post-and-beam lattice of interlocking and flared octagonal voids between the pillar portions. The voids may then be filled with material capable of hardening, such as concrete. Further, the concrete in the voids may be reinforced with at least one steel reinforcing bar.

According to yet another aspect of the invention, a mold for forming an insulated concrete form has: an elongated horizontal frame having opposing ends and opposing sides; a first end plate and a second end plate, each end plate extending upward along respective frame ends and having opposing interior sides; a first set of arms and a second set of arms, each set of arms slidingly attached to the frame along a respective side of the frame and extending laterally from the respective sides of the frame; a first side plate and a second side plate, each side plate attached to a respective set of arms and extending upward, each side plate having opposing interior sides; a slave pallet element supported by the frame, the slave pallet element abutting a lower portion of the interior sides of the end plates and the side plates; and a first spine member and a second spine member. The first spine member is attached to the interior side of the first side plate, and the second spine member attached to the interior side of the second side plate. The first end plate, the second end plate, the first side plate, the second side plate, the slave pallet element, the first spine member and the second spine member cooperate to define a mold cavity. The first side plate and the second side plate, along with the first spine member and the second spine member, may be pulled horizontally outward guided by the sets of arms to clear the mold cavity.

The second end plate may hingedly attached at a respective frame end.

Additionally, the mold may have an elongated horizontal caster deck member having an upward-facing surface, and a plurality of casters positioned on the upward-facing surface. Each caster has an upward-facing, weight-bearing roller element. The caster deck member is positioned between the frame and the slave pallet element such that the weight-bearing roller elements of the plurality of casters support the slave pallet element. Thus, the second end plate may be rotated downward about the respective frame end, such that the slave pallet may be rolled out from the mold cavity on the casters.

The spine members preferably have a plurality of opposing projections which meet. The opposing projections define transverse voids through a form to be formed in the mold. The spine members may further have base portions along the side plates. The base portions define longitudinal voids along a perimeter of a form to be formed in the mold. The base portions may have a semi-octagonal cross-section, wherein the opposing projections include end projections having a semi-octagonal cross-section and post projections having an octagonal cross-section. Further, quasi-octagonal wedges may span between the base portions and the opposing projections.

The mold for forming an insulated concrete form may also have spacer strips removably attached along top edges of the end plates and the side plates. The spacer strips allow additional thickness to be added to a portion of the mold cavity above the spine members. The spacer strips may be removed from the side plates and placed between the frame and the slave pallet element to raise the slave pallet element and reduce a thickness of a portion of the mold cavity between the spine members and the slave pallet element.

The side plates may further have wheeled support legs which support the weight of the side plates while allowing the side plates to be pulled out from or pushed in toward said frame.

Better understanding may be had by referring to the following detailed description of exemplary embodiments and drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary insulated concrete form in accordance with the invention.

FIG. 2 is a top view of the exemplary form of FIG. 1.

FIG. 3 is a front view of the exemplary form of FIG. 1.

FIG. 4 is a right side view of the exemplary form of FIG. 1.

FIG. 5 is a front view of the exemplary form of FIG. 1 taken along line 4-4 of FIG. 2.

FIG. 6 is a top cross-sectional view of the exemplary form of FIG. 1 taken along line 5-5 of FIG. 4.

FIG. 7 is a side cross-sectional view of the exemplary form of FIG. 1 taken along line 6-6 of FIG. 2.

FIG. 8 is a top view of an arrangement of exemplary forms.

FIG. 9 is a front view of the arrangement of FIG. 7.

FIG. 10 is a right side view of the arrangement of FIG. 7.

FIG. 11 is a perspective view of an exemplary mold used to form an insulated concrete form having multiple pillar portions, said mold in a closed configuration.

FIG. 12 is a perspective view of the exemplary mold of FIG. 11 wherein the mold is in an open position and a slave pallet element partially extends from the mold.

FIG. 13 is a perspective view of the exemplary mold of FIG. 11, further showing an insulated concrete form having multiple pillar portions that has been formed in the mold.

