Patent Grant
11674322
This application relates to methods and apparatus (systems) for restoring, repairing, reinforcing, protecting, insulating and/or cladding a variety of structures. Some embodiments provide stay-in-place liners (or portions thereof) for containing concrete or other curable material(s). Some embodiments provide stay-in-place liners (or portions thereof) which line interior surfaces of supportive formworks and which are anchored to curable materials as they are permitted to cure.
Concrete is used to construct a variety of structures, such as building walls and floors, bridge supports, dams, structures, raised platforms and the like. Typically, concrete structures are formed using embedded reinforcement bars (often referred to as rebar) or similar steel reinforcement material, which provides the resultant structure with increased strength. Over time, corrosion of the embedded reinforcement material can impair the integrity of the embedded reinforcement material, the surrounding concrete and the overall structure. Similar degradation of structural integrity can occur with or without corrosion over sufficiently long periods of time, in structures subject to large forces, in structures deployed in harsh environments, in structures coming into contact with destructive materials or the like.
There is a desire for methods and apparatus for repairing and/or restoring existing structures which have been degraded or which are otherwise in need of repair and/or restoration.
There is a desire for methods and apparatus for repairing and/or restoring existing multi-sided structures such as pilasters and columns which extend from a surface where the multi-sided structure has been degraded or which are otherwise in need of repair and/or restoration.
In some situations, multi-sided structure 12B may not have sufficient structural rigidity to support a repair structure mounted directly to structure 12B (e.g. in the case that multi-sided structure 12B is ornamental). In some situations, surfaces 14B may be sufficiently damaged that it would be undesirable to mount a repair structure directly to any of surfaces 14B.
There is a desire for methods and apparatus for repairing and/or restoring existing multi-sided structures such as pilasters and columns which extend from a surface where the multi-sided structure has been degraded or which are otherwise in need of repair and/or restoration and where the multi-sided structure is not sufficiently strong or has sufficient degradation that a repair structure cannot be directly mounted to the multi-sided structure itself.
Portions 12A of structure 10 respectively form inside corners 20A, 20B with multi-sided structure 12B. Portion 12A may constrain the ability to work in a vicinity of multi-sided structure 12B and, in particular, in a vicinity of surface 14B which is in need of repair and/or restoration.
Exemplary structure 10 also includes portions 18A, 18B on opposing sides of portions 12A, 12B. In the case where portions 12A, 12B are walls, portions 18A, 18B may represent a floor and ceiling, for example. Portions 18A, 18B of structure 10 respectively form inside corners 22A, 22B with portions 12A, 12B. Portions 18A, 18B constrain the ability to work in a vicinity of portions 12A, 12B and, in particular, in a vicinity of surface 14B which is in need of repair and/or restoration. For example, it may not be possible to access surface 14B of multi-sided structure 12B by moving in one or more directions parallel with surface 14B from one side of portion 18A (or 18B) to the opposing side of portion 18A (or 18B). Instead, it may be necessary or desirable to access surface 14A from a direction normal to surface 14B (e.g. in directions 21 or 23 (
There is a general desire to repair and/or restore existing structures wherein there are constraints on the ability to access the portion(s) and/or surface(s) of the existing structures.
Constraints on access to existing structures (and/or portion(s) and/or surface(s) thereof) in need of repair and/or restoration are not limited to constraints imposed by other portions of the same structure, as is the case of exemplary structure 10 of
Some structures have been fabricated with inferior or sub-standard structural integrity. By way of non-limiting example, some older structures may have been fabricated in accordance with seismic engineering specifications that are lower than, or otherwise lack conformity with, current seismic engineering standards. There is a desire to reinforce existing structures to upgrade their structural integrity or other aspects thereof. There is a corresponding desire to reinforce existing structures wherein there are constraints on the ability to access portion(s) and/or surface(s) of the existing structures.
There is also a desire to protect existing structures from damage which may be caused by, or related to, the environments in which the existing structures are deployed and/or the materials which come into contact with the existing structures. By way of non-limiting example, structures fabricated from metal or concrete can be damaged when they are deployed in environments that are in or near salt water or in environments where the structures are exposed to salt or other chemicals (and/or biochemicals) used to de-ice roads. There is a corresponding desire to protect existing structures wherein there are constraints on the ability to access portion(s) and/or surface(s) of the existing structures.
Previously known techniques for repairing, restoring, reinforcing, protecting, insulating and/or cladding existing structures often are difficult and time-consuming to implement. There is a general desire to repair, restore, reinforce, protect, insulate and/or clad existing structures in a simple and time-efficient manner.
The desire to repair, restore, reinforce and/or protect existing structures is not limited to concrete structures. There are similar desires for existing structures fabricated from other materials.
The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
One aspect of the invention provides a method for repairing a multi-sided structure protruding from a first surface to cover at least a portion of the multi-sided structure with a repair structure. The method comprises mounting a retainer to the first surface, coupling a first brace connector component of a first brace to a first panel, the first brace extending non-parallel and non-orthogonal to the first panel, coupling the first panel to a primary retainer connector component of the retainer, the first panel extending generally non-parallel to the first surface such that a tangential plane of the first panel is facing, and spaced apart from, a second surface of the multi-sided structure to provide a space between the first panel and the multi-sided structure, coupling a second brace connector component of the first brace to a secondary retainer connector component of the retainer, the first brace extending non-parallel and non-orthogonal to the retainer and introducing a curable material into the space between the first panel and the multi-sided structure, the first panel acting as at least a portion of a framework for containing the curable material until the curable material cures to provide a repair structure cladded, at least in part, by the first panel.
In some embodiments, the method comprises coupling the first brace connector component of the first brace to the first panel before coupling the first panel to the retainer. In some embodiments, the method comprises coupling the first panel to the retainer and concurrently coupling the second brace connector component of the first brace to the retainer. In some embodiments, the method comprises comprising coupling the first panel to the retainer after coupling the second brace connector component of the first brace to the retainer. In some embodiments, the method comprises coupling the first panel to the retainer before coupling the second brace connector component of the first brace to the retainer.
In some embodiments, coupling the first panel to the retainer comprises forcing the first panel in an inward direction toward the primary retainer connector of the retainer to form a panel-retainer connection.
In some embodiments, forming the panel-retainer connection comprises extending a protrusion of the primary retainer connector component of the retainer into a receptacle of a first panel connector component of the first panel, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the panel-retainer connection. In some embodiments, forming the panel-retainer connection comprises extending a protrusion of a first panel connector component of the first panel into a receptacle of the primary retainer connector component of the retainer, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the panel-retainer connection.
In some embodiments, coupling the first brace to the retainer comprises forcing the first brace in an inward direction toward the secondary retainer connector of the retainer to form a brace-retainer connection.
In some embodiments, forming the brace-retainer connection comprises extending a protrusion of the second brace connector component of the first brace into a receptacle of the secondary retainer connector component of the retainer, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the brace-retainer connection.
In some embodiments, forming the panel-retainer connection comprises extending a protrusion of the secondary retainer connector component of the retainer into a receptacle of the second brace connector component of the first brace, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the brace-retainer connection.
In some embodiments, forcing the first brace in the inward direction toward the secondary retainer connector of the retainer to form the brace-retainer connection comprises applying force to a shoulder or surface of the second retainer connector component with a tool (e.g. a crowbar, hammer, block of wood, etc.) and wherein the second retainer connector component comprises one or more sidewalls for aligning the tool with the shoulder or surface.
In some embodiments, coupling the first brace connector component of the first brace to the first panel comprises sliding the first brace connector in a longitudinal direction relative to a third panel connector component to form a panel-brace connection.
