Modular framework substructures for creating insulated concrete walls and related walls, systems, and methods

Abstract

Modular framework substructures for creating insulated concrete walls are disclosed, along with related systems and methods. The substructures include interior panels defining, at least in part, an interior passageway for concrete. The interior panels extend between exterior panels to define, at least in part, additional passageways for insulation. Openings are provided in the exterior panels for concrete which may flow between the interior passageways of adjacent substructures. The substructures include interlocking features for connecting adjacent substructures. The substructures may vary in size and shape and may be arranged in various fashions to create various size and shape walls.

What is claimed is: 
     
         1 . A method for creating insulated concrete walls, said method comprising:
 providing substructures, each comprising:
 exterior panels defining, at least in part, a partial enclosure; 
 interior panels, each extending between at least two of said exterior panels; 
 an interior passageway defined, at least in part, by interior facing surfaces of at least some of the interior panels; 
 one or more additional passageways defined, at least in part, by exterior facing surfaces of at least some of the interior panels and interior facing surfaces of at least some of the exterior panels; and 
 openings located in at least some of the exterior panels and providing access to the interior passageway from an exterior of the substructure; 
   depositing insulating material within each of the one or more additional passageways;   positioning the substructures adjacent to one another to create one or more forms, each of said one or more forms having a common fluid passageway comprising the interior passageways of the substructures of the respective form; and   depositing concrete within the common interior passageway of each of the one or more forms.   
     
     
         2 . The method of  claim 1  wherein:
 the step of depositing insulating material within each of the one or more additional passageways is performed before positioning the substructures adjacent to one another to create the one or more forms. 
 
     
     
         3 . The method of  claim 2  further comprising:
 allowing the insulating material to cure, wherein the insulating material is provided as a liquid which solidifies when cured. 
 
     
     
         4 . The method of  claim 3  wherein:
 the step of depositing insulating material within each of the one or more additional passageways is performed at an offsite location; and 
 the steps of positioning the substructures adjacent to one another to create one or more forms and depositing concrete within the common interior passageway of each of the one or more forms is performed at an installation site. 
 
     
     
         5 . The method of  claim 1  wherein:
 at least some of the substructures are of different size and shape from other of the structures. 
 
     
     
         6 . The method of  claim 1  wherein:
 the openings of at least some of the substructures are at least substantially parallel with one another; and 
 the openings of at least some other of the substructures are at least substantially perpendicular to one another. 
 
     
     
         7 . The method of  claim 1  wherein:
 each of the substructures comprise one or more interlocking features. 
 
     
     
         8 . The method of  claim 7 :
 wherein at least a respective one of the substructures comprises a framework located at a lower portion of the respective substructure; and   further comprising: fitting the framework of the respective substructure within the interior panels of a second respective one of the substructures located vertically below the respective substructure.   
     
     
         9 . The method of  claim 7 :
 wherein at least a first respective one of the substructures comprises one or more tabs located on a lower portion of the first respective one of the substructures, and at least a second respective one of the substructures comprises a corresponding set of one or more recesses, each located at an upper portion of one of the interior panels of the second respective one of the substructures; and   further comprising mating each of the one or more tabs of the first respective one of the substructures with the corresponding set of one or more recesses of the second respective one of the substructures.   
     
     
         10 . The method of  claim 7 :
 wherein at least a two of the substructures each comprises a set of one or more apertures, each located at one of the exterior panels of the respective substructure; and   further comprising connecting the at least a two of the substructures, which are disposed laterally adjacent to one another, by passing a piece of material through at least one of the set of one or more apertures of each of the at least a two of the substructures.   
     
     
         11 . The method of  claim 1 :
 wherein each of the substructures comprises notches located along a lower edge of the one or more openings; and   further comprising placing rebar in the notches of at least some of the substructures prior to the step of depositing concrete within the common interior passageway of each of the one or more forms.   
     
     
         12 . The method of  claim 1  wherein:
 each of the substructures comprises at least one flank panel, wherein each flank panel is offset vertically and laterally from an associated one of the exterior panels; and 
 the step of positioning the substructures adjacent to one another to create one or more forms comprises placing the at least one flank panel of a respective substructure against the exterior panels of an adjacent substructure such that the at least one flank panel of the respective substructure partially overlaps the exterior panels of the adjacent substructure. 
 
     
     
         13 . A modular framework substructure for creating an insulated concrete wall, said substructure comprising:
 exterior panels defining, at least in part, a partial enclosure;   interior panels, each extending between at least two of said exterior panels;   an interior passageway defined, at least in part, by interior facing surfaces of at least some of the interior panels;   one or more additional passageways defined, at least in part, by exterior facing surfaces of at least some of the interior panels and interior facing surfaces of at least some of the exterior panels; and   openings located in at least some of the exterior panels and providing access to the interior passageway from an exterior of the substructure;   one or more interlocking features for interlocking the substructure to an adjacent substructure.   
     
     
         14 . The substructure of  claim 12 :
 wherein at least some of the interior panels intersect; and   further comprising additional openings in portions of the at least some of the interior panels which extend between the intersection and one of the said exterior panels.   
     
     
         15 . The substructure of  claim 12  wherein:
 each of the interior panels extends between a same set of two of the exterior panels; and 
 each of the interior panels are spaced apart from one another. 
 
     
     
         16 . The substructure of  claim 12  wherein:
 said one or more interlocking features comprise a framework comprising an extending portion of a middle portion of at least some of the interior panels extending beyond a lower edge of the exterior panels, and at least one of:
 a tab located at the framework and a mating recess located at one of the interior panels; 
 an aperture located at one of the exterior panels; and 
 flank panels, each offset vertically and laterally from an associated one of the exterior panels. 
 
 
     
     
         17 . The substructure of  claim 12  further comprising:
 interior supports comprising vertically extending protrusions provided along interior facing surfaces of the exterior panels. 
 
     
     
         18 . A system for creating an insulated concrete wall, said system comprising:
 substructures, each comprising:
 exterior panels defining, at least in part, a partial enclosure; 
 interior panels, each extending between at least two of said exterior panels; 
 an interior passageway defined, at least in part, by interior facing surfaces of at least some of the interior panels; 
 one or more additional passageways defined, at least in part, by exterior facing surfaces of at least some of the interior panels and interior facing surfaces of at least some of the exterior panels; and 
 openings located in at least some of the exterior panels and providing access to the interior passageway from an exterior of the substructure; 
 one or more interlocking features for interlocking the substructure to an adjacent substructure. 
   
     
     
         19 . The system of  claim 18  wherein:
 at least some of the substructures vary in size and shape from other of the substructures. 
 
     
     
         20 . The system of  claim 18  wherein:
 said one or more interlocking features of each of said substructures comprise:
 a framework comprising an extending portion of a middle portion of at least some of the interior panels extending beyond a lower edge of the exterior panels; 
 a tab located at the framework and a mating recess located at one of the interior panels; 
 an aperture located at one of the exterior panels; and 
 flank panels, each offset vertically and laterally from an associated one of the exterior panels.