FIG. 14 is a perspective view of an exemplary spine member of the exemplary mold of FIG. 11.

DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

A. Insulated Concrete Form

An insulated concrete form made in accordance with the present invention may be constructed from a material such as a lightweight/low density material described below.

With reference to FIGS. 1-7, an exemplary insulated concrete form 10 has a unitary construction, including a first side wall portion 12, a second side wall portion 14, and a pillar portion 16, which extend between the two side wall portions 12, 14. The pillar portion 16 has a first tapered section 18, a second tapered section 20, and a center section 22 extending between the tapered sections 18, 20. The first tapered section 18, the second tapered section 20, and the center section 22 have an octagonal-shaped longitudinal cross-section, and are axially aligned with each other. The first tapered section 18 tapers in from the first side wall portion 12 at a 45° angle to the center section 22. The second tapered section 20 tapers in from the second side wall portion 14 at a 45° angle to the center section 22. Preferable, the first tapered section 18 is substantially complementary with the second tapered section 20 and both cooperate with the center section 22 and the side wall portions 12, 14 to define semi-octagonal voids of equilateral sides, as will be further described below.

Together, the side wall portions 12, 14 and the pillar portion 16 define a series of voids. As depicted in FIG. 2, a leftward-facing vertical semi-octagonal void 24a and a rightward-facing vertical semi-octagonal void 24b are defined by the side wall portions 12, 14 and pillar portion 16 of the form 10. As depicted in FIG. 4, an upward facing horizontal semi-octagonal void 26a and a downward-facing horizontal semi-octagonal void 26b are defined by the side wall portions 12, 14 and the pillar portion 16. These octagonal voids have equilateral sides.

As shown in FIG. 8, it is contemplated that by placing a predetermined number of forms 10 side-by-side with each other, a form 10 of a predetermined length can be formed. The forms 10 may be placed such that the right faces 28a, 28b of the side wall portions 12, 14 of a first form abut the left faces 30a, 30b of the side wall portions 12, 14 of a second form. In this manner, the rightward-facing vertical semi-octagonal void 24b of one form and the leftward-facing vertical semi-octagonal void 24a of a second form forms a complete vertical substantially octagonal void 32. Note that the octagonal void 32 tapers out at either end of the void 32 in complement with the tapered sections 18, 20 of the pillar portion 16 of each form 10. Of course, forms 10 of a desired length may be of a unitary construction, for example, by using a mold to form a form having multiple pillar portions.

Turning now to FIGS. 8-10, it is contemplated that forms 10 of a predetermined length may be stacked on top of one another to create a wall structure 100 of a predetermined height. The forms 10 may be stacked such that the top edges 34, 36 of the side wall portions 12, 14 of a lower form abut the bottom edges 38, 40 of the side wall portions 12, 14 of an upper form. When the forms 10 are stacked in this manner, the upward facing horizontal semi-octagonal void 26a of a lower form and the downward-facing horizontal semi-octagonal void 26b of an upper form form a complete horizontal substantially octagonal void 42 running the length of the forms 10. The stacked forms 10 of the wall structure 100 are oriented such that pillar portions 16 align with each other, such that continuous vertical octagonal voids 32 running the height of the wall structure 100 are created.

With reference to FIGS. 8-10, the vertical octagonal voids 32, the upward facing horizontal semi-octagonal void 26a of the upper-most form, the downward-facing horizontal semi-octagonal void 26b of the lower-most form, the horizontal octagonal voids 42, the leftward-facing vertical semi-octagonal voids 24a of the left-most forms and the rightward-facing vertical semi-octagonal voids 24b of the right-most forms created by the stacked forms 10 all interconnect to form a grid or a post-and-beam lattice of interlocking and flared octagonal voids defined by the structure 100 of the stacked forms 10.

The forms 10 are placed adjacent to each other and joined together using traditional methods known in the art. It is contemplated that the exemplary wall structure 100 is substantially rectangular in shape, but other shapes and configurations are possible without departing from the spirit and scope of the present invention.