In some embodiments, forming the panel-brace connection comprises sliding a projection of the third panel connector component into a channel of the first brace connector in the longitudinal direction.
In some embodiments, forming the panel-brace connection comprises sliding a projection of the first brace connector into a channel of the third panel connector component in the longitudinal direction.
In some embodiments, the retainer comprises a base and the primary and secondary retainer connector components each extend in an outward direction, opposite the inward direction, from the base. In some embodiments, the primary retainer connector component is separated from the secondary retainer connector component in a transverse direction by a spacing. In some embodiments, the primary and secondary retainer connector components are integral to the base.
In some embodiments, the base of the retainer comprises one or more mounting features located in the spacing and mounting the retainer to the first surface comprises mounting the retainer to the first surface of using the one or more mounting features. In some embodiments, the one or more mounting features comprises one or more apertures and mounting the retainer to the first surface comprises passing one or more fasteners through the one or more apertures and into the first surface.
In some embodiments, the first brace extends from the first panel at an angle between 20° and 70°. In some embodiments, the first brace extends from the first panel at an angle between 40° and 50°. In some embodiments, the first brace extends from the first panel at an angle of approximately 45°. In some embodiments, the first brace extends from the retainer at an angle between 20° and 70°. In some embodiments, the first brace extends from the retainer at an angle between 40° and 50°. In some embodiments, the first brace extends from the retainer at an angle of approximately 45°.
In some embodiments, the first panel extending generally non-parallel to the first surface such that the tangential plane of the first panel is facing, and spaced apart from, the second surface of the multi-sided structure comprises the first panel extending generally normal to the first surface such that the tangential plane of the first panel is generally parallel to, and spaced apart from, the second surface of the multi-sided structure.
In some embodiments, the space between the first panel and the multi-sided structure comprises a space between the first panel and the second surface of the multi-sided structure. In some embodiments, the first panel extending generally non-parallel to the first surface comprises the first panel extending generally normal to the first surface.
In some embodiments, the multi-sided structure comprises a pilaster. In some embodiments, the multi-sided structure comprises a column. In some embodiments, the multi-sided structure is ornamental.
In some embodiments, the method comprises connecting a second panel to the first panel by forcing a first panel connector component of the second panel in an inward direction toward a second panel connector of the first panel to form a panel-panel connection.
In some embodiments, the method comprises connecting a number, n, of panels to the first panel by forcing a first panel connector component of an ith panel in an inward direction toward a second panel connector of an (i−1)th panel to form a panel-panel connection, where n is any positive integer and i is a count from two to n+1. In some embodiments, the method comprises connecting a second retainer to a second panel connector of the n+1th panel. In some embodiments, connecting the n+1th panel to the second retainer comprises forcing the n+1th panel in an inward direction toward a primary retainer connector of the second retainer to form a second panel-retainer connection. In some embodiments, forming the second panel-retainer connection comprises extending a protrusion of the second panel connector component of the n+1th panel into a receptacle of the primary retainer connector component of the second retainer, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the second panel-retainer connection. In some embodiments, forming the panel-retainer connection comprises extending a protrusion of the primary retainer connector component of the second retainer into a receptacle of the second panel connector component of the n+1th panel, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the second panel-retainer connection.
In some embodiments, the method comprises mounting the second retainer to the first surface.
In some embodiments, the method comprises coupling a first brace connector component of a second brace to the n+1th panel, the second brace extending non-parallel and non-orthogonal to the n+1th panel and coupling a second brace connector component of the second brace to a secondary connector component of the second retainer, the second brace extending non-parallel and non-orthogonal to the second retainer.
In some embodiments, the method comprises connecting a standoff to the ith panel by connecting a first standoff connector component to a third connector of the ith panel, deforming the standoff such that a transverse spacing between the first standoff connector component of the standoff and a second standoff connector component of the standoff is approximately equal to a transverse spacing between the third connector of the ith panel and a fourth connector of the ith panel and connecting the second standoff connector component to the fourth connector of the ith panel.
In some embodiments, coupling the first standoff connector component to the third connector component of the ith panel comprises sliding the first standoff connector component in a longitudinal direction relative to the third panel connector component of the ith panel to form a first panel-standoff connection. In some embodiments, forming the first panel-standoff connection comprises sliding a projection of the third panel connector component of the ith panel into a channel of the first standoff connector component in the longitudinal direction. In some embodiments, forming the first panel-standoff connection comprises sliding a projection of the first standoff connector component into a channel of the third panel connector component of the ith panel in the longitudinal direction. In some embodiments, coupling the second standoff connector component to the fourth connector component of the ith panel comprises sliding the second standoff connector component in a longitudinal direction relative to the fourth panel connector component of the ith panel to form a second panel-standoff connection. In some embodiments, forming the second panel-standoff connection comprises sliding a projection of the fourth panel connector component of the ith panel into a channel of the second standoff connector component in the longitudinal direction. In some embodiments, forming the second panel-standoff connection comprises sliding a projection of the second standoff connector component into a channel of the fourth panel connector component of the ith panel in the longitudinal direction.
In some embodiments, when the panel-retainer connection is formed, the primary retainer connector of the retainer and the first and second panel connectors of the first panel are each offset from the tangential plane of the first panel.
Another aspect of the invention provides an apparatus for repairing a multi-sided structure protruding from a first surface to cover at least a portion of a surface of the multi-sided structure with a repair structure. The apparatus comprises a retainer mounted to the first surface, a first brace connector component of a first brace coupled to a first panel, the first brace extending non-parallel and non-orthogonal to the first panel, the first panel coupled to a primary retainer connector component of the retainer. The first panel extending generally non-parallel to the first surface such that a tangential plane of the first panel is generally facing, and spaced apart from, a second surface of the multi-sided structure to provide a space between the first panel and the multi-sided structure. A second brace connector component of the first brace is coupled to a secondary retainer connector component of the retainer, the first brace extending non-parallel and non-orthogonal to the retainer. A curable material is provided in the space between the first panel and the multi-sided structure, the first panel acting as at least a portion of a framework for containing the curable material until the curable material cures to provide a repair structure cladded, at least in part, by the first panel.
In some embodiments, the first brace connector component of the first brace is coupled to the first panel before coupling the first panel to the retainer. In some embodiments, the first panel is concurrently coupled to the retainer and the second brace connector component of the first brace. In some embodiments, the first panel is coupled to the retainer after the second brace connector component of the first brace is coupled to the retainer. In some embodiments, the first panel is coupled to the retainer before the second brace connector component of the first brace is coupled to the retainer.
In some embodiments, the first panel is coupled to the retainer by forcing the first panel in an upward direction toward the primary retainer connector of the retainer to form a panel-retainer connection.
In some embodiments, the panel-retainer connection comprises a protrusion of the primary retainer connector component of the retainer extended into a receptacle of a first panel connector component of the first panel, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the panel-retainer connection.
In some embodiments, the panel-retainer connection comprises a protrusion of the primary retainer connector component of the first panel extended into a receptacle of the primary retainer connector component of the retainer, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the panel-retainer connection.
In some embodiments, the first brace is coupled to the retainer by the first brace being forced in an inward direction toward the secondary retainer connector of the retainer to form a brace-retainer connection.
In some embodiments, the brace-retainer connection comprises a protrusion of the second brace connector component of the first brace extended into a receptacle of the secondary retainer connector component of the retainer, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the brace-retainer connection.
In some embodiments, the panel-retainer connection comprises a protrusion of the secondary retainer connector component of the retainer extended into a receptacle of the second brace connector component of the first brace, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the brace-retainer connection.
