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WO2007118150A2 - Forme en beton isole et moule pour la fabriquer - Google Patents

Forme en beton isole et moule pour la fabriquer Download PDF

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Publication number
WO2007118150A2
WO2007118150A2 PCT/US2007/066070 US2007066070W WO2007118150A2 WO 2007118150 A2 WO2007118150 A2 WO 2007118150A2 US 2007066070 W US2007066070 W US 2007066070W WO 2007118150 A2 WO2007118150 A2 WO 2007118150A2
Authority
WO
WIPO (PCT)
Prior art keywords
octagonal
side wall
tapered section
section
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2007/066070
Other languages
English (en)
Other versions
WO2007118150A3 (fr
Inventor
David E. West
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to CN2007800195135A priority Critical patent/CN101454520B/zh
Publication of WO2007118150A2 publication Critical patent/WO2007118150A2/fr
Anticipated expiration legal-status Critical
Publication of WO2007118150A3 publication Critical patent/WO2007118150A3/fr
Ceased legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/42—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities
    • E04B2/54—Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities the walls being characterised by fillings in all cavities in order to form a wall construction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0081—Embedding aggregates to obtain particular properties
    • B28B23/0087—Lightweight aggregates for making lightweight articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/0029—Moulds or moulding surfaces not covered by B28B7/0058 - B28B7/36 and B28B7/40 - B28B7/465, e.g. moulds assembled from several parts
    • B28B7/0035—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding
    • B28B7/0041—Moulds characterised by the way in which the sidewalls of the mould and the moulded article move with respect to each other during demoulding the sidewalls of the mould being moved only parallelly away from the sidewalls of the moulded article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/10—Moulds with means incorporated therein, or carried thereby, for ejecting or detaching the moulded article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/28—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid
    • E04B2/40—Walls having cavities between, but not in, the elements; Walls of elements each consisting of two or more parts kept in distance by means of spacers, all parts being solid the walls being characterised by fillings in all cavities in order to form a wall construction
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8623—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers and at least one form leaf being monolithic
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8623—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers and at least one form leaf being monolithic
    • E04B2/8629—Walls made by casting, pouring, or tamping in situ made in permanent forms with spacers and at least one form leaf being monolithic with both form leaves and spacers being monolithic

Definitions

  • 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.
  • 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.
  • 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.
  • 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-
  • 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.
  • 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
  • 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.
  • 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
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the side wall portions 12, 14 and the pillar portion 16 define a series of voids.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the wall structure 100 can be reinforced.
  • the grid of vertical and horizontal substantially octagonal voids may be filled with a material such as reinforcing concrete and/or rebar.
  • 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.
  • temporary closure members 102, 104 are shown in FIGs.
  • 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 45° 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.
  • the form 10 of the present invention made from the insulated concrete
  • MA349 00MA1 597242 3B LOUISVILLE ⁇ Q material described above is substantially fireproof, bug proof, mold proof, wind proof, sound-reducing and is economical to build.
  • the qualities (e.g., strength, "R" value, etc.) of the resulting wall may depend, in part, on the various dimensions of the form.
  • 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.
  • the width of the forms used to build the wall can be adjusted to affect the "R" value of the wall.
  • 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.
  • 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.
  • 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.
  • forms may be provided having a pair of side wall portions and any number of pillar portions, which wall portions and pillar
  • MA349 00MA1 597242 3B LOUISVILLE ⁇ ⁇ 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.
  • 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.
  • 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.
  • the first end plate 204 is fixedly attached to a frame end
  • 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.
  • MA349 00MA1 597242 3B LOUISVILLE ⁇ 2 206 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • the slave pallet element 218 forms the floor of the mold cavity.
  • 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
  • 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.
  • 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.
  • 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
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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.
  • other foaming agents may be used in place of FOAMCELL A-100, which produces a high-density foam, known to one of ordinary skill
  • the selected foaming agent is one which will not degrade the selected aggregate.
  • 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.
  • 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.
  • 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.
  • 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.
  • the molded product will have a lighter initial weight and will cure more quickly, i.e., less water to evaporate from the molded product.
  • 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.
  • 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.
  • 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.
  • the gaps or voids enhance the strength of the cured material.
  • 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.
  • 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.
  • MA349 00MA1 597242 3B LOUISVILLE ⁇ Q 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 X 1.3 X 8 feet, which form is then allowed to air cure for about two days before being ready for use.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Moulds, Cores, Or Mandrels (AREA)
  • On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)

Abstract

La présente invention concerne une forme en béton isolé qui comporte : une première partie de paroi latérale ; une seconde partie de paroi latérale sensiblement parallèle à ladite première partie ; et une partie de pilier s'étendant entre lesdites parties de parois latérales. La partie de pilier comporte : une première partie effilée ; une seconde partie effilée ; et une partie centrale s'étendant entre lesdites parties effilées. La première partie effilée, la seconde partie effilée et la partie centrale ont chacune une coupe transversale longitudinale octogonale. La forme en béton isolé peut comprendre une pluralité de parties de pilier s'étendant entre les parties de parois latérales, les parties de pilier de ladite pluralité de parties de pilier étant sensiblement parallèles entre elles. Une structure de paroi peut être formée à partir d'une pluralité de telles formes en béton isolé. Un moule pour la formation d'une forme en béton isolé comporte : une première plaque latérale et une seconde plaque latérale ; un élément de palette esclave soutenu par un cadre et venant buter contre une partie inférieure des côtés intérieurs des plaques latérales ; et un premier élément vertébral et un second élément vertébral fixés aux plaques latérales. La première plaque latérale et la seconde plaque latérale, au même titre que le premier élément vertébral et le second élément vertébral, peuvent être tirées horizontalement vers l'extérieur pour vider la cavité du moule.
PCT/US2007/066070 2006-04-05 2007-04-05 Forme en beton isole et moule pour la fabriquer Ceased WO2007118150A2 (fr)

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US60/744,303 2006-04-05

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CN104002368A (zh) * 2014-05-21 2014-08-27 杨炎林 便于混凝土预制件生产时模具拆装方便的方法

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CN102873741B (zh) * 2012-09-13 2014-08-06 燕山大学 一种可移动式模具
CN104002368A (zh) * 2014-05-21 2014-08-27 杨炎林 便于混凝土预制件生产时模具拆装方便的方法

Also Published As

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CN101454520B (zh) 2011-09-28
CN101454520A (zh) 2009-06-10
WO2007118150A3 (fr) 2008-12-04
US20070245659A1 (en) 2007-10-25

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