After the plurality of forms 10 are positioned and joined together into the desired wall structure 100, the wall structure 100 can be reinforced. For example, the grid of vertical and horizontal substantially octagonal voids may be filled with a material such as reinforcing concrete and/or rebar. Of course, the leftward facing vertical semi-octagonal voids 24a of the left-most forms and the rightward-facing vertical semi-octagonal voids 24b of the right-most forms must be temporarily closed or sealed prior to filling the structure 100 with concrete to contain the concrete within the structure 100. Thus, temporary closure members 102, 104 are shown in FIGS. 8-10, with the understanding that any equivalent structure could be utilized for this purpose without departing from the scope of the teachings described herein. In this regard, the present invention includes a wall structure 100 arranged in a post-and-beam lattice of interlocking and flared octagonal voids between the pillar portions 16, whereby the voids are filled with reinforcing concrete and/or rebar, to create a wall structure 100.

The strength of the structure 100 created from the forms 10 of the present invention depends, in part, on the lattice of vertical and horizontal substantially octagonal voids 32, 42 defined by the structure of the forms, which form 450 compound angles at every intersection between vertical and horizontal voids 32, 42. Less effective insulation and finishing systems include either concrete slabs or assemblies creating cylindrical voids, which do not provide 45° compound angles at intersection between vertical and horizontal voids. The substantially octagonal voids 32, 42 created by the plurality of stacked forms 10 of the present invention, once filled with a suitable material, result in a structure that is at least 80% stronger than assemblies using cylindrical voids, and at least 60% stronger than systems using concrete slabs. The result is a tremendously strong wall system that may be designed to be capable of withstanding the lateral wind load resistance and torque that can exist in a wind storm or hurricane. Additionally, the form 10 of the present invention made from the insulated concrete material described above is substantially fireproof, bug proof, mold proof, wind proof, sound-reducing and is economical to build.

When a wall structure is created by stacking forms and filling the horizontal and vertical octagonal voids with a reinforcing material, such as concrete and/or rebar, the qualities (e.g., strength, “R” value, etc.) of the resulting wall may depend, in part, on the various dimensions of the form. For example, the distances between adjacent octagonal voids and the outer dimensions of the octagonal voids of the forms used to build the wall can be adjusted to affect the ability of the wall to withstand lateral wind load resistance and torque that could exist in a wind storm or hurricane. For another example, the width of the forms used to build the wall can be adjusted to affect the “R” value of the wall. For another example, the height and length of the wall can be adjusted to accommodate the needs of a particular building project and/or the standards in a particular market or part of the country.

An exemplary form may be provided having a height of 16 inches, a length of 96 inches, a width of 14 inches, a distance between the center of adjacent octagonal voids of 16 inches, and outer dimensions of the octagonal voids of 6 inches by 6 inches. Another exemplary form may be provided having a height of 32 inches, a length of 96 inches, a width of 14 inches, a distance between the center of the octagonal voids of 16 inches, and outer dimensions of the octagonal voids of 6 inches by 6 inches. Other exemplary forms may be scaled upward or downward in size, depending on the intended purpose. For instance, to construct a structure having a height of greater than 40 feet, it is desirable that the outer dimensions of the octagonal voids be 8 inches by 8 inches. Smaller structures may require forms having octagonal voids measuring 4 inches by 4 inches.

The above-described exemplary insulated concrete forms are examples of the insulated concrete form 10 of the present invention and other embodiments and designs may be provided without departing from the spirit and scope of the present invention. For example, in certain other embodiments, forms may be provided having a pair of side wall portions and any number of pillar portions, which wall portions and pillar portions of the forms define various substantially octagonal voids. Forms of various complementary sizes may be stacked adjacent one another to form a wall of any desired height or width, forming grids of horizontal and vertical substantially octagonal voids. Additionally, the principles taught herein may also be applied to insulated concrete forms for forming a structure having a post and beam lattice of interlocking voids that are in other, multi-faceted, non-cylindrical cross-sectional shapes, such as square or hexagonal.

