Method and Apparatus for Using Foam Panels As Forms For Making Concrete Walls

Abstract

A foam panel concrete form is provided for using concrete reinforcement rods which extend on each side of a joint in the foam panel concrete form and into complementary shaped openings in ties which hold two adjacent panels in a spaced and parallel relationship. The concrete reinforcement rod can pass into the openings in adjacent ties with little resistance in a first rotary position of the concrete reinforcement rod. When the concrete reinforcement rod is rotated to a second rotational position within the openings the reinforcement rod is in a tight frictional fit in the openings for helping to hold adjacent ties and the adjacent foam panels in a fixed relationship with respect to each other during a time when concrete is poured between the foam panels, thereby also serving to re-enforce the concrete after the concrete has cured.

1 . Apparatus comprising:
 a concrete reinforcement rod having a longitudinal axis and having a cross sectional shape transverse to the longitudinal axis, which cross sectional shape includes at least one diameter thereof which is larger than another diameter thereof;   a first foam panel having at least one side disposed substantially in a first plane;   a second foam panel having at least one side disposed substantially in a second plane which is substantially parallel to the first plane;   a first tie having one portion thereof disposed in the first foam panel and a second portion thereof disposed in the second foam panel;   a first opening disposed in the first tie, said first opening being approximately the same cross sectional shape as the cross sectional shape of the concrete reinforcement rod whereby the rod can pass into the first opening with little resistance in a first rotary position of the concrete reinforcement rod;   a third foam panel having at least one side disposed substantially in the first plane;   a fourth foam panel having at least one side disposed substantially in the second plane;   a second tie having one portion thereof disposed in the third foam panel and a second portion thereof disposed in the fourth foam panel;   a second opening disposed in the second tie, said second opening being approximately the same cross sectional shape as the cross sectional shape of the concrete reinforcement rod whereby the rod can pass into the second opening with little resistance in the first rotary position of the concrete reinforcement rod; and   the concrete reinforcement rod having a second rotational position within the first and second openings wherein the reinforcement rod is in a tight frictional fit in the first and second openings of the first and second ties for helping to hold the first and second ties and the first, second, third and fourth panels to be held in a fixed relationship with respect to each other during a time when concrete is poured between the first and second and the third and fourth foam panels and thereby serving to re-enforce the concrete after the concrete has cured.   
   
   
       2 . The apparatus of  claim 1  comprising:
 a second concrete reinforcement rod having a longitudinal axis and having a cross sectional shape transverse to the longitudinal axis, which cross sectional shape includes at least one diameter thereof which is larger than another diameter thereof;   a third opening disposed in the first tie, said third opening being approximately the same cross sectional shape as the cross sectional shape of the concrete second reinforcement rod whereby the second reinforcement rod can pass into the third opening with little resistance in a first rotary position of the second concrete reinforcement rod;   a fourth opening disposed in the second tie, said fourth opening being approximately the same cross sectional shape as the cross sectional shape of the second concrete reinforcement rod whereby the second concrete reinforcement rod can pass into the fourth opening with little resistance in the first rotary position of the second concrete reinforcement rod; and   the second concrete reinforcement rod having a second rotational position within the third and fourth openings wherein the reinforcement rod is in a tight frictional fit in the third and fourth openings of the first and second ties for helping to hold the first and second ties and the first, second, third and fourth foam panels to be held in a fixed relationship with respect to each other during the time when concrete is poured between the first and second and the third and fourth foam panels and thereby serving to re-enforce the concrete after the concrete has cured.   
   
   
       3 . The apparatus of  claim 2  including means on a top portion of the first and second ties for holding at least one additional concrete reinforcement rod in alignment between the first and second and third and fourth foam panels while concrete is being poured and to serve to re-enforce the concrete after the concrete has cured. 
   
   
       4 . The apparatus of  claim 2  including at least two spaced apart members extending upwardly from each one of the first and second ties and having at least one additional concrete reinforcement rod disposed between the said at least two spaced apart members on each of the first and second ties while concrete is being poured and to serve to re-enforce the concrete after the concrete has cured. 
   
   
       5 . The apparatus of  claim 1  further having a corner section comprising:
 a fifth foam wall having one side in substantially the same plane as the first plane and being disposed against the first foam wall;   a sixth foam wall having one side in a plane substantially transverse to the first plane, the sixth foam wall being disposed against the one side of the fifth foam wall;   a third tie being disposed at least partially in the fifth foam wall and having a first corner opening therein that is approximately the same size and shape as the first opening disposed in the first tie;   a fourth tie being disposed at least partially in the sixth foam wall and having a second corner opening therein that is approximately the same size and shape as the first opening disposed in the first tie;   a fifth tie being having a third corner opening in one end thereof and a fourth corner opening in the other end thereof, both of the third and fourth corner openings being approximately the same size and shape as the first opening disposed in the first tie;   a first fastener disposed through the first corner opening in the third tie and the third corner opening in the fifth tie; and   a second fastener disposed through the second corner opening in the fourth tie and the fourth corner opening in the fifth tie.   
   