In some embodiments, the second retainer connector component comprises a shoulder or surface and one or more sidewalls for aligning a tool (e.g. a crowbar, hammer, block of wood, etc.) with the shoulder or surface, the first brace being forced in an inward direction toward the secondary retainer connector of the retainer to form a brace-retainer connection comprises applying force to the shoulder or surface of the second retainer connector component with the tool.
In some embodiments, the first brace connector component of the first brace being coupled to a first panel comprises the first brace connector the first brace connector being slid in a longitudinal direction relative to a third panel connector component to form a panel-brace connection.
In some embodiments, the panel-brace connection comprises a projection of the third panel connector component being slid into a channel of the first brace connector in the longitudinal direction. In some embodiments, the panel-brace connection comprises a projection of the first brace connect being slid into a channel of the third panel connector component in the longitudinal direction.
In some embodiments, wherein the retainer comprises a base and the primary and secondary retainer connector components each extend in an outward direction, opposite the inward direction, from the base. In some embodiments, the primary retainer connector component is separated from the secondary retainer connector component in a transverse direction by a spacing. In some embodiments, the primary and secondary retainer connector components are integral to the base.
In some embodiments, the base of the retainer comprises one or more mounting features located in the spacing and the retainer is mounted to the first surface through the one or more mounting features. In some embodiments, the one or more mounting features comprises one or more apertures and the retainer is mounted to the first surface by passing one or more fasteners through the one or more apertures and into the first surface.
In some embodiments, the first brace extends from the first panel at an angle between 20° and 70°. In some embodiments, the first brace extends from the first panel at an angle between 40° and 50°. In some embodiments, the first brace extends from the first panel at an angle of approximately 45°. In some embodiments, the first brace extends from the retainer at an angle between 20° and 70°. In some embodiments, the first brace extends from the retainer at an angle between 40° and 50°. In some embodiments, the first brace extends from the retainer at an angle of approximately 45°.
In some embodiments, the first panel extends generally non-parallel to the first surface such that the tangential plane of the first panel is facing, and spaced apart from, the second surface of the multi-sided structure comprises the first panel extending generally normal to the first surface such that the tangential plane of the first panel is generally parallel to, and spaced apart from, the second surface of the multi-sided structure.
In some embodiments, the space between the first panel and the multi-sided structure comprises a space between the first panel and the second surface of the multi-sided structure. In some embodiments, the first panel extends generally non-parallel to the first surface comprises the first panel extending generally normal to the first surface.
In some embodiments, wherein the multi-sided structure comprises a pilaster. In some embodiments, the multi-sided structure comprises a column. In some embodiments, the multi-sided structure is ornamental.
In some embodiments, the apparatus comprises a second panel connected to the first panel by forcing a first panel connector component of the second panel in an inward direction toward a second panel connector of the first panel to form a panel-panel connection.
In some embodiments, the apparatus comprises a number, n, of panels connected to the first panel by forcing a first panel connector component of an ith panel in an inward direction toward a second panel connector of an (i−1)th panel to form a panel-panel connection, where n is any positive integer and i is a count from two to n+1. In some embodiments, the apparatus comprises a second retainer connected to a second panel connector of the n+1th panel. In some embodiments, the n+1th panel is connected to the second retainer comprises forcing the n+1th panel in an inward direction toward a primary retainer connector of the second retainer to form a second panel-retainer connection.
In some embodiments, the second panel-retainer connection comprises a protrusion of the second panel connector component of the n+1th panel extended into a receptacle of the primary retainer connector component of the second retainer, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the second panel-retainer connection.
In some embodiments, the panel-retainer connection comprises a protrusion of the primary retainer connector component of the second retainer extended into a receptacle of the second panel connector component of the n+1th panel, the receptacle shaped to prevent removal of the protrusion from the receptacle and the receptacle resiliently deformed by the extension of the protrusion into the receptacle to thereby apply a restorative force to the protrusion to maintain the second panel-retainer connection.
In some embodiments, the second retainer is mounted to the first surface.
In some embodiments, a first brace connector component of a second brace is coupled to the n+1th panel, the second brace extending non-parallel and non-orthogonal to the n+1th panel and a second brace connector component of the second brace is coupled to a secondary connector component of the second retainer, the second brace extending non-parallel and non-orthogonal to the second retainer.
In some embodiments, a standoff is connected to the ith panel by, connecting a first standoff connector component to a third connector of the ith panel, deforming the standoff such that a transverse spacing between the first standoff connector component of the standoff and a second standoff connector component of the standoff is approximately equal to a transverse spacing between the third connector of the ith panel and a fourth connector of the ith panel and connecting the second standoff connector component to the fourth connector of the ith panel.
In some embodiments, the first standoff connector component being coupled to the third connector component of the ith panel comprises sliding the first standoff connector component in a longitudinal direction relative to the third panel connector component of the ith panel to form a first panel-standoff connection.
In some embodiments, the first panel-standoff connection comprises a projection of the third panel connector component of the ith panel slid into a channel of the first standoff connector component in the longitudinal direction.
In some embodiments, the first panel-standoff connection comprises a projection of the first standoff connector component slid into a channel of the third panel connector
In some embodiments, coupling the second standoff connector component to the fourth connector component of the ith panel comprises sliding the second standoff connector component in a longitudinal direction relative to the fourth panel connector component of the ith panel to form a second panel-standoff connection.
In some embodiments, the second panel-standoff connection comprises a projection of the fourth panel connector component of the ith panel slid into a channel of the second standoff connector component in the longitudinal direction.
In some embodiments, the second panel-standoff connection comprises a projection of the second standoff connector component slid into a channel of the fourth panel connector component of the ith panel in the longitudinal direction.
In some embodiments, the primary retainer connector of the retainer and the first and second panel connectors of the first panel are each offset from the tangential plane of the first panel.
Another aspect of the invention provides an apparatus for repairing a multi-sided structure protruding from a first surface to cover at least a portion of a surface of the multi-sided structure with a repair structure. The apparatus comprises a retainer mountable to the first surface, a first brace connector component of a first brace coupleable to a first panel to extend non-parallel and non-orthogonal to the first panel. The first panel is coupleable to a primary retainer connector component of the retainer to extend generally non-parallel to the first surface such that a tangential plane of the first panel is generally facing, and spaced apart from, a second surface of the multi-sided structure to provide a space between the first panel and the multi-sided structure. A second brace connector component of the first brace is coupleable to a secondary retainer connector component of the retainer to extend non-parallel and non-orthogonal to the retainer. The first panel acts as at least a portion of a framework for containing a curable material in the space between the first panel and the multi-sided structure until the curable material cures to provide a repair structure cladded, at least in part, by the first panel.
Another aspect of the invention provides a method for interconnecting edge-adjacent panels of an apparatus for repairing a multi-sided structure protruding from a first surface. The method comprises providing a retainer comprising a first edge component and a panel comprising a second edge component, orienting the retainer and the panel in an edge-to-edge relationship and thereby aligning the first and second edge components with one another, providing a tool comprising: a first arm having a first handle, the first arm terminating at a first tool head comprising a first roller; and a second arm having a second handle, the second arm terminating at a second tool head comprising a second roller, the second arm pivotally coupled to the first arm by a pivot joint, positioning the tool at a first location relative to the retainer and the panel and configuring the first and second tool faces to respectively engage the first and second edge components, moving the tool in a longitudinal direction to thereby cause the first roller to roll along the first edge component and the second roller to roll along the second edge component thereby forcing the first edge component into a locked configuration with the second edge component.
In some embodiments, the method comprises moving the first and second handles toward each other by movement of the pivot joint to cause corresponding movement of the first and second tool faces toward one another other before moving the tool in the longitudinal direction. In some embodiments, the method comprises pivoting the first and second arms relative to the first and second tool heads.
