Insulated concrete wall system

Abstract

An insulated wall system comprises a plurality of foldable blocks, each having two panels of rigid insulated foam, multiple inserts embedded in the panels, and ties between pairs of inserts. Each insert has one or more connectors, each with an end hole that swivelably receives the end leg of a tie in a manner that enables the block to fold. Each connector further has a top opening that releaseably captures the middle leg of the tie and rigidly locks the block against folding. The connectors are double-ended, and the inserts are invertible in the panels. Corner and T-walls are made by simple cuts in the standard blocks. Plates and ties are used to hold together the blocks of a main wall and an intersecting T-wall. The connectors of a panel may contact either the connectors of the other panel, or the other panel itself, when the block is folded.

1 . An insulated concrete wall system comprising: 
 a. a plurality of blocks erected on top of an alongside one another into a form, each block comprising: 
 i. first and second parallel panels made of a rigid insulative material;  
 ii. a plurality of first inserts imbedded in the first panel, and a plurality of second inserts imbedded in the second panel, each insert comprising: 
 A. a base imbedded in an associated panel and defining a base plane;  
 B. at least one web upstanding from the base and imbedded in the associated panel; and  
 C. at least one connector supported on said at least one web and exposed outside of the associated panel, said at least one connector defining an end hole that swivelably receives a selected one of the ties, and a top opening that coacts with the end hole to selectively lock the selected tie to at least one connector; and  
 
 iii. a plurality of ties each cooperating with associated first and second inserts to hold the panels together, the ties first and second inserts selectively cooperating as hinges that enable the block to hold and unfold prior to being erected into a form, and selectively cooperating to lock the panels into an unfolded rigid block having a predetermined space between the panels, wherein each tie has a middle leg of a predetermined length, and two ends legs and each tie end leg is received in the end hole of the associated connector, wherein each tie end leg is selectively swivelable within the end hole in the associated connector to thereby enable the block to fold and unfold, and wherein each tie middle leg is selectively captured in the associated connector top opening to snap lock the tie to the connector and thereby form the rigid block; and  
   b. concrete in the spaces between the blocks first and second panels.    
     
     
         2 . The insulated concrete wall system of  claim 1  wherein: 
 a. said at least one connector of each insert has a notch defined by an end surface and a side surface;    b. the connector end hole is in the notch end surface;    c. the connector top opening is in the notch side and end surfaces; and    d. each connector is double ended having two notches and two top openings so that each insert is invertible in the associated panel.    
     
     
         3 . A block for an insulated concrete wall system comprising: 
 a. first and second panels made of a selected rigid insulated material;    b. a plurality of first and second inserts embedded in the first and second panels, respectively, and wherein each insert comprises at least one connecter that is exposed outside of the associated panel, said at least one connector defining an end hole that swivelably receives the end log of an associated tie and said at least one connector defining a top opening that cooperated with the end hole to releasably lock the tie middle leg to the connector; and    c. a plurality of ties each cooperating with a respective first insert and second insert to selectively swivel therein and thereby enable the block to fold and unfold, and to selectively lock to the respective first and second inserts and thereby render the block rigid.    
     
     
         4 . The block of  claim 3  wherein the block is foldable to contact the first panel with the second inserts and to contact the second panel with the first inserts.  
     
     
         5 . The block of  claim 3  wherein the block is foldable to contact the first inserts with the second inserts  
     
     
         6 . The block of  claim 3  wherein: 
 a. said at least one connector has two top openings; and    b. the end hole of said at least one connector intersects both top openings.    
     
     
         7 . Apparatus for construction an insulated concrete wall comprising: 
 a. first and second panels made of a rigid insulative foam, the panels having respective interior faces and exterior faces; and    b. means for holding the panels together selectively in an unfolded configuration whereat the panels are locked rigidly together at a predetermined space apart and in folded configuration whereat the panels are movable relative to each other, wherein said means for holding the panels together comprises: 
 i. multiple pairs of first and second inserts embedded in the first and second panels, respectively, wherein each insert comprises: 
 A. a base embedded in the panel;  
 B. at least one web upstanding from the base and embedded in the associated panel; and  
 C. at least one connector supported on each web and exposed from the interior face of the associated panel, said at least one connector having an end hole that swivelably receives an end log of a tie, and a top opening that selectively captures and releases a middle leg of the tie, wherein: 
 I. each connector has a top surface, opposed side walls, and opposed end walls;  
 II. there is a notch in at least one end wall of each connector that is defined by a side surface and an end surface;  
 III. the end hole of each connector is in the notch end surface; and  
 IV. the top opening of each connector is in the notch side and end surfaces; and  
 
