Composite insulated plywood, insulated plywood concrete form and method of curing concrete using same

Abstract

The invention comprises a concrete form. The concrete form comprises a first panel having a first primary surface for contacting plastic concrete and a second primary surface opposite the first surface; and a second panel having a first primary surface and a second primary surface opposite the first surface, the second panel being attached to the first panel so that the first primary surface of the second panel is adjacent the second primary surface of the first panel. The concrete form also comprises a layer of radiant heat reflective material and a layer of insulating material disposed between and covering the second primary surface of the first panel and first primary surface of the second panel. A method of using the concrete form is also disclosed.

What is claimed is: 
     
       1. A method of forming concrete, the method comprising:
 placing plastic cementitious-based material between a pair of opposed insulated, removable concrete forms, wherein each insulated, removable concrete form comprises:
 an insulated panel comprising:
 a first panel of wood or plywood having a first primary surface and an opposite second primary surface, wherein the first panel contacts the plastic concrete, wherein the first panel defines a plane; 
 a layer of polymeric foam insulating material contacting the second primary surface of the first panel, wherein the layer of polymeric foam insulating material has an R-value of greater than 4; and 
 a second panel of wood or plywood having a first primary surface and an opposite second primary surface, wherein the second primary surface of the second panel contacts the layer of polymeric foam insulating material so that the layer of polymeric foam is disposed between the first and second panels; 
 
 a concrete form frame for supporting the insulated panel, the concrete form frame comprising a plurality of bracing members oriented transversely with respect to the second primary surface of the second panel, wherein no portion of the concrete form frame is in the plane defined by the first panel and wherein the plurality of bracing members contact the first primary surface of the second panel; 
 
 allowing the plastic cementitious-based material to cure for a desired time; and 
 removing the pair of opposed insulated, removable concrete forms from the at least partially cured concrete. 
 
     
     
       2. The method of  claim 1 , wherein the insulated concrete form has an R-value of greater than 8. 
     
     
       3. The method of  claim 2 , wherein the first panel of wood or plywood further comprises a concrete release coating on the first primary surface of the first panel. 
     
     
       4. The method of  claim 3 , wherein the layer of polymeric foam of insulating material comprises polyvinyl chloride, urethane, polyurethane, polyisocyanurate, phenol, polyethylene, polyimide or polystyrene. 
     
     
       5. The method of  claim 3 , wherein the layer of polymeric foam of insulating material comprises polyisocyanurate or polystyrene. 
     
     
       6. A method of forming concrete, the method comprising:
 placing plastic cementitious-based material between a pair of opposed insulated, removable concrete forms, wherein each insulated, removable concrete form comprises:
 an insulated panel comprising:
 a first panel of wood or plywood having a first primary surface and an opposite second primary surface, wherein the first panel contacts the plastic concrete, wherein the first panel defines a plane; 
 a layer of polymeric foam insulating material contacting the second primary surface of the first panel, wherein the layer of polymeric foam insulating material has an R-value of approximately 4 to approximately 40; and 
 a second panel of wood or plywood having a first primary surface and an opposite second primary surface, wherein the second primary surface of the second panel contacts the layer of polymeric foam insulating material; 
 
 a concrete form frame for supporting the insulated panel, the concrete form frame comprising a plurality of bracing members oriented transversely with respect to the first primary surface of the second panel, wherein no portion of the concrete form frame is in the plane defined by the first panel and wherein the plurality of bracing members contact the first primary surface of the second panel; 
 
 allowing the plastic cementitious-based material to cure for a desired time; and 
 removing the pair of opposed insulated, removable concrete forms from the at least partially cured concrete. 
 
     
     
       7. The method of  claim 6 , wherein the first panel of wood or plywood further comprises a concrete release coating on the first primary surface of the first panel. 
     
     
       8. The method of  claim 7 , wherein the layer of polymeric foam of insulating material comprises polyvinyl chloride, urethane, polyurethane, polyisocyanurate, phenol, polyethylene, polyimide or polystyrene. 
     
     
       9. The method of  claim 7 , wherein the layer of polymeric foam of insulating material comprises polyisocyanurate or polystyrene.