Surface panel and associated ICF system for creating decorative and utilitarian surfaces on concrete structures
AssigneeMichael Boynoff
InventorWilliam A. Johns
Life of this patent
Estimating the term…
Abstract
A surface panel for creating decorative and utilitarian motif surfaces on concrete structures is disclosed. This surface panel allows motif surfaces of brick, stone, tile or siding to be applied to the exterior and interior of concrete structures. The surface panel can be used with other surface panels, or alternatively, as a component of an insulating concrete form (ICF) system. When used with an ICF system, the exterior surface of a concrete structure has a motif surface of brick, stone, tile or siding, while the interior of the structure has an insulating polystyrene surface. The surface panel described herein allows concrete structures including buildings, walls, pillars, and stanchions to be built efficiently and without skilled labor.
Claims18
An insulating surface panel for creating concrete structures having motif components imbedded in a surface thereof, said surface panel comprising:
- a) an exterior surface;
- b) a plurality of motif components, each of said plurality of motif components having a front part and a back part;
- c) an adhesive;
- and
- d) an interior surface opposite from said exterior surface for contacting a pourable concrete mixture, said interior surface comprising a plurality of recessed regions separated by borders, each of said plurality of recessed regions being sized and shaped to conform to the front part of one of said plurality of motif components, wherein the front part of each of said plurality of motif components is glued into one of said plurality of recessed regions which conforms to the motif component's front part, with said adhesive, such that the back part of each motif component protrudes beyond said interior surface;
- and wherein said insulating surface panel is composed of an insulating foam, whereby each motif component is tightly secured in said insulating surface panel and the front part of each motif component is protected from contact with concrete.
An insulating concrete form for creating a motif on at least one surface of a concrete structure when concrete is poured into the insulating concrete form, said insulating concrete form comprising:
- a) an insulating interior panel, said insulating interior panel composed of an insulating foam and said insulating panel being oriented vertically;
- b) an insulating surface panel positioned vertically and opposite from said insulating interior panel, said insulating surface panel composed of an insulating foam, comprising
- i) an exterior surface,
- ii) a plurality of motif components, each of said plurality of motif components having a front part and a back part,
- iii) an adhesive;
- and
- iv) an interior surface opposite from said exterior surface for contacting a pourable concrete mixture, said interior surface comprising a plurality of recessed regions separated by borders, each of said plurality of recessed regions being sized and shaped to conform to the front part of one of said plurality of motif components, wherein the front part of each of said plurality of motif components is glued into one of said plurality of recessed regions which conforms to the motif component's front part, with said adhesive, such that the back part of each motif component protrudes above said interior surface;
- whereby each motif component is tightly secured in said insulating surface panel and the front part of each motif component is protected from contact with concrete;
- c) at least one spacer positioned between said insulating interior panel and said insulating surface panel to hold said insulating interior panel and said insulating surface panel in uniform spaced relation;
- and
- d) a plurality of fasteners attached to said at least one spacer and extending through said insulating exterior panel and said insulating surface panel so as to hold said insulating interior panel and said insulating surface panel together to form a well for pouring a concrete mixture therein.
A method for casting in place a vertical concrete structural wall with at least one surface decorated with motif components imbedded therein comprising the steps of:
- a) erecting an insulating concrete form in position to cast said vertical structural wall, said insulating concrete form comprising
- i) an insulating interior panel composed of an insulating foam,
- ii) an insulating surface panel composed of said insulating foam, positioned opposite said insulating interior panel, said insulating surface panel comprising an exterior surface, and an interior surface opposite from said exterior surface for contacting a pourable concrete mixture, said interior surface comprising a plurality of recessed regions separated by borders,
- iii) at least one spacer positioned between said insulating exterior panel and said insulating surface panel to hold said insulating exterior panel and said insulating surface panel in uniform spaced relation, and
- iv) a plurality of fasteners attached to said at least one spacer and extending through said insulating exterior panel and said insulating surface panel so as to hold said insulating interior panel and said insulating surface panel together to form a well for pouring a concrete mixture therein;
- b) gluing a plurality of motif components, each motif component having a front part and a back part, into said recessed regions of said interior surface of said insulating surface panel with an adhesive, wherein the front part of each of said plurality of motif components is glued into one of said plurality of recessed regions such that it is formably held within the one region into which it is glued, and such that the back part of each motif component protrudes above said interior surface;
- c) filling the well of said insulating concrete form with a pourable concrete mixture to form the structural wall therein;
- d) allowing said pourable concrete wall to cure in place;
- e) removing said insulating surface panel to reveal a wall surface with motif components imbedded therein.
Dependencies are inferred from the claim text.