Composite board for insulated concrete walls

Abstract

An insulation panel for a poured concrete wall and a method of constructing an insulated concrete wall provide a pre-finished concrete wall structure that is ready for drywall installation and/or direct mounting of heavy objects such as cabinets or the like. The insulation panel includes a rigid structural substrate sheet, an insulation sheet secured to the rigid substrate sheet in substantially overlapping relationship, and a plurality of anchor members projecting from the insulation sheet, the anchor members being configured to be securely anchored in a poured concrete wall.

The invention claimed is:  
     
         1 . An insulation panel for a poured concrete wall, comprising: 
 a rigid structural substrate sheet having opposite sides;    a sheet of insulation material having opposite sides, a first side of the sheet of insulation material secured to a first side of the substrate sheet in substantially overlapping relationship; and    a plurality of anchor members projecting from a second side of the insulation material, each anchor member being configured to be securely anchored in a poured concrete wall.    
     
     
         2 . The insulation panel of  claim 1 , wherein the sheet of insulation material has grooves in its opposite vertical edges for receipt of a retainer.  
     
     
         3 . The insulation panel of  claim 1 , wherein the rigid structural substrate sheet comprises lumber, plywood, pressboard, strand board, wood laminate, particle board, or fiberboard.  
     
     
         4 . The insulation panel of  claim 1 , wherein the rigid structural substrate has a thickness for about {fraction (7/16)} inch to about ½ inch.  
     
     
         5 . The insulation panel of  claim 1 , wherein the sheet of insulation material comprises an expanded plastic material.  
     
     
         6 . The insulation panel of  claim 1 , wherein the sheet of insulation material comprises expanded polystyrene or expanded polyurethane.  
     
     
         7 . The insulation panel of  claim 1 , wherein the thickness of the sheet of insulation material is from about 1½ inches to about 2½ inches.  
     
     
         8 . The insulation panel of  claim 1 , wherein each anchor member is position within a recess defined in the surface of the sheet of insulation material.  
     
     
         9 . The insulation panel of  claim 1 , wherein the anchor member is configured so that it has an enlarged head portion, a tapered neck portion, or both an enlarged head portion and a tapered neck portion.  
     
     
         10 . A method of constructing an insulated poured concrete wall comprising: 
 arranging wall forms in spaced relationship to form opposing wall surfaces defining a cavity;    arranging insulation panels adjacent at least one of the opposing wall surfaces, each of the insulation panels comprising a rigid structural substrate sheet having opposite sides, a sheet of insulation material having opposite sides, a first side of the sheet of insulation material secured to a first side of the substrate sheet in substantially overlapping relationship, and a plurality of anchor members projecting from a second side of the sheet of insulation material, the anchor members being configured to be securely anchored in a poured concrete wall;    pouring concrete into the cavity, whereby each of the projecting anchor members is surrounded by the poured concrete; and    allowing the concrete to cure, whereby the projecting anchor members are embedding within the concrete.    
     
     
         11 . The method of  claim 10 , wherein the sheet of insulation material has grooves in its opposite vertical edges for receipt of a retainer.  
     
     
         12 . The method of  claim 10 , wherein the rigid structural substrate sheet comprises lumber, plywood, pressboard, strand board, wood laminate, particle board, or fiberboard.  
     
     
         13 . The method of  claim 10 , wherein the rigid structural substrate has a thickness for about {fraction (7/16)} inch to about ½ inch.  
     
     
         14 . The method of  claim 10 , wherein the sheet of insulation material comprises an expanded plastic material.  
     
     
         15 . The method of  claim 10 , wherein the sheet of insulation material comprises expanded polystyrene or expanded polyurethane.  
     
     
         16 . The method of  claim 10 , wherein the thickness of the sheet of insulation material is from about 1½ inches to about 2½ inches.  
     
     
         17 . The method of  claim 10 , wherein each anchor member is position within a recess defined in the surface of the sheet of insulation material.  
     
     
         18 . The method of  claim 10 , wherein the anchor member is configured so that it has an enlarged head portion, a tapered neck portion, or both an enlarged head portion and a tapered neck portion.  
     
     
         19 . An insulated poured concrete wall, comprising: 
 a concrete wall layer having opposing wall surfaces; and    a plurality of insulation panels arranged adjacent at least one of the opposing wall surfaces, each of the insulation panels including a rigid structural substrate sheet having opposite sides, a sheet of insulation material having opposite sides, a first side of the sheet of insulation material secured to a first side of the substrate sheet in substantially overlapping relationship, and a plurality of anchor members projecting from a second side of the sheet of insulation material, wherein the anchor members are configured so that they are securely anchored in the concrete wall layer.    
     
     
         20 . The wall of  claim 19 , wherein the sheet of insulation material has grooves in its opposite vertical edges for receipt of a retainer.  
     
     
         21 . The wall of  claim 19 , wherein the rigid structural substrate sheet comprises lumber, plywood, pressboard, strand board, wood laminate, particle board, or fiberboard.  
     
     
         22 . The wall of  claim 19 , wherein the rigid structural substrate has a thickness for about {fraction (7/16)} inch to about ½ inch.  
     
     
         23 . The wall of  claim 19 , wherein the sheet of insulation material comprises an expanded plastic material.  
     
     
         24 . The wall of  claim 19 , wherein the sheet of insulation material comprises expanded polystyrene or expanded polyurethane.  
     
     
         25 . The wall of  claim 19 , wherein the thickness of the sheet of insulation material is from about 1½ inches to about 2½ inches.  
     
     
         26 . The wall of  claim 19 , wherein each anchor member is position within a recess defined in the surface of the sheet of insulation material.  
     
     
         27 . The wall of  claim 19 , wherein the anchor member is configured so that it has an enlarged head portion, a tapered neck portion, or both an enlarged head portion and a tapered neck portion.