 
 ii. multiple ties between respective pairs of first and second inserts in the first and second panels, respectively, each tie having a middle leg that is selectively lockable in the associated first and second inserts to lock the panels rigidly in the unfolded configuration, each tie further having end legs that are swivelable received in the associated inserts to enable the panels to move relative to each other when the tie middle leg is not locked in the associated inserts.  
   
     
     
         8 . The apparatus of  claim 7  where in each connector end hole defines a longitudinal centerline, and each connector top opening defines longitudinal axis that intersects and is substantially perpendicular to the end hole longitudinal centerline.  
     
     
         9 . The apparatus of  claim 7  wherein: 
 a. each connector has a top surface, opposed side walls, and opposed end walls; and    b. there is a notch in each end wall of each connector, each notch being defined by a respective end surface and side surface;    c. the end hole of each connector extends between the end surfaces of the associated notches; and    d. there is a top opening associated with each notch, each top opening being in the side and end surfaces of the associated notch so that each container is double-ended.    
     
     
         10 . The apparatus of  claim 7  wherein each connector comprises at least one tab projecting from a side wall.  
     
     
         11 . The apparatus of  claim 7  wherein: 
 a. each tie is made from a rod having a predetermined radius; and    b. the end surfaces of the notches of each connector are offset from the longitudinal centerline of the end hole by a distance equal to approximately the radius of the tie rod.    
     
     
         12 . The apparatus of  claim 7  wherein the side walls of said at least one connector are formed with respective cutouts that break into the end hole so that the insert is manufactureable in a selected mold by reciprocating the mold only in directions parallel to the end hole longitudinal centerline.  
     
     
         13 . The apparatus of  claim 7  further comprising a plate that joins the connectors to each other.  
     
     
         14 . The apparatus of  claim 7  wherein the first inserts are contactable with the second inserts when the panels are in the folded configuration.  
     
     
         15 . The apparatus of  claim 7  wherein the first inserts are contactable with the second panel when the panels are in the folded configuration.  
     
     
         16 . The apparatus of  claim 7  wherein one web is embedded in the base.  
     
     
         17 . The apparatus of  claim 7  wherein a pair of webs are embedded in the base.  
     
     
         18 . An article of manufacture useful as an insert in a block for constructing insulated concrete walls comprising: 
 a. a base that defines a base plane;    b. at least one web upstanding from the base;    c. at least one connector supported on said at least one web, said at least one connector having opposed side walls and opposed end walls, a top surface, an end hole in the end wall, and a top opening in the top surface, the end hole and the top opening having respective equal diameters and intersecting at substantially 90 degrees to each other, wherein the top opening subtends an angle of approximately 270 degrees and has a longitudinal axis offset from the notch side surface.    
     
     
         19 . The article of manufacture of  claim 18  further comprising at least one tab that projects from a selected connector sidewall.  
     
     
         20 . The article of manufacture of  claim 18  wherein said at least one connector defines two top openings each having a diameter equal to the end hole diameter and intersecting the end hole at substantially 90 degrees.  
     
     
         21 . In combination: 
 a. a pair of panels each made of a rigid insulative foam and having respective interior faces;    b. a pair of inserts each comprising a web and a base embedded in a respective panel, and a connector exposed from the interior face of the associated panel, the connector of each insert having a top surface at a predetermined distance from the panel interior face, and opposed sidewalls and end walls; and    c. means for holding the panels to each other in parallel relationship and keeping the top surfaces of the connectors of the pair of inserts generally in flat facing contact with each other so that concrete poured between the panels has a thickness generally equal to twice the predetermined distance, said means for holding comprising at least one staple shaped tie having a middle leg and end legs received in respective inserts.    
     
     
         22 . The combination of  claim 21  wherein the predetermined distance is approximately 0.50 inches to thereby enable a concrete wall of approximately 1.00 inches thick to be poured.