B. Mold for Making Insulated Concrete Forms

As shown in FIG. 11 through FIG. 14, an exemplary embodiment of a mold 200 for forming a form as described above comprises an elongated horizontal frame 202, a first end plate 204, a second end plate 206, a first set of arms 207, 208, 209, a second set of arms 210, 211, 212, a first side plate 213, a second side plate 214, an elongated horizontal caster deck member 216, a slave pallet element 218, a first spine member 220, and a second spine member 222. The first end plate 204, second end plate 206, first side plate 213, second side plate 214, slave pallet element 218, first spine member 220 and second spine member 222 cooperate to define a mold cavity having an open top. The mold cavity is for forming an insulated concrete form as described above.

The elongated horizontal frame 202 has opposing sides and opposing ends. The elongated horizontal frame 202 serves as a base to which the end plates 204, 206, arms 207, 208, 209, 210, 211, 212, side plates 213, 214, and caster deck member 216 are connected. The elongated horizontal frame 202 of the exemplary mold 200 is supported on wheels 223 which facilitate easy movement of the assembly.

The first end plate 204 and the second end plate 206 extend upwardly, substantially vertically, along respective frame ends. The end plates 204, 206 have opposing interior sides 224, 226. In the exemplary embodiment, the first end plate 204 is fixedly attached to a frame end, and the second end plate 206 is hingedly attached to the other frame end. A first hinge 228 is shown in FIG. 12, and a second complementary hinge is concealed in the figure. Advantageously, the second end plate 206 may therefore be opened outward with respect to frame 202 and the first end plate 204 to facilitate opening of the mold 200 and removal of a insulated concrete form 299 (FIG. 13) formed therein, as described below. A handle 205 aids in this action.

The first set of arms 207, 208, 209, and the second set of arms 210, 211, 212 are slidingly attached to the frame 202 along respective sides of the frame 202. The sliding attachment allows the arms 207, 208, 209, 210, 211, 212 to extend and retract laterally from the respective sides of the frame 202, the benefit of which will be explained below. In the exemplary embodiment, the arms 207, 208, 209, 210, 211, 212 are preferably made of C-shaped track that cooperates with rollers or wheels (hidden) fixed to the frame 202 (similar to a garage door track and roller configuration) to guide the travel of the arms substantially normal to a longitudinal axis of the frame 202. A stop mechanism (not shown) is provided to prevent the arms from becoming detached from the frame 202.

The first side plate 213 is attached to distal ends of the first set of arms 207, 208, 209 along a lower portion of said first side plate 213 and extends upwardly, substantially vertically, along one side of the frame 202. The second side plate 214 is attached to distal ends of the second set of arms 210, 211, 212 and also extends upwardly, substantially vertically, along the other side of the frame 202. The side plates 213, 214 have respective opposing interior sides 230, 232. Additionally, in the exemplary embodiment 200 shown, the side plates 213, 214 have respective wheeled support legs 234a, 234b, 236a, 236b which support the weight of the side plates 213, 214 while allowing the side plates to be pulled out from or pushed in toward the frame 202. Advantageously, the side plates 213, 214 may be opened outward (or closed inward) with respect to the frame 202 and each other, guided by said arms 207, 208, 209, 210, 211, 212 in a drawer-like fashion, to facilitate opening of the mold 200 and removal of a insulated concrete form 299 (FIG. 13) formed therein, as described below. Handles 238a, 238b, 240a, 240b on the respective side plates 213, 214 aid in this action.

The elongated horizontal caster deck member 216 is positioned on the frame 202, and has an upward-facing surface 242 and a plurality of casters 244. The plurality of casters 244 are positioned on the upward-facing surface 242. Each of the plurality of casters 244 has an upward-facing, weight-bearing roller element 246 to support the slave pallet element 218 and an insulated concrete form to be formed in the exemplary mold 200. As shown in FIG. 13, the casters 244 of the exemplary mold 200 are positioned in pairs along the length of the caster deck member 216.

