Adjustably Interconnectable Formwork
An adjustable connector system for stay-in place formwork has a male adjustable connector end that can be inserted into a corresponding female adjustable connector end at variable positions. Using adjustable connector ends in assembling a formwork system increases accuracy by facilitating on-site adjustability of the length and/or diameter measurements of the system. The stay-in-place formwork can be used to create building surfaces, including ceiling panels, siding and walls, and can be used for forming concrete structures, such as walls and sumps.
This invention relates to stay-in-place formwork for creating building surfaces such as ceiling panels, siding and walls, and for forming concrete structures.
CROSS REFERENCE TO RELATED APPLICATIONSNone.
GOVERNMENT SUPPORTNone.
BACKGROUNDConcrete structures are formed by pouring concrete into a particular space, usually in the presence of steel reinforcing bars (re-bars) to add strength to the structure. Wall elements known as concrete forms can be used to keep the concrete contained so that the poured concrete solidifies in the location and shape desired.
Various designs and uses of concrete forms are known. For example, modular formwork elements and assemblies are described in U.S. Pat. Nos. 5,740,648, 6,219,984 and 6,694,692 to Piccone, which are incorporated herein by reference.
Formwork elements are prefabricated and then pieced together on-site. Concrete forms typically have discrete inner and outer wall panels to create inner and outer wall surfaces. The inner and outer wall panels can be held in place by cross-panels (or reinforcing panels) that span the inner and outer wall panels, creating a formwork assembly having a series of vertically extending cells into which concrete may be poured and left to harden. The inner and outer wall panels can be further reinforced by the addition of bracing panels, which can be connected to an inner or outer wall and/or a cross-panel at 45 degree angles. The cross-panels and bracing panels are usually formed with apertures so that re-bars and poured concrete can pass through the apertures to connect adjacent cells and form a continuous reinforced concrete structure.
Known concrete forms of this nature are often made from polyvinyl chloride (PVC). Manufacturing tolerance variations and expansions and/or contractions of PVC and other materials due to temperature changes can give rise to variances between the required length or diameter of a structure and the measured and/or manufactured formwork panels.
Prefabricated ceiling panels and siding panels can be subject to similar manufacturing tolerance variations and expansion and/or contraction.
There exists a need for a way to make on-site adjustments to the length of prefabricated formwork panels so that the resulting formwork structure is assembled to its correct dimensions.
SUMMARY OF INVENTIONAn apparatus of building components has a first component with a female adjustable connection and a second component with a male adjustable connection, such that the male adjustable connection is lockably insertable into the female adjustable connection in a plurality of positions thereby varying the length of the combination of first and second components.
A method of installing a building structure involves inserting a first male adjustable connection end of a first building component into a first female adjustable connection end of a second building component. The first male and female adjustable connection ends are adjustable with respect to each other to lockably adjust a distance that the first male adjustable connection end is inserted into the first female adjustable connection end to effectively adjust the length of the combination of the first and second building components.
In figures which illustrate non-limiting embodiments of the invention:
Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
With reference to
In
Embodiment 10, through fixed female connection ends 30 and 32, can be connected to known fixed-length modular formwork panels, such as those described in U.S. Pat. No. 5,740,648 to Piccone, to add an adjustable length variation segment.
With reference to
Reinforcing formwork members 70 and 72 are shown with truncated portions representing indeterminate length at points 74. Reinforcing panel member 70 has a female fixed connection end 80 which snaps into male connection fixed end 76 of reinforcing panel 52. Similarly, reinforcing panel 58 has a female fixed connection end 78 which is snapped into by male connection end 82 of reinforcing panel 72. Male connection end 84 of reinforcing panel 52 is snapped into female can fixed connection end 88 of reinforcing panel 70. Male fixed connection end 90 of reinforcing panel 72 is snapped into female connection end 86 of reinforcing panel 58. The resulting wall structure creates an inside wall surface 92 and an outside wall surface 94. The space between the inside wall surface 92 and the outside wall 94 forms a cavity 96, which is suitable for receiving concrete/cement and/or insulation, as required.