In some embodiments, the method comprises disengaging the tool from the first and second edge components and the locked configuration of the first and second edge components is maintained after the tool is disengaged from the first and second edge components.
Another aspect of the invention provides a tool for assembling at least a portion of an apparatus for repairing a multi-sided structure protruding from a first surface, the apparatus comprising a retainer and a panel having first and second edge components and connectable in an edge-to-edge relationship wherein the first and second edge components engage one another. The tool comprises a first arm having a first handle, the first arm terminating at a first tool head comprising a first roller, a portion of which is shaped to be complimentary to at least a portion of the first edge component for engaging the portion of the first edge component a second arm having a second handle, the second arm terminating at a second tool head comprising a second roller, a portion of which is shaped to be complimentary to at least a portion of the second edge component for engaging the second edge component, the second arm pivotally coupled to the first arm by a pivot joint. The first and second handles are moveable toward one another by movement of the pivot joint causing corresponding movement of the first and second rollers toward one another and thereby forcing the first and second edge components into a locked configuration.
In some embodiments, the first and second tool heads are pivotally mounted to the first and second arms respectively.
In some embodiments, the tool comprises a bias mechanism between the first and second handles to bias the first and second tool heads into a spaced apart relationship. In some embodiments, the tool comprises a locking mechanism for overcoming the bias mechanism and securing the first and second tool faces in abutment with one another.
Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
One aspect of the invention provides a method for repairing a multi-sided structure protruding from a first surface to cover at least a portion of the multi-sided structure with a repair structure. A retainer is mounted to the first surface. A first brace connector component of a first brace is coupled to a first panel such that the first brace extends non-parallel and non-orthogonal to the first panel. The first panel is coupled to a primary retainer connector component of the retainer such that the first panel extends generally non-parallel to the first surface such that a plane (or tangential plane) of the first panel is facing, and spaced apart from, a second surface of the multi-sided structure to provide a space between the first panel and the multi-sided structure. A second brace connector component of the first brace is coupled to a secondary retainer connector component of the retainer, such that the first brace extends non-parallel and non-orthogonal to the retainer. A curable material is introduced into the space between the first panel and the multi-sided structure, the first panel acting as at least a portion of a framework for containing the curable material until the curable material cures to provide a repair structure cladded, at least in part, by the first panel.
Another aspect of the invention provides an apparatus for repairing a multi-sided structure protruding from a first surface to cover at least a portion of the multi-sided structure with a repair structure. A retainer is mounted to the first surface. A first brace connector component of a first brace is coupled to a first panel such that the first brace extends non-parallel and non-orthogonal to the first panel. The first panel is coupled to a primary retainer connector component of the retainer such that the first panel extends generally non-parallel to the first surface such that a plane (or tangential plane) of the first panel is facing, and spaced apart from, a second surface of the multi-sided structure to provide a space between the first panel and the multi-sided structure. A second brace connector component of the first brace is coupled to a secondary retainer connector component of the retainer, such that the first brace extends non-parallel and non-orthogonal to the retainer. A curable material is introduced into the space between the first panel and the multi-sided structure, the first panel acting as at least a portion of a framework for containing the curable material until the curable material cures to provide a repair structure cladded, at least in part, by the first panel.
Aspects of the invention also provide repair structures fabricated using the methods and formwork apparatus described herein. Kits may also be provided in accordance with some aspects of the invention. Such kits may comprise portions of the apparatus according to various embodiments and may facilitate effecting one or more methods according to various embodiments.
In some embodiments, formwork apparatus 100 may be used with an external formwork (or external bracing (not shown) which supports the formwork apparatus 100 while concrete or other curable material cures in space 104. The external formwork may be removed and optionally re-used after the curable material cures. In some embodiments, formwork apparatus 100 may be used (with or without external formwork or bracing) to fabricate independent structures (i.e. structures that do not line existing structures and are otherwise independent of existing structures).
In currently preferred embodiments, retainers 110, braces 150 and panels 140 are fabricated from suitable plastic (e.g. polyvinyl chloride (PVC)) using an extrusion process. It will be understood, however, that retainers 110, braces 150 and/or panels 140 could be fabricated from other suitable materials, such as, by way of non-limiting example, other suitable plastics, other suitable metals or metal alloys, polymeric materials, fiberglass, carbon fiber material or the like and that retainers 110, braces 150 and/or panels 140 could be fabricated using any other suitable fabrication techniques.
Generally, formwork apparatus 100 components may be formed of a resiliently (e.g. elastically) deformable material such as appropriate plastics described above. The resiliently deformable nature of these components allow formwork apparatus 100 components to be deformed as connections, such as edge-to-edge connections between panels 140, are formed. As a result, formwork apparatus 100 components (or portions thereof) may apply restorative deformation forces on other formwork apparatus 100 components (or portions thereof) and may allow for components to resiliently “snap” back to a less deformed state. This may allow for more secure connections or connections that may withstand deformation while minimizing leaking and the creation of gaps in the connection.
Retainers 110 are coupled to existing structure 10 such that at least a portion of retainers 110 extend away from surface 14A thereof. Retainers 110 are elongated in longitudinal direction 119.
As shown in
Retainers 110 may be mounted to existing structure 10 such that base 112 contacts or abuts surface 14A of existing structure 10. However, surface 14A of existing structure 10 may be uneven (e.g. surface 14A may vary in inward-outward direction 123) along longitudinal direction 119. Spacers may therefore be employed to accommodate such unevenness along longitudinal direction 119. For example, the inward-outward direction 123 dimension of each spacer may be chosen such that a distal end of each spacer (e.g. the end of spacer that is furthest from surface 14A) may define a portion of a hypothetical plane as desired. In this way, when base 112 of a retainer 110 is mounted against the spacers, retainer 110 is parallel with the hypothetical plane. The hypothetical plane may be a vertical plane. This is not mandatory. The hypothetical plane could be sloped, if desired. In this way, retainers 110 remain straight in longitudinal direction 119 which in turn facilitates coupling of panels 140 to retainers 110.
In some embodiments, the spacers are complementarily threaded to the fasteners 50. For example, the spacers may comprise a threaded nut. By rotating the spacers clockwise or counter-clockwise, the inward-outward direction 123 distance of the distal end of each spacer to surface 14A of existing structure 10 may be adjusted without requiring multiple spacers or spacers of different lengths. In some embodiments, each spacer comprises a pair of threaded nuts to prevent unwanted movement of spacer. In some embodiments, the spacers comprise one or more wedges that may be interleaved to space apart retainer 110 from surface 14A of existing structure 10.
In some embodiments, to prevent fastener 50 from pulling through aperture 114, one or more washers may be employed between the fastener 50 and base 112. Such washers may be flat washers or curved washers. Such washers may, for example, comprise metal, polymer or composite materials. In some embodiments, to prevent fastener 50 and/or washer from crushing base 112 or a portion of base 112, one or more ridges 116 may be provided on base 112. Ridges 116 may extend in inward-outward direction 123 from base 112. Ridges 116 may extend along longitudinal direction 119 continuously or may be discontinuous (e.g. ridges 116 may only be present near apertures 114). Ridges 116 may serve to reinforce base 112 near apertures 114 and may serve to prevent overtightening of fasteners 50. Ridges 116 may also serve to help center washers around apertures 114.
Base 112 may comprise one or more pairs of ridges 116 such that each washer contacts at least one pair of ridges 116. In the
In some embodiments, primary retainer connector component 120 and secondary retainer connector component 130 are spaced apart in transverse direction 121. For example, in the illustrated embodiment, apertures 114 and ridges 116 are located in the transverse direction 121 space between primary retainer connector component 120 and secondary retainer connector component 130. When base 112 is mounted to surface 14A of existing structure 10, primary retainer connector component 120 and secondary retainer connector component 130 extend in inward-outward direction 123 from base 112 and from surface 14A.
