Method and apparatus for insulating a concrete wall

Abstract

An insulated concrete wall system is disclosed in which the insulation is provided at the time the concrete wall is poured.

1 . A system for insulating a concrete wall between two spaced: apart wall forms while the concrete wall is being poured comprising: 
 (a) at least one panel of thermal insulation material in said space;    (b) a plurality of elements extending through at least a portion of the thickness of said insulation panel, said elements having head portions; and    (c) at least one connecting means extending vertically and over said plurality of elements.    
   
   
       2 . The apparatus of  claim 1  wherein said at least one connecting means engages said wall form.  
   
   
       3 . The apparatus of  claim 1  wherein said at least one connecting means engages said insulation panel.  
   
   
       4 . The apparatus of  claim 1  wherein said elements comprise webs and said connecting means comprise at least one channel having a U-shaped cross-section.  
   
   
       5 . The apparatus of  claim 4  wherein said at least one panel with said webs and channels is positioned so as to be in engagement with a surface of the concrete wall after the concrete wall is poured.  
   
   
       6 . The apparatus of  claim 4  wherein said at least one panel with said webs and channels is positioned so as to be in engagement with the inner surface of the concrete wall after the concrete wall is poured.  
   
   
       7 . The apparatus of  claim 4  wherein said at least one panel with said webs and channels is positioned so as to be in engagement with both the outer and inner surfaces of the concrete wall after the concrete wall is poured.  
   
   
       8 . An apparatus for insulating both sides of a concrete wall while it is being formed comprising: 
 (a) spaced apart layers of insulation material positioned between the wall forms and in engagement with the inner surfaces of the wall forms;    (b) a plurality of elements with apertures extending through each of said spaced apart layers of insulation and into the space between the wall forms and extending in opposite directions; and    (c) said elements having enlarged portions at least partially embedded in the outer surface of each of said insulation layers.    
   
   
       9 . The apparatus of  claim 8  including vertically extending means in engagement with said elements for forming a vertical surface for receiving a plurality of connector means.  
   
   
       10 . The apparatus of  claim 8  including vertically extending channel means surrounding said enlarged portions.  
   
   
       11 . An apparatus for insulating at least one side of a concrete wall while said wall is being poured into the space between wall forms comprising; 
 (a) at least one horizontally extending footer below grade;    (b) at least one insulation panel extending vertically upward from said footer;    (c) a plurality of webs extending horizontally through said at least one insulation panel into said space; and    (d) vertically extending members engaging said webs.    
   
   
       12 . The apparatus of  claim 11  wherein said webs include head portions and said vertically extending members engage said head potions.  
   
   
       13 . The apparatus of  claim 11  wherein said one side of said concrete wall comprises the inside of said wall.  
   
   
       14 . The apparatus of  claim 11  wherein said one side of said concrete wall comprises the outer of said wall.  
   
   
       15 . The apparatus of  claim 11  wherein said at least one side of said concrete wall comprises the inside and outer of said wall.  
   
   
       16 . A method of insulating a concrete wall between two spaced apart wall forms forming a space into which concrete is to be poured comprising; 
 (a) forming at least one panel of insulation;    (b) forming apertures in said at least one panel;    (c) inserting horizontally extending elements into said apertures such that said elements protrude outwardly of said panel;    (d) sliding said at least one panel with said elements into the space between said wall forms and into engagement with at least one of said wall forms.    
   
   
       17 . The method of  claim 16  wherein said at least one panel comprises first and second panels spaced apart.  
   
   
       18 . The method of  claim 16  including the step of connecting said wall forms together by horizontally extending tie means after said at least one panel is slid between said wall forms, and subsequently sliding additional panels into said space and installing additional tie means.  
   
   
       19 . A method of forming insulation layers for use in insulating a concrete wall comprising: 
 (a) providing a block of insulation material;    (b) cutting apertures through said entire block;    (c) cutting said block into a plurality of layers with each layer having said apertures;    (d) inserting horizontally extending elements through said apertures in at least one of said layers so as to form portions of said elements extending beyond the thickness of said at least one layer.    
   
   
       20 . The method of  claim 19  including the further step of surrounding said elements with concrete.  
   
   
       21 . The method of  claim 19  wherein the step of inserting said elements through said insulation layer includes the steps of leaving a portion of said elements exposed on the side of insertion into said layers.  
   
   
       22 . The method of  claim 21  including the additional step of securing elongated members to said extending portions of said elements.  
   
   
       23 . A thermal insulating apparatus comprising: 
 (a) at least one thermal insulation panel;    (b) a plurality of elongated elements extending through at least a portion of the thickness of said at least one insulation panel, said elements having head portions; and    (c) means for engaging said heads and securing said elements together.    
   
   
       24 . The thermal insulating panel of  claim 23  wherein each of said elongated elements include at least one aperture means for permitting concrete to flow through said elongated elements from a first side to the second side of said elements.  
   
   
       25 . The thermal insulating panel of  claim 23  wherein said means for engaging said head comprise channels having U-shaped cross-sections.