The slave pallet element 218 is positioned on the plurality of casters 244, and abuts a lower portion of the end plate interior sides 224, 226 and the side plate interior sides 230, 232 when the end plates 204, 206 and side plates 213, 214 are in a closed position with respect to the frame 202 and each other. Thus, the slave pallet element 218 forms the floor of the mold cavity. Additionally, the slave pallet element 218 is independent from the end plates 205, 206 and side plates 213, 214, allowing it to support an insulated concrete form that has been formed in the exemplary mold 200 to facilitate removal of the insulated concrete form from the mold 200.

The first spine member 220 is attached to the first side plate interior side 230, and the second spine member 222 is attached to the second side plate interior side 232. Each spine member 220, 222 has, respectively, a semi-octagonal base portion 248, 250, semi-octagonal end projections 252, 254, 256, 258 at each end thereof, and a plurality of octagonal post projections 260a-e, 262a-e. Additionally, a plurality of quasi-octagonal wedges 264, 266 span between the respective semi-octagonal base portions 248, 250, semi-octagonal end projections 252, 254, 256, 258, and octagonal post projections 260a-e, 262a-e. Advantageously, respective opposing semi-octagonal end projections 252, 254, 256, 258, and respective opposing octagonal post projections 260a-e, 262a-e meet when the side plates 213, 214 are in a closed position.

The exemplary mold 200 forms a block form, as described above, with the block form on its side. That is to say, the spine members 220, 222 form the flared semi-octagonal and octagonal voids of the block form, and the space in the mold cavity above and below the spine members 220, 222 forms the side walls of the block form. The opposing semi-octagonal end projections 252, 254, 256, 258, and plurality of opposing octagonal post projections 260a-e, 262a-e define the vertical semi-octagonal and octagonal voids of an insulated concrete form to be formed in the exemplary mold 200. The plurality of quasi-octagonal wedges 264, 266 serve to define, along with the semi-octagonal end projections 252, 254, 256, 258, and plurality of opposing octagonal post projections 260a-e, 262a-e, an octagonal pillar portion of such an insulated concrete form, and further define the 45 degree compound angles at every intersection between the horizontal and vertical voids of the insulated concrete form. The semi-octagonal base portions 248, 250 define upward-facing and downward-facing horizontal semi-octagonal voids of such an insulated concrete form.

One of skill in the art will recognize that the scope of the claimed mold is not limited to the described octagonal/semi-octagonal configuration of spine members 220, 222, as the principles taught herein would also apply to square, hexagonal and other such configurations. Additionally, it should be noted that the design of the exemplary mold 200 allow easy scaling up or scaling down of the insulated concrete form to be produced therein by using interchangeable, scaled up/down spine members 220, 222. Thus, insulated concrete forms having voids with outer dimensions of 8 inches by 8 inches, 6 inches by 6 inches, or 4 inches by 4 inches may be formed with the use of appropriately scaled spine members 220, 222.

Respective spacer strips 268, 270, 272, 274 are removably attached along the top edges of the end plates 204, 206 and the side plates 213, 214. The spacer strips 268, 270, 272, 274 allow additional “thickness” to be added to the side wall portion of the block form that is formed above the spine members 220, 222. Further, by removing the spacer strips 272, 274 from the top edges of the side plates 213, 214 and placing them between the frame 202 and the caster deck member 216, the “thickness” of the side wall portion of the block that is formed below the spine members 220, 222 can be reduced by raising the slave pallet element 218 toward the spine members 220, 222.

Advantageously, all of the interior surfaces of the elements that define the mold cavity of the exemplary mold 200 are coated with an epoxy rubber to facilitate release of an insulated concrete form formed in the exemplary mold 200 from the elements of the exemplary mold.

In use, the end plates 204, 206 and the side plates 213, 214 of the exemplary mold 200 are closed and the mold cavity is filled with a liquid composition to be cured into an insulated concrete form. The liquid composition is allowed to adequately cure and solidify. Then, the side plates 213, 214, along with the spine members 220, 222 are pulled horizontally outward to clear the mold cavity. The second end plate 206 is opened downward, and the slave pallet element 218, with the cured insulated concrete form 299 (FIG. 13), is rolled out from the mold cavity on the casters 244.