Primary retainer connector component 120 may be attached to base 112 by a stem 120A. Stem 120A may protrude from base 112 at an angle φ such that a panel 140 mounted to primary retainer connector component 120 extends at angle φ to base 112 of retainer 110. In some embodiments, angle φ is equal to approximately 90°. This is not mandatory. Angle φ may be any angle desired and may be chosen based on a shape of multi-sided structure 12B. Stem 120A may be supported by one or more reinforcements 118. In some embodiments, reinforcement 118 may be located on an outer side of stem 120A, such as is depicted in
Primary retainer connector component 120 may comprise any suitable connector component complementary to a connector component of panel 140. In some embodiments, primary retainer connector component 120 comprises any suitable connector component capable of being connected to a panel 140 by forcing a connector component of panel 140 in inward-outward direction 123 toward primary retainer connector component 120 to form an edge-to-edge connection 125.
In some embodiments, primary retainer connector component 120 may comprise a protrusion 122 that is connectable to a receptacle 162 of a first panel connector component 160 of a panel 140 to form a connection 125. Panel 140 may also comprise a second panel connector component 170 that comprises a protrusion 172 that is substantially similar to protrusion 122 of primary retainer connector component 120. Protrusion 172 of a first panel 140-1 may be connectable to a first panel connector component 160 of a second panel 140-2 to form a connection 165 and protrusion 172 of second panel 140-2 may be connectable to a first panel connector component 160 of a third panel 140-3 and so on. In the illustrated embodiment panels 140 (including corner panels 140′) are connected to one another in edge-to-edge connections until a final panel 140 connects to a second retainer 110′ at connection 125′. Second retainer 110′ may comprise a primary retainer connector component 120′ comprising a receptacle 122′ substantially similar to receptacle 162 of panel 140. Connections 125, 125′, 165 are substantially similar and may each be formed in a substantially similar manner. For convenience and to avoid repetition, only the formation of connection 125 is described herein in detail. However, it should be understood that connections 125′ and 165 are substantially similar and may each be formed in a substantially similar manner.
First panel connector component 160 comprises a receptacle 162 shaped to complement and receive protrusion 122. Receptacle 162 comprises a base 162A with a pair of walls 164A, 1648 extending from base 162A to form a space 164 therebetween. Walls 164A, 164B comprise a pair of hooked arms 166A, 166B forming an opening 166 therebetween.
Receptacle 162 may also comprise one or more optional protrusions 1 (in the illustrated embodiment there are two protrusions 168A, 168B) which extend into space 164. In the illustrated embodiment, protrusions 168A, 168B comprise shaped indentations formed in walls 164A, 164B. In other embodiments, protrusions 168A, 168B may comprise convexities that extend from walls 164A, 164B into space 164 (e.g. thickened regions of walls 164A, 164B). As discussed in more detail below, protrusions 168A, 168B of first panel connector component 160 engage protrusion 122 of primary retainer connector component 120 when connection 125 is formed.
As shown in
As is also shown in
As shown in
In the locked position of some embodiments, hooked arms 166A, 166B engage a locking portion 126 of primary retainer connector component 120. In the
Once hooked arms 166A, 166B reach the locked configuration, they may abut base 122A to plug opening 166, as shown in
The locked configuration of connection 125 is supplemented by restorative deformation forces applied to protrusion 122 by optional protrusions 168A, 168B. Optional protrusions 168A, 168B may be formed by bends in the shape of walls 164A, 164B, as shown in the
In some cases, tips 167C, 167D of hooked arms 166A, 166B may become caught on protrusion 122 as wide end 124B passes by hooked arms 166A, 166B, hindering the completion of connection 125. The resilient deformation forces caused by the interaction of protrusions 168A, 168B with the tapered body of protrusion 122 may remedy this situation by forcing protrusion 122 back in transverse direction 121 against tips 167C, 167D. Because, in the illustrated embodiment, wide end 124B has already passed tips 167C, 167D, the force caused by protrusions 168A, 168B will tend to force tips 167C, 167D to slide into concavities 126A, 126B and complete connection 125.
While primary retainer connector component 120 is described as comprising a protrusion 122, this is not mandatory. Instead, a primary retainer connector component 120′ of a retainer 110′ may, for example, comprise a receptacle similar to receptacle 162 of first panel connector component 160 as shown in
Connections 125, 125′ and 165, and in particular connector components 120, 120′, 160, 170, of the illustrated embodiment are symmetrical about and/or aligned with the plane of panels 140. The alignment and/or (at least) outer symmetry of connections 125, 125′, 165 with the plane of panels 140 may provide a strong connection by minimizing potential moments applied to connections 125, 125′, 165. That is, forces applied to panels 140 in plane cause minimal moments on connections 125,125′, 165, reducing any twisting which could tend to release or weaken connections 125, 125′, 165. In some embodiments, this in-line symmetry of connections 125, 125′, 165 and connector components 120, 120′, 160, 170 is not necessary. In some embodiments, it may be desirable to provide an exterior surface of panels 140 with a flush appearance. Consequently, connections 125, 125′, 165 and connector components 120, 120′, 160, 170 may be inwardly offset from the plane of panels 140.
First panel connector component 160 and primary retainer connector component 120′ each have an outer profile with a generally elliptical shape. Shapes such as the elliptical shape of connector components 160, 120′ may provide an aerodynamic connection that reduces the drag associated with connections 125, 125′, 165. Reducing drag may be important when, for example, formwork apparatus 100 is used in an aqueous environment and it is desirable to maintain appropriate flow conditions around connections 125, 125′, 165. The elliptical shape of connector components 160, 120′ also reduces the number of sharp corners in connections 125, 125′, 165. This can reduce the potential negative impact on users and/or fauna that may interact with formwork apparatus 100.
In some embodiments, a brace 150 may be connected to retainer 110 and panel 140 as shown in
In some embodiments, brace 150 is configured to extend from base 112 of retainer at approximately 45° and from panel 140 at approximately 45°. This is not necessary. For example, brace 150 could be configured to extend from base 112 of retainer at approximately 20° and from panel 140 at approximately 70°. In general, brace may be configured to extend from base 112 of retainer at an angle α and from panel 140 at an angle β, where the sum of α and β is approximately equal to the angle φ between panel 140 and corner connector component 110.
Brace 150 is elongated in longitudinal direction 119, has a flat portion 152, a first brace connector component 154 and a second brace connector component 156. First brace connector component 154 may extend from flat portion 152 at angle λ (e.g. 135°) and second brace connector component 156 may extend from flat portion 152 at angle δ (e.g.) 135°). Angles λ and δ allow brace 150 to be connected to base 112 of retainer at an angle α and to panel 140 at an angle β, as shown in
Second brace connector component 156 of brace 150 may be connectable to panel 140 using any suitable method or connector components. In some embodiments, panel 140 comprises a connector component 142 in the form of a T-connector component sized and shaped to cooperate with a C or channel shaped second brace connector component 156 of brace 150. In some embodiments, a connection 155 is formed between second brace connector component 156 of brace 150 and connector component 142 by sliding second brace connector component 156 relative to connector component 142. In some embodiments, sliding second brace connector component 156 relative to connector component 142 comprises sliding T-connector component 142 in longitudinal direction 119 into a channel 156A defined by second brace connector component 156 of brace 150. In some embodiments, second brace connector component 156 may be connected to connector component 142 by forcing them toward one another in transverse direction 121 and/or inward-outward direction 123 or by pivoting second brace connector component 156 of brace 150 relative to connector component 142. Connection 155 may comprise a snap-together connection, a friction fit connection, a displacement fit connection or the like.
