The technology disclosed herein relates to form-work systems for fabricating structures from concrete or other curable construction materials. Particular embodiments provide stay-in-place formwork panels, systems for modular stay-in-place formworks and methods for providing such modular stay-in-place formworks which include anti-deformation panels.
It is known to fabricate structural parts for building walls from concrete using modular stay-in-place forms. Examples of such modular stay in place forms include those described in US patent publication No. 2005/0016103 (Piccone) and PCT publication No. WO96/07799 (Sterling). A representative drawing depicting a partial form 28 according to one prior art system is shown in top plan view in
Form 28 includes support panels 36A which extend between, and connect to each of, wall segments 27, 29 at transversely spaced apart locations. Support panels 36A include male T-connector components 42 slidably received in the receptacles of female C-connector components 38 which extend inwardly from inwardly facing surfaces 31A or from female C-connector components 32. Form 28 comprises tensioning panels 40 which extend between panels 30 and support panels 36A at various locations within form 28. Tensioning panels 40 include male T-connector components 46 received in the receptacles of female C-connector components 38.
In use, form 28 is assembled by slidable connection of the various male T-connector components 34, 42, 46 in the receptacles of the various female C-connectors 32, 38. Liquid concrete is then introduced into form 28 between wall segments 27, 29. The concrete flows through apertures (not shown) in support panels 36A and tensioning panels 40 to fill the interior of form 28 (i.e. between wall segments 27, 29). When the concrete solidifies, the concrete (together with form 28) provide a structural component (e.g. a wall) for a building or other structure.
A problem with prior art systems is referred to colloquially as “pillowing”. Pillowing refers to the outward deformation of wall panels 30 due to the weight and corresponding outward pressure generated by liquid concrete when it is introduced into form 28. Pillowing may be reduced to some degree by support panels 36A and tensioning panels 40 which connect to wall panels 30 at female C-connector components 38. Despite the presence of support panels 36A and tensioning panels 40 and their connection to wall panels 30 at connector components 38, wall panel 30 may still exhibit pillowing. By way of example, pillowing may occur in the regions of panels 30 between support panels 36A, tensioning panels 40 and their corresponding connector components 38.
Another problem with prior art systems is referred to colloquially as “bellying”. Bellying refers to another type of outward deformation of wall panels due to the weight and corresponding pressure generated by liquid concrete when it is introduced into form 28. Bellying typically occurs near the middle of the vertical dimension of a wall formed from concrete. In contrast to pillowing, which creates convexities along the transverse dimensions of panels 30 (as shown in
Deformation of panels due to the weight of liquid concrete can lead to a number of related problems including, without limitation, unsightly wall appearance, panel fatigue, reduction in structural integrity and/or the like.
There is accordingly a general desire to provide modular stay-in-pace formwork components that minimize and/or otherwise reduce (in relation to the prior art) outward deformation of panels under the weight of liquid concrete.
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 formwork apparatus for forming a concrete structure comprising a plurality of elongated panels comprising connector components at their transverse edges for connecting to one another in edge-adjacent relationship. Each one of the elongated panels comprises an outer surface that extends between its transverse edges and an inner surface that extends between its transverse edges at a location inwardly spaced apart from the outer surface. The inner surface comprises one or more inwardly projecting convexities that extend between the transverse edges. The inwardly projecting convexities may comprise arcuate-shaped surfaces. The inwardly projecting convexities may comprise a plurality of transversely adjacent convexities. There may be brace elements that extend part way between, or all the way between, the outer and inner surfaces.
In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.
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.
In drawings 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 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.
Particular embodiments of the invention provide a formwork apparatus for forming a concrete structure comprising a plurality of elongated panels comprising connector components at their transverse edges for connecting to one another in edge-adjacent relationship. Each one of the elongated panels comprises an outer surface that extends between its transverse edges and an inner surface that extends between its transverse edges at a location inwardly spaced apart from the outer surface. The inner surface comprises one or more inwardly projecting convexities that extend between the transverse edges. The inwardly projecting convexities may comprise arcuate-shaped surfaces. The inwardly projecting convexities may comprise a plurality of transversely adjacent convexities. There may be brace elements that extend part way between, or all the way between, the outer and inner surfaces.