   
       6 . The apparatus of  claim 5  wherein the first, second, third and fourth corner openings are approximately the same shape as the cross sectional shape of the a first opening disposed in the first tie and wherein the first fastener has one portion thereof with a cross sectional size and shape similar to the cross sectional shape of the first reinforcement rod, the first fastener having an intermediate portion that is smaller in an intermediate portion another portion that will not fit through the openings in the first, second, third and fourth corner openings and whereby the one portion of the first fastener is in abutment with one of the third, fourth and fifth ties when installed through the first, second, third and fourth corner openings and the another portion of the first fastener is in abutment with one of one of the third, fourth and fifth ties when installed through the first, second, third and fourth corner openings. 
   
   
       7 . The apparatus of  claim 1  having a fifth foam wall having one side in substantially the same plane as the first plane and being disposed against the first foam wall;
 a sixth foam wall having one side in a plane substantially transverse to the first plane, the sixth foam wall being disposed against the one side of the fifth foam wall;   a third tie being disposed at least partially in the fifth foam wall and having a first corner opening therein that is approximately the same size and shape as the first opening disposed in the first tie;   a fourth tie being disposed at least partially in the sixth foam wall and having a second corner opening therein that is approximately the same size and shape as the first opening disposed in the first tie; and   a first fastener disposed through the first corner opening in the third tie and the second corner opening in the fourth tie.   
   
   
       8 . The apparatus of  claim 7  wherein the first and second corner openings are approximately the same shape as the cross sectional shape of the a first opening disposed in the first tie and wherein the first fastener has one portion thereof with a cross sectional size and shape similar to the cross sectional shape of the first reinforcement rod, the first fastener having an intermediate portion that is smaller in an intermediate portion another portion that will not fit through the openings in the first and second corner openings and whereby the one portion of the first fastener is in abutment with one of the third and fourth ties when installed through the first and second corner openings and the another portion of the first fastener is in abutment with one of one of the third and fourth ties when installed through the first and second corner openings. 
   
   
       9 . The apparatus of  claim 6  further comprising:
 a sixth tie being disposed at least partially in the fifth foam wall and having a fifth corner opening therein that is approximately the same size and shape as the first opening disposed in the first tie;   a seventh tie being disposed at least partially in the sixth foam wall and having a sixth corner opening therein that is approximately the same size and shape as the first opening disposed in the first tie; and   a third fastener disposed through the fifth corner opening in the sixth tie and the sixth corner opening in the seventh tie.   
   
   
       10 . The apparatus of  claim 9  wherein the fifth and sixth corner openings are approximately the same shape as the cross sectional shape of the a first opening disposed in the first tie and wherein the third fastener has one portion thereof with a cross sectional size and shape similar to the cross sectional shape of the first reinforcement rod, the third fastener having an intermediate portion that is smaller in an intermediate portion another portion that will not fit through the openings in the fifth and sixth corner openings and whereby the one portion of the third fastener is in abutment with one of the sixth and seventh ties when installed through the fifth and sixth corner openings and the another portion of the third fastener is in abutment with one of one of the sixth and seventh ties when installed through the fifth and sixth corner openings. 
   
   
       11 . The apparatus of  claim 1  further comprising:
 a fifth foam panel having at least one side disposed in a third plane substantially perpendicular to the first plane and in abutment with the first foam panel;   a sixth foam panel having at least one side disposed in a fourth plane substantially perpendicular to the first plane and in abutment with the third foam panel; and   wherein the concrete reinforcement rod extends through the third and fourth planes.   
   
   
       12 . A method of constructing a concrete form comprising:
 placing a first tie having one portion thereof disposed in a first foam panel and a second portion thereof disposed in a second foam panel;   placing the first foam panel having at least one side disposed substantially in a first plane;   placing the second foam panel having at least one side disposed substantially in a second plane which is substantially parallel to the first plane;   providing a concrete reinforcement rod having a longitudinal axis and having a cross sectional shape transverse to the longitudinal axis, which cross sectional shape includes at least one diameter thereof which is larger than another diameter thereof;   placing a first opening disposed in the first tie, said first opening being approximately the same cross sectional shape as the cross sectional shape of the concrete reinforcement rod whereby the rod can pass into the first opening with little resistance in a first rotary position of the concrete reinforcement rod;   providing a second tie having one portion thereof disposed in a third foam panel and a second portion thereof disposed in a fourth foam panel;   placing the third foam panel having at least one side disposed substantially in the first plane;   placing the fourth foam panel having at least one side disposed substantially in the second plane; arranging to have a second opening disposed in the second tie, said second opening being approximately the same cross sectional shape as the cross sectional shape of the concrete reinforcement rod whereby the rod can pass into the second opening with little resistance in the first rotary position of the concrete reinforcement rod;   placing the concrete reinforcement rod into the first and second openings of the first and second ties respectively in the first rotary position thereof; and   rotating the concrete reinforcement rod to a second rotational position within the first and second openings wherein the reinforcement rod is in a tight frictional fit in the first and second openings of the first and second ties for helping to hold the first and second ties and the first, second, third and fourth panels to be held in a fixed relationship with respect to each other during a time when concrete is poured between the first and second and the third and fourth foam panels and thereby serving to re-enforce the concrete after the concrete has cured.   
   