In practice, brace 150 may be connected to panel 140 prior to connecting panel 140 to retainer 110. After brace 150 is connected to panel 140, the combination of panel 140 and brace 150 may together be attached to retainer 110 by forcing the combination of panel 140 and brace 150 in inward-outward direction toward retainer 110 to form connections 125 and 135. In some embodiments, connections 125 and 135 are formed simultaneously as the combination of panel 140 and brace 150 is forced in inward-outward direction toward retainer 110. In other embodiments, connection 125 is formed prior to connection 135 or connection 135 is formed prior to connection 125, as desired.
Since space 104 may be relatively limited (e.g. between surface 14 of existing structure 10/multi-sided structure 12B and panels 140), it may be difficult to access first brace connector component 154 to form connection 135. For this reason, it may be beneficial to employ a first brace connector component 154 that is capable of being connected to secondary retainer connector component 130 by applying force in inward-outward direction 123 without having to access first brace connector component 154 itself. In some embodiments, first brace connector component 154 comprises a shoulder or surface 154G for receiving a tool (e.g. a screwdriver, hammer, block of wood, crowbar etc.) to apply force in inward-outward direction 123 to first brace connector component 154 as needed. In some embodiments, one or more surfaces 154H may be shaped and/or oriented (e.g. beveled or tapered) toward surface 154G to facilitate aligning a tool with surface 154G.
First brace connector component 154 may comprise one or more arrowheads 154B, each having a transverse cross-sections shaped like an arrowhead, at locations on spine 154A, spaced apart from brace 150. For example, in
First arrowhead 154B-1 may comprise any suitable transverse cross-sectional shape such as a circle, a triangle, a rhombus or an arrowhead as described below. In the illustrated embodiment, a transverse cross-section of arrowhead 154B-1 comprises lobes projecting transversely in opposing directions from spine 154A. The transversely projecting lobes taper in direction 127 away from brace 150. As can be seen from
Second arrowhead 154B-2 may comprise any suitable transverse cross-sectional shape and may or may not be the same transverse cross-sectional shape as first arrowhead 154B-1. In the illustrated embodiment, arrowhead 154B-2 comprises lobes projecting transversely in opposing directions from spine 154A. The transversely projecting lobes taper in direction 127 away from brace 150. As can be seen from
Returning back to
In some embodiments, a beveled guide portion 1301 may protrude from or near each of first convexities 130F, as depicted in
First cavity 130A may correspond in shape to arrowhead 154B. This is not mandatory. Alternatively, first cavity 130A may comprise a different shape that is complementary to the shape of one or both of arrowheads 154B such as the circular shape of second cavity 130B. Similarly, second cavity 130B may be substantially circular in shape as depicted or may comprise a different shape that is complementary to one or both of arrowheads 154B.
Convexities 130F of first portion 132A of wall 132 define opening 130E. Opening 130E may be relatively smaller that a maximum transverse dimension of arrowheads 154B. Opening 130E may also be relatively larger than a minimum transverse dimension of arrowheads 154B, such as the transverse dimension at tip 154F, to allow tip 154F to be inserted into opening 130E. Similarly, neck cavity 130D may be relatively smaller than a maximum transverse dimension of arrowheads 154B and relatively larger than a minimum transverse dimension of arrowheads 154B, such as the transverse dimension at tip 154F, to allow tip 154F to be inserted into neck 130D.
In the first locked position of the illustrated embodiment, the extension of convexities 130F into concavities 154E secures or locks connection 135 by providing an obstacle that hinders first wall portions 132A from being moved away from one another and releasing second arrowhead 154B-2 and hinders first brace connector component 154 from being withdrawn from secondary retainer connector component 130 (e.g. in inward-outward direction 123).
At this point, first arrowhead 154B-1 has partially passed opening 130E and neck 132D is not able to completely snap back due to the force exerted by first arrowhead 154B-1 on opening 130E. Similar to with second arrowhead 154B-2, convexities 130F are shaped to complement similarly beveled surfaces 154C of first arrowhead 154B-1, thereby facilitating the insertion of first arrowhead 154B-1 into opening 130E of secondary retainer connector component 130 and the corresponding widening of opening 130E due to the deformation of first wall portions 132A.
As can be seen in
As the force pushing second arrowhead 154B-2 into contact with end 130H of second cavity 130B is removed, neck 132D and leg 154G may snap back (due to the resilient deformation), thereby forcing tapered surfaces 154C out of neck cavity 130D and thereby forcing first brace connector component 154 into a second locked position, as illustrated in
In the second locked position of the illustrated embodiment, convexities 130G, 130F engage concavities 154E. The extension of convexities 130F, 130G into concavities 154E secures or locks connection 135 by providing multiple obstacles that hinder first wall portions 132A, neck 132D and second wall portions 132B from being moved away from one another and releasing arrowheads 154 and thereby hinder first brace connector component 154 from being withdrawn from secondary retainer connector component 130 (e.g. in inward-outward direction 123). The second locked configuration is supplemented by restorative deformation forces applied to tapered surfaces 154C of first arrowhead 154B-1 by neck 132D
Referring back to
In the illustrated embodiment, first panel 140-1 is connected to a second panel 140-2 by a connection 165. In the illustrated embodiment, second panel 140-2 comprises a corner panel 140′. This is not mandatory. Second panel 140-2 may comprise a straight panel 140 or a corner panel 140′ as desired or based on the shape of multi-sided structure 12B. Second panel 140-2 is in turn connected to a third panel 140-3 which is in turn connected to a fourth panel 140-4—also a corner panel 140′—which is in turn connected to a fifth panel 140-5, each connected by connections 165. Fifth panel 140-5 is connected to a second retainer 110-2 (and optionally a brace 150), which is in turn mounted to existing structure 10 such that formwork apparatus 100 substantially surrounds surfaces 14B-1, 14B-2 and 14B-3 of three-sided structure 12B to form space 104 for receiving curable material such as concrete to form repair structure 102.
Corner panel 140′ is substantially similar to panel 140 except in that first panel connector component 160 of corner panel 140′ is arranged at an angle ϕ with respect to second panel connector component 170 or corner panel 140′ where angle ϕ is not zero or substantially equal to zero. For example, in the case of the illustrated embodiment, angle ϕ is equal to approximately 90°. This is not mandatory. Angle ϕ may be chosen based on a shape of multi-sided structure 12B. Moreover, any combination of panels 140 and corner panels 140′ may be employed to define a space 104 of a desired shape around multi-sided structure 12B. While panel 140′ is depicted as having a beveled corner 140A, this is not mandatory. Corner 140A may be square or rounded or shaped as desired.
Second retainer 110-2 is substantially like first retainer 110-1 except in that primary retainer connector component 120′ of second retainer 110-2 comprises a receptacle 122′ similar to receptacle 162, as discussed herein. In this way, panels 140 may be connected to first retainer 110-1 and second retainer 110-2 to form formwork apparatus 100 without adapters between retainer 110-1 (or retainer 110-2) and panels 140.
In some embodiments, it may be desirable to employ one or more standoffs to maintain alignment of panels 140 with respect to existing structure 10 and/or multi-sided structure 12B. In some embodiments, standoffs may be attached directly to existing structure 10 and/or multi-sided structure 12B and panels 140. In other embodiments, it is not practical and/or desirable to attach standoffs to existing structure 10 and/or multi-sided structure 12B.