C. Lightweight/Low-Density Material for Making Molded Products

The present invention includes a low density/lightweight material that may be used to make insulated concrete form wall panels, lightweight decorative products and shapes such as trim, edging, decretive window trim and sills; dowels and columns; flat panels used as an exterior insulation and finish systems; and for other types of construction where a masonry product is required and strength, mass of the product, insulation, fire resistance, and/or mold resistance may be an issue.

The cement used to prepare the low density/lightweight material of the present invention may be, for example, Portland cement. The aggregate may be, for example, polystyrene, ground plastics, wood, glass or other recyclable material. The cement volume-reducing compound may be a foaming agent, for example, a plant-based foaming agent capable of creating high density foamed air bubbles. One advantageous foaming agent is sold under the trade name FOAMCELL A-100, by Goodson & Associates, Inc., of Wheat Ridge, Co. This foaming agent has an expansion of 29 to 35 times and a foam density of 1.8-2.2 lbs. cu. ft, producing 270 cu. ft. foam per gal. Alternatively, other foaming agents may be used in place of FOAMCELL A-100, which produces a high-density foam, known to one of ordinary skill in the art. Preferably, the selected foaming agent is one which will not degrade the selected aggregate. For example, if the aggregate is animal-based or composed of particular organic material, such as a polymer, the selected foaming agent should not be an animal-based material or other agent which would degraded aggregate material.

An exemplary low density/lightweight material made in accordance with the present invention includes cement, an aggregate, and a cement volume-reducing compound capable of reducing the volume of cement required to bind the all of the elements of the low density/lightweight material. The low density/lightweight material may additionally include a curing accelerator. When the material is poured into a mold to create a product, the curing accelerator will reduce the production time, i.e., it may be removed from the mold more quickly. Alternatively or additionally, the low density/lightweight material may include a liquid polymer. When the product is being used to create a product, the liquid polymer will increase the strength of and add pliability to the resulting product. Alternatively or additionally, the low density/lightweight material may include a water reducer, which reduces the amount of water required to bring the low density/lightweight material to a desired consistency for filling a mold. Additionally, when the water reducer is used, the molded product will have a lighter initial weight and will cure more quickly, i.e., less water to evaporate from the molded product. Hence, when the water reducer is used, the molded product will have a higher tensile and flexural strength sooner. As such, the final molded product is ready for use or may be transported at an earlier time point. Alternatively or additionally, the low density/lightweight material may include a mold release agent, which will minimize any tendency of the molded product to stick to the mold.

The curing accelerator that is used may be, for example, a calcium-containing curing accelerator or other suitable curing accelerator. The liquid polymer that is used may be, for example, a polyurethane-based liquid polymer or other suitable liquid polymer. The water reducer that is used may be, for example, a high-range water reducer, e.g., superplasticizers, a mid-range water reducer, or another suitable water reducer. The mold release agent that is used may be, for example, a silicone-based mold release agent or other suitable mold release agent.

The combination of the constituents which comprise the cement mixture, along with the respective ratios of those constituents results in a highly advantageous cement material for use in the present insulated concrete foam. For example, the foaming agent produces high-density foam which creates microscopic air bubbles, gaps or voids in the concrete mixture as it cures. The air bubbles account for as much as 15% of the volume of the cured mixture, thus producing a lighter material with insulating properties. Further, the gaps or voids enhance the strength of the cured material. In addition, the use of a polymer based filler provides for a less brittle concrete material.

Table 1 provides the per unit formula for an exemplary low density/lightweight material.

TABLE 1
Basic Per Unit Formula: (depending on block size)
90 to 120 pounds of Portland cement
8 lbs to 11 lbs ground polystyrene
16–18 oz plant based foaming
agent to create high density
foamed air bubbles
Cement curing accelerator
12–14 oz liquid polymer
6–8 gallons of approx. 95° F. water
Water reducer (3 to 4 oz)
Mold release agent (3 to 4 oz)

The exemplary low density/lightweight material has a mixture ratio of cement, to polymer filler to foaming agent, based on weight, of 110:11:1-1.125.