   
       13 . The method of  claim 12  wherein the rotating of the concrete reinforcement rod from the first to the second position thereof is done by access from above the first and second foam panels. 
   
   
       14 . The method of  claim 12  wherein the placing of the concrete reinforcement rod through the first and second openings is done by first cutting an access hole cut in the side of one of the foam panels and inserting the concrete reinforcement rod through the access hole and placing the concrete reinforcement rod into the first and second openings. 
   
   
       15 . The method of  claim 14  wherein the rotating of the concrete reinforcement rod from the first to the second position thereof is done by accessing the concrete reinforcement rod and then rotating the concrete reinforcement rod from the first to the second position thereof. 
   
   
       16 . The method of  claim 15  including blocking the hole and pouring concrete between the first, second third and fourth foam panels. 
   
   
       17 . Apparatus comprising:
 a dowel having a circular cross sectional shape having a first diameter;   a first tie adapted to be disposed in a first foam panel and a second portion thereof disposed in a second foam panel;   a first opening disposed in the first tie, said first opening being approximately the same cross sectional shape as the cross sectional shape of the whereby the dowel can pass into the first opening with little resistance;   a second tie having one portion thereof adapted to be disposed in a third foam panel and a second portion thereof adapted to be disposed in a fourth foam panel;   a second opening disposed in the second tie, said second opening being approximately the same cross sectional shape as the cross sectional shape of the dowel whereby the dowel can pass into the second opening with little resistance;   a first resilient block having an opening therein which is of a second diameter which is smaller than the first diameter of the dowel whereby the dowel can be disposed in tight frictional contact within the opening in the first resilient block to hold the first resilient block attached to one end of the dowel;   a second resilient block having an opening therein which is of the second diameter which is smaller than the first diameter of the dowel whereby another end of the dowel can be disposed in tight frictional contact within the opening in the second resilient block to hold the second resilient block attached to the other end of the dowel; and   whereby the first and second ties are disposed between the first and second resilient blocks for shipping purposes.   
   
   
       18 . The method of  claim 17  wherein the first and second resilient blocks are comprised of rubber. 
   
   
       19 . Apparatus comprising:
 a connector having a longitudinal axis and having a cross sectional shape transverse to the longitudinal axis, which cross sectional shape includes at least one cross sectional dimension thereof which is larger than another cross sectional dimension thereof;   a first foam panel having at least one side disposed substantially in a first plane;   a second foam panel having at least one side disposed substantially in a second plane which is substantially parallel to the first plane;   a first tie having one portion thereof disposed in the first foam panel and a second portion thereof disposed in the second foam panel;   a first opening disposed in the first tie, said first opening being approximately the same cross sectional shape as the cross sectional shape of the connector whereby the connector can pass into the first opening with little resistance in a first rotary position of the connector;   a third foam panel having at least one side disposed substantially in the first plane;   a fourth foam panel having at least one side disposed substantially in the second plane;   a second tie having one portion thereof disposed in the third foam panel and a second portion thereof disposed in the fourth foam panel;   a second opening disposed in the second tie, said second opening being approximately the same cross sectional shape as the cross sectional shape of the connector whereby the connector can pass into the second opening with little resistance in the first rotary position of the connector; and   the connector having a second rotational position within the first and second openings wherein the connector is in the first and second openings of the first and second ties for holding the first and second ties and the first, second, third and fourth panels in a fixed relationship with respect to each other during a time when concrete is poured between the first and second and the third and fourth foam panels and thereby also serving to re-enforce the concrete after the concrete has cured.   
   
   
       20 . A method of constructing a concrete form comprising:
 placing a first tie having one portion thereof disposed in a first foam panel and a second portion thereof disposed in a second foam panel;   placing the first foam panel having at least one side disposed substantially in a first plane;   placing the second foam panel having at least one side disposed substantially in a second plane which is substantially parallel to the first plane;   providing a connector having a longitudinal axis and having a cross sectional shape transverse to the longitudinal axis, which cross sectional shape includes at least one cross sectional dimension thereof which is larger than another cross sectional dimension thereof;   placing a first opening disposed in the first tie, said first opening being large enough whereby the connector can pass into the first opening with little resistance in a first rotary position of the connector;   providing a second tie having one portion thereof disposed in a third foam panel and a second portion thereof disposed in a fourth foam panel;   placing the third foam panel having at least one side disposed substantially in the first plane;   placing the fourth foam panel having at least one side disposed substantially in the second plane;   arranging to have a second opening disposed in the second tie, said second opening being approximately the same cross sectional shape as the first opening whereby the connector can pass into the second opening with little resistance in the first rotary position of the connector;   placing the connector into the first and second openings of the first and second ties respectively in the first rotary position thereof; and   rotating the connector to a second rotational position within the first and second openings wherein the connector is in the first and second openings of the first and second ties for holding the first and second ties and the first, second, third and fourth panels to be held in a fixed relationship with respect to each other during a time when concrete is poured between the first and second and the third and fourth foam panels and thereby serving to re-enforce the concrete after the concrete has cured.