Standoff 300 may comprise a longitudinally extending deformable section 310 which extends transversely between a first standoff connector component 320 and a second standoff connector component 330. In some embodiments, a longitudinal dimension of standoff 300 is approximately equal to the longitudinal dimension of panels 140. This is not mandatory. For example, in some embodiments, the longitudinal dimension of standoff 300 is smaller than the longitudinal dimension of panels 140. As shown in
First and second standoff connectors 320, 330 may be shaped to connect to component 142 of panel 140. In some embodiments, panel 140 comprises a connector component 142 in the form of a T-connector component sized and shaped to cooperate with a C or channel shaped standoff connector component 320, 330 of standoff 300. In some embodiments, a connection 340 is formed between first or second standoff connector component 320, 330 of standoff 300 and connector component 142 by sliding first or second standoff connector component 320, 330 in longitudinal direction 119 relative to connector component 142. In some embodiments, sliding first or second standoff connector component 320, 330 relative to connector component 142 comprises sliding T-connector component 142 into a channel 322 or channel 332 defined by first standoff connector component 320 or second standoff connector component 330 respectively. In some embodiments, first or second standoff connector component 320, 330 may be connected to connector component 142 by forcing them toward one another in transverse direction 121 and/or inward-outward direction 123 or by pivoting first or second standoff connector component 320, 330 relative to connector component 142. Connection 340 may comprise a snap-together connection, a friction fit connection, a displacement fit connection or the like.
As can be seen by comparing
When first and second connections 340-1, 340-2 are both formed, standoff 300 may retain at least some of the deformation caused during the formation of first and second connections 340-1, 340-2. In some embodiments, restorative deformation forces associated with restoring standoff 300 to its undeformed state (e.g. due to the resiliency or elastic nature of standoff 300) may cause at least some restorative deformation of standoff 300 to its undeformed state (e.g. to increase transverse dimension 350). Such restorative deformation forces may cause first and second standoff connectors 320, 330 to push against connectors 142 of panel 140 in positive and negative transverse directions 121 thereby increasing friction between first and second standoff connectors 320, 330 and connectors 142 of panel 140. Such increased friction may prevent or impede relative movement of standoff 300 and panel 140 in longitudinal direction 119. In some embodiments, such increased friction may be employed to locate standoff 300 at a desired position in longitudinal direction 119 relative to panel 140 without standoff 300 moving under, for example, the force of gravity or forces associated with curable material poured into space 104.
Once installed, standoff 300 may function to maintain a desired spacing between existing structure 10 and/or multi-sided structure 12B and panels 140 (e.g. standoff 300 may function to maintain space 104). Any number of standoffs 300 may be employed, as desired. In some embodiments, first standoff connector component 320 may be connected to a first panel 140-1 and a second standoff connector component 330 may be connected to a second panel 140-2 (not depicted). In some embodiments, standoff 300 may be connected to one or more panels 140 without substantial deformation of standoff 300.
In some embodiments, it may be desirable to provide an exterior surface of panels 140 and retainers 110 with a flush appearance. Consequently, connections and connector components may be inwardly offset from the plane of panels 140.
Stem 420A may be supported by one or more reinforcements 418. In some embodiments, reinforcements 418 may be located on an outer side of stem 420A and on an inner side of stem 420A, such as is depicted in
First panel connector component 460 comprises a receptacle 464A shaped to complement and receive protrusion 424A. Receptacle 464A comprises walls 464B, 464C each having a catch 462A, 462B extending into receptacle 464A at spaced apart locations to engage spaced apart barbs 422A, 422B of primary connector component 420. Receptacle 464A forms an opening 464D between catch 462B and a finger 462C. As barb 422A and catch 462A and barb 422B and catch 462B extend in similar orientations to one another, barbs 422A, 422B are able to slide past catches 462A, 462B as panel 440 moves relative to retainer 410 in direction 123. Once connection 425 is formed, barbs 422A, 422B extend into concavities behind catches 462A, 462B and catches extend into concavities behind barbs 422A, 422B, such that panel 440 is hindered from moving relative to retainer 410 in transverse direction 123. In some embodiments, barbs 422A, 422B and catches 462A, 462B have an angle of between 30 and 60 degrees relative to the plane of panel 440 and stem 420A of retainer 410.
As primary connector component 420 begins to engage first panel connector component 460, a tip 422F of protrusion 424A may first engage catch 462B of receptacle 464A. In the illustrated embodiment, tip 422F is slightly beveled in a direction similar to the extension of catch 462B to facilitate tip 422F sliding past catch 462B into 464D between catch 462B and finger 462C of receptacle 464A. In some embodiments, tip 422F may have an angle of between 0 and 45 degrees relative to stem 424B. In some embodiments, tip 422F may have an angle of between 5 and 20 degrees relative to stem 424B.
Catch 462B is displaced in direction 121 by tip 422F as barb 422A engages finger 462C of receptacle 464A. This displacement results in resilient deformation of wall 464B and expansion of opening 464D. The sliding of barb 422A over finger 462C is facilitated by barb 422A extending toward base 368 of protrusion 424A and away from tip 422F (i.e. in transverse direction 123) as barb 422A extends away from stem 424B. In some embodiments, the sliding of tip 422F and/or barb 422A past catch 462B and finger 462C may cause some resilient deformation of wall 464C and corresponding displacement of finger 462C in direction 121.
As the connection process moves past this intermediate stage, tip 422F and barb 422A contact catch 462A and barb 422B contacts catch 462B. The interaction between barb 422B and catch 462B and barb 422A and catch 462A may cause resilient deformation of both wall 464B and stem 424B in direction 121 and/or wall 464C in direction 121. This allows each of barbs 422A, 422B to move past catches 462A, 462B into receptacle 464A to form connection 425.
At about the same time, finger 462C of first panel connector component 460 begins to contact finger 422C of primary connector component 420 causing wall 464C to deform in direction 121 and/or finger 422C to deform until finger 422C enters concavity 462E first panel connector component 460. Together, finger 462C and concavity 462E provide a finger lock 463 between primary connector component 420 and first panel connector component 460. Finger lock 463 provides a relatively even external surface between panel 440 and retainer 410. An even surface between panel 440 and retainer 410 of connection 425 may provide a suitable surface for additional coverings such as paint, wallpaper, sealant and/or the like.
When connection 425 is completed, the interaction between barbs 422A, 422BA and catches 462A, 462B prevent primary connector component 420 from moving relative to first panel connector component 460 in transverse direction 123 and thereby disengaging from first panel connector component 460.
The particular elements and shape of the elements of primary connector component 420 and first panel connector component 460 may be varied in numerous ways. For example, the angle of barbs 422A, 422B and catches 462A, 462B may vary from 5 degrees to 85 degrees. Also, in some embodiments, barbs 422A, 422B and/or catches 462A, 462B may comprise surfaces that are rough, jagged, adhesive or the like to strengthen the engagement between barbs 422A, 422B and catches 462A, 462B. In some embodiments, barbs 422A, 422B and/or catches 462A, 462B may comprise hooks shaped to engage the corresponding barbs 422A, 422B and/or catches 462A, 462B. In some embodiments, finger lock 463 may comprise hooks, jagged surfaces, or other connection mechanisms. In some embodiments, finger lock 463 is not necessary.
While primary retainer connector component 420 is described as comprising a protrusion 424A, this is not mandatory. Instead, a primary retainer connector component 420′ of a retainer 410′ may, for example, comprise a receptacle similar to receptacle 464A of first panel connector component 460 as shown in
Retainers 510, 510′ and panel 540 are substantially similar to retainers 410, 410′ and panel 440, except as described below. For example, primary connector component 520 of retainer 510 may comprise a securing protrusion 564E and a tab 564F. Similarly, second panel connector component 570 of panel 540 may also comprise a securing protrusion and tab similar to securing protrusion 564E and tab 564F. Connection 525 and connections between first and second panel connector components 560, 570 are formed in substantially the same way as connection 425 described above, except as follows.