An exemplary method of making a product using the low density/lightweight material will now be described. Water is provided and heated to about 95° Fahrenheit. The cement and cement volume-reducing compound, e.g., plant-based foaming agent, are added to the heated water. If an accelerator and/or liquid polymer are being used, these compounds are also added to the heated water. If a water reducer and/or a mold release agent are being used, these compounds are also added to the heated water. The polystyrene, provided in bead form, is then added and blended until all polystyrene beads are covered. The resulting slurry is then placed into a mold of choice and cured until a resulting molded product is ready to be removed, e.g., about 1.5 hours when a curing accelerator is being used and the molded product is a form having dimensions of about 1×1.3×8 feet, which form is then allowed to air cure for about two days before being ready for use.

One of ordinary skill in the art will recognize that additional compositions and configurations are possible without departing from the teachings of the invention. This detailed description, and particularly the specific details of the exemplary embodiments disclosed, is given primarily for illustration and no unnecessary limitations are to be understood therefrom, for modifications will become evident to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the claimed invention.

Claims

1. An insulated concrete form, comprising:

a first side wall portion;

a second side wall portion substantially parallel with said first side wall portion; and

a pillar portion extending between said side wall portions, said pillar portion having a first tapered section, a second tapered section, and a center section extending between said tapered sections, said first tapered section, said second tapered section and the center section each having an octagonal-shaped longitudinal cross-section, said first tapered section tapers in from said first side wall at a 45° angle to the center section, said second tapered section tapers in from said second side wall at a 45° angle to the center section, said first tapered section is substantially complementary with said second tapered section,

wherein said side wall portions and said pillar portion define a series of voids, said voids include a leftward-facing vertical flared semi-octagonal void, a rightward-facing vertical flared semi-octagonal void, an upward facing horizontal flared semi-octagonal void, and a downward-facing horizontal flared semi-octagonal void.

2. The insulated concrete form of claim 1, wherein said pillar portion includes the first tapered section, the second tapered section, and the center section being axially aligned with each another.

3. The insulated concrete form of claim 1, and further comprising:

a plurality of pillar portions extending between said side wall portions, each said pillar portion having a first tapered section, a second tapered section, and a center section extending between said tapered sections, said first tapered section, said second tapered section and the center section each having an octagonal-shaped longitudinal cross-section, said first tapered section tapers in from said first side wall at a 45° angle to the center section, said second tapered section tapers in from said second side wall at a 45° angle to the center section, said first tapered section is substantially complementary with said second tapered section,

wherein said plurality of center sections are substantially parallel with each other;

wherein said side wall portions and said pillar portions define a series of voids, said voids include a leftward-facing vertical flared semi-octagonal void, a rightward-facing vertical flared semi-octagonal void, an upward facing horizontal flared semi-octagonal void, and a downward-facing horizontal flared semi-octagonal void;

wherein said leftward-facing vertical flared semi-octagonal void and an adjacent rightward-facing vertical flared semi-octagonal void form a complete vertical flared octagonal void.

4. The insulated concrete form of claim 1, wherein said first side wall portion, said second side wall portion, and pillar portion are composed of a concrete material comprising cement, a polymer filler and a plant based high-density foaming agent.

5. The insulating concrete of claim 4, wherein the ratio of cement, to polymer filler to foaming agent, based on weight, is 110:11:1-1.125.