In the illustrated embodiment of
Panels 102, support members 104 and tensioning members 106 may be fabricated from a lightweight and resiliently and/or elastically deformable material (e.g. a suitable plastic) using an extrusion process. By way of non-limiting example, suitable plastics include: poly-vinyl chloride (PVC), acrylonitrile butadiene styrene (ABS) or the like. In other embodiments, panels 102, support members 104 and/or tensioning members 106 may be fabricated from other suitable materials, such as steel or other suitable alloys, for example. Although extrusion is the currently preferred technique for fabricating panels 102, support members 104 and tensioning members 106, other suitable fabrication techniques, such as injection molding, stamping, sheet metal fabrication techniques or the like may additionally or alternatively be used.
Panels 102 are elongated in longitudinal directions 120 and extend in transverse directions 122. In the illustrated embodiment, panels 102 have a substantially similar transverse cross-section along their entire longitudinal dimension, although this is not necessary. In general, panels 102 may have a number of features which differ from one another as explained in more particular detail below. The transverse edges 118 of panels 102 comprise connector components 118A which are connected to complementary connector components 124A at the inner and outer edges 124 of support members 104 so as to connect panels 102 in edge-adjacent relationship and to thereby provide wall segments 126, 128 of formwork 100. Support members 104 connect in this manner to an edge-adjacent pair of panels 102 at both inner and outer edges 124 of support members 104 to provide connections 130. In the illustrated embodiment, connector components 118A of panels 102 comprise female C-shaped connector components 118A which are complementary to male T-shaped connector components 124A of support members 104. In this manner, male T-shaped connector components 124A may be slidably received in female C-shaped connector components 118A by relative longitudinal movement between support members 104 and panels 102.
In other embodiments, connector components 118A, 124A may be different than those shown in the illustrated embodiment and may connect to one using techniques other than relative sliding, such as, by way of non-limiting example, deformable “snap-together” connections, pivotal connections, push on connections and/or the like. In some embodiments, panels 102 may be provided with male connector component and support members 104 may comprise female connector components.
Each of the panels 102 of the illustrated embodiment, comprises an outer surface 114 which faces an exterior of its associated formwork wall segment 126, 128 and an inner surface 116 which faces an interior of its associated formwork wall segment 126, 128. In the illustrated embodiment, outer surface 114 is substantially flat, although in other embodiments, outer surface 114 may be provided with desired shapes (e.g. corrugation or the like). Inner surface 116, however, has an arcuate shape as it extends between transverse edges 118 of panel 102 to provide an inward facing surface which is convex between transverse edges 118.
Extending between outer surface 114 and inner surface 116, panel 102 comprises a plurality of brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B. As best seen in the top plan view of
In the illustrated embodiment, a pair of slightly different panels 102A, 102B are used to provide outside corner 112B.
Support members 104 of the illustrated embodiment may comprise optional additional connector components 144 for connecting to optional tensioning members 106. In the illustrated embodiment, connector components 144 comprise T-shaped male connector components 144 that may be slidably received in complementary C-shaped female connector components 150 of tensioning members 106. This is not necessary. In other embodiments, connector components 144, 150 of support members 104 and tensioning members 106 may comprise any of the types of connector components described above in relation to connector components 118A, 124A. Support members 104 comprise a number of apertures 146, 148 which permit a flow of liquid concrete therethrough. Similarly, tensioning members 106 comprise apertures 152 which permit a flow of liquid concrete therethrough.
In the illustrated embodiment, a slightly different support member 104A is used to provide inside corner 112A.
In the illustrated embodiment, tensioning member 106 is also used to help provide strength to inside corner 112A by connecting between connector components 144 of the orthogonal pair of support members 104, 104A. In other embodiments, tensioning member 106 is not required. In the illustrated embodiment, tensioning members 106 are not used in straight wall segments 126, 128 of formwork 100. This is not necessary, however. In other embodiments, inner surfaces 116 of panels 102 may be provided with suitable connector components, so that tensioning members 106 may be connected between support members 104 and panels 102—e.g. in a manner similar to tensioning members 40 connecting between support members 36 and panels 30 (
In operation, formwork 100 is assembled as describe above by: connecting panels 102 in edge-adjacent relationships using connections 130 between edge-adjacent panels 102 and corresponding support members 104; connecting panels 102A, 102B to provide any outside corners 112B; and connecting support members 104, 104A, panels 102 and optionally tensioning members 106 to one another to provide any inside corners 112A. Ends of wall segments (e.g. wall segments 126, 128) may be finished with end panels (not shown) which may be similar to support members 104, except without apertures 146, 148 and with connector components 124A, 144 on one side only. In other embodiments, such end panels are not required and ends of wall segments may be finished with conventional removable formwork components (e.g. reinforced plywood). Once formwork 100 is assembled, concrete (or some other suitable curable construction material) is introduced into an interior 160 of formwork 100—e.g. between inner surfaces 116 of opposing panels 102 of opposing formwork wall segments 126, 128. Pressure caused by the weight of the liquid concrete in interior region 160 will exert outward force on inner surfaces 116 of panels 102—for example in the directions indicated by arrows 162.