During the formation of connection 525 and as protrusion 524A is extended further into receptacle 564A, tip 522F engages securing protrusion 564E. In the illustrated embodiment, securing protrusion 564E is shaped as an indentation in wall 564B, which may facilitate the resilient deformation of wall 564B by providing an area more susceptible to bending (i.e. resilient deformation). Also, securing protrusion 564E may force stem 524B in direction 121 to help catch 562B engage barb 522B when connection 525 is made. In other embodiments, securing protrusion 564E may be provided by a thickening of wall 564B and a corresponding protrusion which extends into receptacle 564A.
When connection 525 is completed, the interaction between barbs 522B, 522A and catches 562A, 562B prevent first connector panel component 560 from moving relative to primary connector component 520 in transverse direction 123 and thereby disengaging primary connector component 520. Also, securing protrusion 564E may prevent barb 522A from slipping over catch 562B if, for example, retainer 510 and panel 540 are bent relative to one another. As mentioned, securing protrusion 564E applies a restorative deformation force in direction 121 to stem 524B, thereby hindering disengagement of barb 522A and catch 562B.
In some embodiments, securing protrusion 564E may extend from wall 564B (as opposed to being an indentation thereof as shown in, for example,
Tab 564F may be located proximate catch 562A at an end of wall 564B. Tab 564F allows for connection 525 to be disengaged by permitting a user to apply a force in direction 121 to tab 564F, causing resilient deformation of wall 564B and allowing barbs 522A, 522B to be disengaged from catches 562A, 562B. Once barbs 522A, 522B are disengaged from catches 562A, 562B, protrusion 542A may be removed from receptacle 564A, finger lock 563 may be disengaged and primary connector component 520 may be disengaged from first panel connector component 560.
In some embodiments, it may not be possible or desirable to mount a retainer to surface 14A of wall 12A, as discussed herein. For example, where wall 12A and multi-sided structure 12B are co-terminal, as shown in
While retainer 110 (and other retainers described herein such as retainer 410, 410′, 510, 510′, etc.) may be suitable to be attached to edge surface 14C, in a manner similar to that shown in
Any of the retainers described herein may be reinforced by extending the base (e.g. base 112, 412, etc.) past the primary retainer connector component (e.g. primary retainer connector component 120, 420, 520, etc.) and past any reinforcements (e.g. reinforcement 418, 518, etc.). The extension of the base may allow for additional fasteners and/or for additional braces 150 to be employed. Such additional fasteners and/or additional braces may be located outside of space 104.
An outside secondary retainer connector component 630-2 may be provided on base extension 612A. Outside secondary retainer connector component 630-2 may be substantially similar to secondary retainer connector component 130 except that it is located outside of space 104. By attaching a brace 150 from outside secondary retainer connector component 630-2 to a panel (e.g. panel 140, 440, etc.) or a corner panel (e.g. corner panel 140′) as shown in
Additional apertures 614 may be defined by base extension 612A to allow additional fasteners 50 to attach retainer 610 to edge surface 14C. Such additional fasteners 50 may prevent retainer 610 from detaching from edge surface 14C due to, for example, gravity when wall 12A is a ceiling and multi-sided structure 12B protrudes downward from wall 12A.
In the illustrated embodiment, tool 800 comprises handles 802A, 802B which are connected to arms 804A, 804B, respectively. Arms 804A, 804B are pivotally coupled to each other by pivot joint 806. Arm 804A is connected to tool head 808A. Arm 804B is connected to tool head 808B. Tool head 808A has a roller 810A and tool head 808B has a roller 810B. Rollers 810A, 810B may be attached to tool heads 808A, 808B respectively by suitable bearings, bushings or the like to allow rotation of rollers 810A, 810B. The pivoting action of tool 800 about pivot joint 806 is not necessary. In some embodiments, tool 800 may comprise some other mechanism of forcing tool heads 808A, 808B toward one another.
Referring to
Tool 800 may be used to form connection 465 (or connection 425) by carrying out the following steps: (1) move a pair of panels 440 (or retainer 410 and panel 440) into proximity with one another such that first panel connector component 460 is adjacent to and aligned with second panel connector component 470; (2) position tool 800 such that roller 810B engages a portion of first panel connector component 460 and roller 810A engages a portion of second panel connector component 470; (3) squeeze or otherwise move handles 802A, 802B, toward one another so that roller 810A moves closer to roller 810B, thereby pushing second panel connector component 470 into first panel connector component 470 (see, for example,
In some embodiments, tool head 808A may be pivotal about pivot 812A to allow pivoting of tool head 808A relative to arm 804A, and tool head 808B may be pivotal about pivot 812B to allow pivoting of tool head 808B relative to arm 804B to aid in allowing a user to slide tool 800 in longitudinal direction 119 by providing more ergonomic access to handles 802A, 802B—especially when handles 802A, 802B are above a user's shoulders or below a user's waist. Such optional pivoting motion of tool heads 808A, 808B is best seen by comparing
In some embodiments, the tool heads (i.e. tool heads, 808A, 808B) are attached to a pre-existing set of pliers. In some embodiments, the arms of tool 800 are attached by a bias mechanism (such as, for example, a spring) to bias the tool heads toward a spaced apart relationship. In some embodiments, a locking mechanism is provided that may overcome the bias mechanism when the tool heads abut (e.g. similar to a locking pliers tool). Tools 800 are not restricted to being used with the panels discussed therewith but may be used with other types of connector components and other panels described herein.
Processes, methods, lists and the like are presented in a given order. Alternative examples may be performed in a different order, and some elements may be deleted, moved, added, subdivided, combined, and/or modified to provide additional, alternative or sub-combinations. Each of these elements may be implemented in a variety of different ways. Also, while elements are at times shown as being performed in series, they may instead be performed in parallel, or may be performed at different times. Some elements may be of a conditional nature, which is not shown for simplicity.
Where a component (e.g. a connector component, etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e. that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.
Those skilled in the art will appreciate that directional conventions such as “vertical”, “transverse”, “horizontal”, “upward”, “downward”, “forward”, “backward”, “inward”, “outward”, “vertical”, “transverse” and the like, used in this description and any accompanying claims (where present) depend on the specific orientation of the apparatus described. Accordingly, these directional terms are not strictly defined and should not be interpreted narrowly.
Unless the context clearly requires otherwise, throughout the description and any claims (where present), the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, that is, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling or connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import, shall refer to this document as a whole and not to any particular portions. Where the context permits, words using the singular or plural number may also include the plural or singular number respectively. The word “or,” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. For example:
The invention disclosed herein has a number of aspects that include, without limitation, the following aspects.
42. A method according to aspect 41 or any other aspect herein wherein coupling the first standoff connector component to the third connector component of the ith panel comprises sliding the first standoff connector component in a longitudinal direction relative to the third panel connector component of the ith panel to form a first panel-standoff connection.
While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended aspects and aspects hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations and the scope of the aspects should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.
This application is a continuation of Patent Cooperation Treaty (PCT) application No. PCT/CA2020/050172 filed 7 Feb. 2020 which in turn claims the benefit of the priority of U.S. patent application No. 62/803,301 filed 8 Feb. 2019 which is hereby incorporated herein by reference. Both of the applications referred to in the paragraph are herein incorporated herein by reference.
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| Number | Date | Country | |
|---|---|---|---|
| 20210355697 A1 | Nov 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62803301 | Feb 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/CA2020/050172 | Feb 2020 | US |
| Child | 17390724 | US |
