Wall form units and systems

Abstract

A wall form unit for containing a pourable, curable construction material for forming a wall section integrating said wall form unit and said construction material, comprising a first panel and a second panels spaced apart in predetermined relation thereby forming a hollow between first and second panels for defining said wall section and at least one tie assembly having a spacer member for maintaining said first and second panel in predetermined relation, in which both the first panel and second panels are rigid and adapted to retain said construction material, wherein the first panel is constructed of a thermally insulating material and the second panel is constructed of a thermally conducting material. A wall form system for forming a section of wall and wall section and method for constructing same are also defined. The invention also relates to a panel for use in forming a wall form unit and also claims a kit for constructing a wall form unit.

1 . A wall form unit, comprising:
 a first panel comprising a thermally insulating material,   a second panel comprising a thermally conducting material,   a hollow between the first and second panels, and   at least one tie assembly comprising a spacer member for maintaining the first and second panels spaced apart in predetermined relation, in which both the first panel and the second panel are rigid and adapted to retain a construction material.   
     
     
         2 . The wall form unit of  claim 1 , wherein the first panel comprises:
 a composite material and   a polymer or a polymer-based compound.   
     
     
         3 . The wall form unit of  claim 1 , wherein the second panel comprises:
 a first component comprising an inorganic binder, a polymer or a polymer-based compound.   
     
     
         4 . The wall form unit of  claim 1 , wherein the second panel comprises:
 a first component comprising an inorganic binder, a polymer or a polymer-based compound and   a second component comprising graphite, an alumina particle, silica sand, a fine gravel particle, a stone particle, metallic fiber, metallic mesh, or a metallic particle.   
     
     
         5 . The wall form unit of  claim 1 , wherein the second panel comprises a hydraulic inorganic binder. 
     
     
         6 . The wall form unit of  claim 1 , wherein the second panel comprises magnesia cement. 
     
     
         7 . The wall form unit of  claim 1 , wherein the second panel comprises magnesia cement comprising particles of sand, or other additive of high thermal conductivity, distributed throughout the magnesia cement. 
     
     
         8 . The wall form unit of  claim 1 , wherein the second panel comprises phase change material (PCM). 
     
     
         9 . The wall form unit of  claim 1 , wherein the second panel comprises phase change material (PCM) and magnesia or magnesia cement. 
     
     
         10 . The wall form unit of  claim 8 , wherein the phase change material (PCM) is microencapsulated. 
     
     
         11 . A wall form system, comprising:
 a core comprising pourable, curable construction material;   a plurality of panels sheathing the core, wherein the plurality of panels comprises at least two wall form units adapted for interlocking and wherein each wall form unit comprises a first panel and a second panel in predetermined relation, thereby forming a hollow between the first and second panels for receiving the construction material; and   at least one tie assembly comprising a spacer member for maintaining the first panels and the second panels in predetermined relation,   wherein both the first panels and the second panels are rigid and adapted to retain the construction material,   the first panel comprises a thermally insulating material, and   the second panel comprises a thermally conducting material.   
     
     
         12 . A kit comprising components suitable for constructing the wall form unit of  claim 1 . 
     
     
         13 . A wall section, comprising
 at least two of the wall form units of  claim 1 , and   a cured construction material in the hollow between the first and second panels comprising a poured, cured construction material.   
     
     
         14 . A process of erecting a building structure, comprising:
 i) arranging a first panel and a second panel of a plurality of Insulating Concrete Form (ICF) units in predetermined relation for defining a wall section, such that the first and second panels are spaced apart to form a hollow between them,   ii) connecting at least one tie assembly comprising a spacer member for maintaining the first and second panels in predetermined relation,   iii) introducing a pourable, curable construction material into the hollow, and   iv) curing the pourable, curable construction material,   wherein both the first panel and the second panel are rigid and adapted to retain the construction material,   the first panel comprises a thermally insulating material, and   the second panel comprises a thermally conducting material.   
     
     
         15 . The wall form unit of  claim 2 , wherein the polymer or polymer-based compound comprises an expanded polystyrene or polyurethane foam. 
     
     
         16 . The wall form unit of  claim 3 , wherein the second panel further comprises a second component distributed throughout the first component, the second component selected from the group consisting of a thermally conducting particle, a filament, and a mesh. 
     
     
         17 . The wall form unit of  claim 9 , wherein the phase change material (PCM) is microencapsulated. 
     
     
         18 . A wall section comprising the wall form system of  claim 11 . 
     
     
         19 . The wall form unit of  claim 16 , wherein the second component comprises iron, copper, aluminum, lead, tin, silver, or a metal alloy. 
     
     
         20 . The wall form unit of  claim 16 , wherein the first component forms a matrix within the panel, and wherein the second component is distributed throughout the matrix.