With reference to
Connector 102 has an adjustably interconnectable male end 110 for slideably and lockably engaging an adjustably interconnectable female end 112 of connector 106. Connector 102 has a fixed interconnectable female end 116 for slideably and lockably engaging a male connection end 162 of connector 118.
Connector 106 has a fixed interconnectable female end 120 for engaging a male end 126 of formwork member 124. Connector 106 has a fixed interconnectable male end 122 for engaging with a formwork element not shown in
Wall panel 184 is connected to connector 118 and wall panel 186 is connected to connector 142 via fixed connection. Wall panels 176, 178, 184 and 186 are shown to be of indeterminate length at points 74.
With reference to
With reference to
As shown in
With reference to
With reference to
Prefabricated seam-filling segments can correspond to the shape and distance of a male adjustable connector sticking out of a female adjustable connector, whether that distance relates to 1, 2, 3, 4 or more ribs, such that the outer wall surface can be easily and immediately filled into to a flat surface even when the male and female adjustable connection ends 232 and 226 are not completely inserted into one another in a manner that might otherwise leave an indented gap in the outer wall surface 234. Seam filling segment 238 is an example of such a segment, in this case relating to an indentation gap 242 created when two ribs of the male adjustable connection end 232 stick out of the corresponding female adjustable connection end 226.
Adjustable female connection ends 230 are connected to reinforcing members 244 and 246 respectively, forming cell cavity 250. In one instance, a male adjustable connection end of reinforcing member 246 is not inserted completely into the corresponding female adjustable connection end such that a gap 248 appears within the female adjustable connection end. As the male and female adjustable connection ends have a multiplicity of ribs, reinforcing panel 246 is firmly held in position by the adjustable connection irrespective of the gap 248 due to the rib(s) that remain in contact.
Embodiment 260 in
Embodiment 268 in
Connections between a smooth male connection end 262 and a smooth female connection end 264 are adjustable to allow very precise adjustments that do not require choosing one rib distance or another. The connections can be further locked in position, where desired, by glue, or screws, nails, or the like. In suitable applications, the connection can be left without glue, screws or nails or the like to allow for expansion or contraction.
With reference to
The combination of the female adjustable connection ends 272 and 274 on connectors 278 and 280, when combined with double-ended male adjustable connector 276, is such that the spacing between female connector 278 and female connector 280 is adjustable depending upon how much of male connection ends 284 and 286 are inserted into female adjustable connection ends 278 and 280.
In
Embodiment 270, through fixed female connection ends 30 and 32, can be connected to known fixed-length modular formwork panels to add an adjustable length variation segment.
With reference to
Click-in adjustable male connection end 298 and click-in adjustable female connection end 296 are designed to push together in one direction and be locked from expanding apart. It may be possible to separate the two during construction by lifting one piece out of the other in a direction into or out of the plane of the paper in
Embodiment 310 in
Embodiments of this invention can be made from polyvinyl chloride (PVC), or from other suitable plastics, which depending upon the application may include ethylene propylene diene monomer (EPDM), thermoplastic elastomer polyolefin (TPO), cross-linked polyethylene (XLPE, marketed as PEX), polyethylene (PE), high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), nylon, ethylene vinyl acetate (EVA), poly(methyl methacrylate) (Plexiglass™), polypropylene (PP), polyolefins, and fiberglass. However, it is understood that it could be used with panels and connection systems using other suitable materials, such as cast aluminum, sheet metal, carbon fiber, or other suitable metals, synthetic or natural materials, including fiber cement, rubber, or wood. The invention has application for systems of mixed concrete forming and other materials, such as the use of Styrofoam™ or other forms of insulation replacing some or all of the concrete.
Some embodiments of the invention may have modular construction applications completely separate from concrete forming. For example, embodiments 224 and 260 could be used as a ceiling with connection ends 230 and 266, or suitable alternatives, used to secure the ceiling surface beams or other structure. Embodiments 224, 260 and 268, and similar, can be used as siding for buildings and/or for wall or flooring coverings and/or surfaces.