6. A wall structure, comprising:

a plurality of insulated concrete forms, each said form, comprising a first side wall portion, a second side wall portion substantially parallel with said first side wall portion, and a pillar portion extending between said side wall portions, said pillar portion having a first tapered section, a second tapered section, and a center section extending between said tapered sections, said first tapered section, said second tapered section and the center section each having an octagonal-shaped longitudinal cross-section, said first tapered section tapers in from said first side wall at a 45° angle to the center section, said second tapered section tapers in from said second side wall at a 45° angle to the center section, said first tapered section substantially complementary with said second tapered section,

wherein said plurality of forms are placed adjacent to each other such that the center sections of said forms are substantially parallel with each other;

wherein said side wall portions and said pillar portions define a series of voids, said voids include a leftward-facing vertical flared semi-octagonal void, a rightward-facing vertical flared semi-octagonal void, an upward facing horizontal flared semi-octagonal void, and a downward-facing horizontal flared semi-octagonal void;

wherein said leftward-facing vertical flared semi-octagonal void and an adjacent rightward-facing vertical flared semi-octagonal void form a complete vertical flared octagonal void; and

wherein the wall structure is arranged in a post-and-beam lattice of interlocking and flared octagonal voids between the pillar portions.

7. The structure of claim 6, wherein said voids are filled with material capable of hardening.

8. The structure of building a structure of claim 7, wherein the material capable of hardening is concrete.

9. The structure of claim 8, wherein said voids have at least one steel reinforcing bar.

10. The structure of claim 6, wherein said voids have at least one steel reinforcing bar.

11. A mold for forming an insulated concrete form, comprising:

an elongated horizontal frame having opposing ends and opposing sides;

a first end plate and a second end plate, each said end plate extending upward along respective frame ends and having opposing interior sides;

a first set of arms and a second set of arms, each set of arms slidingly attached to said frame along a respective side of said frame and extending laterally from said respective sides of said frame;

a first side plate and a second side plate, each said side plate attached to a respective set of arms and extending upward, each said side plate having opposing interior sides;

a slave pallet element supported by said frame, said slave pallet element abutting a lower portion of said interior sides of said end plates and said side plates; and

a first spine member and a second spine member, said first spine member attached to said interior side of said first side plate, said second spine member attached to said interior side of said second side plate;

wherein said first end plate, said second end plate, said first side plate, said second side plate, said slave pallet element, said first spine member and said second spine member cooperate to define a mold cavity; and

wherein said first side plate and said second side plate, along with said first spine member and said second spine member, may be pulled horizontally outward guided by said sets of arms to clear said mold cavity.

12. The mold for forming an insulated concrete form of clam 11, wherein said second end plate is hingedly attached at a respective frame end.

13. The mold for forming an insulated concrete form of claim 12, further comprising an elongated horizontal caster deck member having an upward-facing surface, and a plurality of casters positioned on said upward-facing surface, each said caster having an upward-facing, weight-bearing roller element, said caster deck member positioned between said frame and said slave pallet element such that said weight-bearing roller elements of said plurality of casters support said slave pallet element; wherein said second end plate may be rotated downward about said respective frame end, such that said slave pallet may be rolled out from said mold cavity on said casters.

14. The mold for forming an insulated concrete form of claim 11, wherein said spine members have a plurality of opposing projections which meet, said opposing projections defining transverse voids through a form to be formed in the mold.

15. The mold for forming an insulated concrete form of claim 14, wherein said spine members further have base portions along said side plates, said base portions defining longitudinal voids along a perimeter of a form to be formed in the mold.

16. The mold for forming an insulated concrete form of claim 15, wherein said base portions have a semi-octagonal cross-section, wherein said opposing projections include end projections having a semi-octagonal cross-section and post projections having an octagonal cross-section, and further comprising quasi-octagonal wedges spanning between said base portions and said opposing projections.

17. The mold for forming an insulated concrete form of claim 11, further having spacer strips removably attached along top edges of said end plates and said side plates, said spacer strips allowing additional thickness to be added to a portion of said mold cavity above said spine members.

18. The mold for forming an insulated concrete form of claim 17, wherein said spacer strips are removed from said side plates and placed between said frame and said slave pallet element to raise said slave pallet element and reduce a thickness of a portion of said mold cavity between said spine members and said slave pallet element.

19. The mold for forming a form of claim 11, wherein said side plates further have wheeled support legs which support the weight of the side plates while allowing the side plates to be pulled out from or pushed in toward said frame.