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. Each substructure includes exterior panels defining, at least in part, a partial enclosure. Interior panel(s) extend between the exterior panels. An interior passageway is defined by the interior panels and the exterior panels. Additional passageway(s) are defined by the interior panels and at least one of the exterior panels and are open to an exterior. Insulating material is deposited within each of the additional passageway(s). The substructures are positioned adjacent to one another to create form(s), each of having a common fluid passageway comprising the interior passageways of the substructures of the respective form. Concrete is deposited within the common interior passageway of each of the one or more forms.

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 the interior panels and an interior facing surface of at least one of the exterior panels; 
 one or more additional passageways defined, at least in part, by exterior facing surfaces the interior panels and interior facing surfaces of at least some of the exterior panels, including the at least one of the exterior panels, wherein said one or more additional passageways are open to an exterior of said substructure; 
   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 a respective one of the one or more forms and one or more additional common fluid passageways comprising the one or more additional passageways of the substructures of the form;   depositing insulating material within each of the one or more additional common fluid passageways; and   depositing concrete within the common interior passageway of each of the one or more forms.   
     
     
         2 . The method of  claim 1 :
 wherein each of the substructures further comprise channels formed by at least one of the exterior panels and at least one of the interior walls; and   further comprising providing a support structure through each of the channels of the substructures such that the support structure connects multiple of the substructures.   
     
     
         3 . The method of  claim 2  wherein:
 each of the channels are free of the insulation and the concrete. 
 
     
     
         4 . The method of  claim 3  wherein:
 each of the support structures comprises a hollow member. 
 
     
     
         5 . The method of  claim 4  wherein:
 each of the substructures form a cuboid shape; 
 the channels comprise four channels, each provided at an interior corner of a respective one of the substructures; 
 one of the support structure extends through each of the channels; 
 each of the channels and support structures comprise a square or rectangular cross section; and 
 the substructures are arranged into a column along the support structures. 
 
     
     
         6 . The method of  claim 5  further comprising:
 providing rebar within the common interior passageway. 
 
     
     
         7 . The method of  claim 6  wherein:
 the step of providing rebar comprises providing four rebar bars in a square or rectangular pattern, where the four rebar bars are connected by wire extending about a perimeter thereof. 
 
     
     
         8 . The method of  claim 1  wherein:
 the interior passageway of each of the substructures forms a channel extending along a longitudinal axis of the respective one of the substructures; and 
 the one or more additional passageways of each of the substructures comprise a first additional passageway extending along a first side of the channel, and a second additional passageway extending along a second side of the channel. 
 
     
     
         9 . The method of  claim 8 :
 wherein each of the first additional passageway and the second additional passageway comprise a series of compartments; and   further comprising extending a first support structure through a different one of the series of compartments of the first additional passageway of each of the structures relative to an immediately vertically adjacent one of the structures and extending a second support structure through a different one of the series of compartments of the second additional passageway of each of the structures relative to an immediately vertically adjacent one of the structures such that the immediately vertically adjacent substructures are laterally offset.   
     
     
         10 . The method of  claim 1  wherein:
 the one or more additional passageways extend along fewer than all of the exterior panels. 
 
     
     
         11 . The method of  claim 1  wherein:
 the one or more additional passageways extend along all of the exterior panels. 
 
     
     
         12 . The method of  claim 1  wherein:
 the interior panels and one or more exterior panels are devoid of openings. 
 
     
     
         13 . The method of  claim 1  wherein:
 each of the substructures comprise openings located in at least some of the exterior panels and providing access to the interior passageway from an exterior of the substructure. 
 
     
     
         14 . 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;   further comprising allowing the insulating material to cure, wherein the insulating material is provided as a liquid which solidifies when cured.   
     
     
         15 . The method of  claim 14  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. 
 
     
     
         16 . The method of  claim 1  wherein:
 at least some of the substructures are of different size and shape from other of the structures. 
 
     
     
         17 . The method of  claim 1 :
 wherein at least some of the substructures comprise holes in one or more of the exterior panels; and   further comprising connecting the substructures by fasteners passed through the holes of immediately adjacent ones of the substructures.   
     
     
         18 . 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. 
 
     
     
         19 . 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 the interior panels and an interior facing surface of at least one of the exterior panels;   one or more additional passageways defined, at least in part, by exterior facing surfaces of the interior panels and interior facing surfaces of at least some of the exterior panels, including the at least one of the exterior panels, wherein said one or more additional passageways are open to an exterior of said substructure; and   channels formed by at least one of the interior panels and the at least some of the exterior panels, including the at least one of the exterior panels.   
     
     
         20 . 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 and an interior facing surface of at least one of the exterior panels; 
 one or more additional passageways defined, at least in part, by exterior facing surfaces of the at least some of the interior panels and interior facing surfaces of at least some of the exterior panels, including the at least one of the exterior panels, wherein said one or more additional passageways are open to an exterior of said substructure; and 
 channels formed by at least one of the exterior panels and at least one of the interior walls; and 
   support structures, each extending through a respective one of the one more channels such that the support structures interconnect the substructures.