As will be apparent to those skilled in the art in the light of the foregoing disclosure the present invention is not limited by what has been particularly shown and described herein. Rather the scope of the present invention includes both combinations and sub-combinations of the features described hereinabove as well as modifications and variations thereof which would occur to a person of skill in the art upon reading the foregoing description and which are not in the prior art. Furthermore, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example, the illustrated embodiments show variable connections that are smooth, or having click-in surface contours, or having alternating perpendicular ribs and gaps, however it is to be understood that any reasonable variable connection is intended to be included within the scope of the invention, including dovetails, rounded protrusions and other suitable variations. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
Claims
1. An apparatus comprising:
- a first component having a first female adjustable connection end; and
- a second component having a first male adjustable connection end, said male adjustable connection end lockably insertable into said female adjustable connection in a plurality of positions to vary a length of a coupled combination of said first and second components.
2. An apparatus as in claim 1, further comprising
- a plurality of wall forming panels coupled to said first and second components to form a wall having an inside wall surface and an outside wall surface, and
- reinforcing panels coupled to said inside wall surface and said outside wall surface.
3. An apparatus as in claim 2, further comprising bracing panels coupled between said reinforcing panels and said inside or outside wall surface at 45 degree angles.
4. An apparatus as in claim 3, wherein said first and second panels comprise plastic.
5. An apparatus as in claim 4, said first female adjustable connection having 3-8 ribs on each side, each of said ribs separated by a corresponding gap.
6. An apparatus as in claim 5, wherein said wall comprises a straight portion of wall.
7. An apparatus as in claim 5, wherein said wall is a cylindrical wall.
8. An apparatus as in claim 6, said wall comprising a concrete wall, said first and second components being concrete forming elements, said wall forming panels being concrete forming panels.
9. An apparatus as in claim 7, said wall comprising a concrete wall, said first and second components being concrete forming elements, said wall forming panels being concrete forming panels.
10. An apparatus as in claim 8, wherein each concrete forming panel is coupled via adjustable connection.
11. An apparatus as in claim 9, wherein each concrete forming panel is coupled via adjustable connection.
12. A method of building a structure comprising:
- inserting a first male adjustable connection end of a first building component into a first female adjustable connection end of a second building component wherein said first male and female adjustable connection ends are adjustable with respect to each other to lockably adjust a distance that said first male adjustable connection end is inserted into said first female adjustable connection end to effectively adjust a length of a coupled combination of said first and second building components.
13. The method of claim 12 further comprising coupling said first and second building components to a plurality of wall forming panels to form a wall having an inside wall surface and an outside wall surface;
- coupling reinforcing panels to said inside wall surface and to said outside wall surface.
14. The method of claim 13 further comprising coupling a bracing panel between said recinforcing panels and said inside wall surface at a 45 degree angle.
15. The method of claim 14 wherein forming said wall comprises forming a straight portion of wall.
16. The method of claim 14 wherein forming said wall comprises forming a cylindrical wall.
17. The method of claim 15 further comprising inserting re-bar into cavities between said inside wall surface and said outside wall surface, and inserting re-bar through apertures in said reinforcing panels.
18. The method of claim 17 further comprising pouring concrete into cavities between said inside wall surface and said outside wall surface, and through apertures in said reinforcing panels.
19. The method of claim 18 further comprising smoothing said outside wall surface by attaching a seam filling segment to fill in an indentation gap from ribs of said first male adjustable connection end sticking out of said female adjustable connection end.
20. An apparatus for forming a concrete wall comprising:
- a first concrete forming element having a first female adjustable connection end; and
- a second concrete forming element having a first male adjustable connection end, said male adjustable connection end lockably insertable into said female adjustable connection in a plurality of positions to vary a length of a coupled combination of said first and second concrete forming elements;
- a plurality of concrete forming panels coupled to said first and second concrete forming elements via adjustable connection to form a wall structure having an inside wall surface and an outside wall surface;
- reinforcing panels coupled to said inside wall surface and said outside wall surface;
- bracing panels coupled between said reinforcing panels and said inside or outside wall surface at 45 degree angles;
- said first and second concrete forming elements comprising plastic;
- said first female adjustable connection having 3-8 ribs on each side, each of said ribs separated by a corresponding gap; and
- said wall structure comprising a straight portion of wall.
Type: Application
Filed: May 21, 2015
Publication Date: Nov 24, 2016
Inventor: Francesco Piccone (Vancouver)
Application Number: 14/719,214