However, the configuration of panels 102 (including the shape of inner surface 116 and the orientations of brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B) may tend to reduce the deformation of panels 102 (or at least the deformation of outer surfaces 114 of panels 102) relative to that of prior art panels. More particularly, the convex (and arcuate convex) shape of inner surface 116 may form an arcuate quasi-truss configuration which tends to redirect outward forces to the transverse edges of panels 102, but since panels 102 are held firmly by support members 104 at their transverse edges, this redirection of outward forced may result in relatively little deformation of outer surfaces 114 of panels 102. Additionally, within panels 102 (i.e. between inner surface 116 and outer surface 114), adjacent brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B themselves have transverse cross-sections that are triangular in nature and provide a series of transversely-adjacent longitudinally-extending truss configurations. In addition, the non-parallel, non-orthogonal and angularly diverse orientation of brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B may tend to re-direct outward forces received on inner surfaces 116 so that such forces become oriented relatively more transversely when they are received in outer surfaces 114. However, because of the non-parallel nature of brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B, the redirection of these forces are at non-parallel orientations. Further, inner surfaces 116 may be able to deform into the spaces between the contact regions of brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B). Another advantage of brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B is that they may provide surface 114 with strength against deformation caused by any external force oriented toward interior 160.
In addition to the truss like characteristics of outer surfaces 114, inner surfaces 116 and brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B of panels 102, these features may also provide some insulating properties which may reduce the rate of transfer of heat across panels 102 relative to prior art panels. In some instates, the spaces between outer surfaces 114, inner surfaces 116 and brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B of panels 102 may be filled with insulation which may further enhance this insulation effect.
Once introduced into interior 160 of formwork 100, the concrete (or other suitable curable construction material) is permitted to solidify. The result is a structure (e.g. a wall) that has its surfaces covered by stay-in-place formwork 100 (e.g. panels 102).
A number of modifications may be provided to formwork 100 and, more particularly, to panels 102. A number of such modifications are described below.
Formwork 200 includes support members 104, 104A and optional tensioning member 106 that are substantially identical to those described above for formwork 100. Formwork 200 also comprises panels 202, 202A, 202B (generally, panels 202) connected (through support members 104) to one another in edge-adjacent relationship at connections 230. Panels 202 differ slightly from panels 102 as described in more detail below.
In addition to providing anchoring features 206, anchor components 204 may be sized and/or shaped to permit stacking of panels 202 for storage and shipping. More particularly, anchor components 204 may be sized and/of shaped such that the innermost extent 208 of anchor components 204 is co-planar with an apex 210 of the convexity of inner surface 216 in a plane substantially parallel to outer surface 214. For example, as shown in
Referring to
Anchor components 204 may be varied in a number of ways while still providing anchoring features 206 and innermost extents 208 having the features described above.
In the illustrated embodiment, panel 302 comprises one set of interior connector components 304 between a corresponding pair of inner-surface convexities 306. It will be appreciated, however, that panels may be provided with different numbers (e.g. pluralities) of sets of connector components 304 between corresponding pairs of adjacent inner-surface convexities 306. The additional connection(s) to support member(s) 104 at locations away from the transverse edges of panels 302 may provide greater strength to formworks constructed using panels 302 or may permit panels 302 to be provided with greater transverse widths (e.g. in direction 122) while providing the same strength and may thereby help to further reduce panel deformation.
Each of inner-surface convexities 306 is similar to inner surface 116 of panel 102 described above and comprises an apex 308A, 308B (collectively, apexes 308). Inner-surface convexities 306 differ from inner surface 116 of panel 102 in that each of inner surface convexities only extent partially across the transverse width of panel 302 (e.g. between edge 118 and interior connector component 304 in the illustrated embodiment). Panel 302 also comprises brace elements 310A, 310B, 312A, 312B (collectively, brace elements 310, 312) which extend between outer surface 114 and each of inner-surface convexities 306 at angles that are non-orthogonal to outer surface 114 and non-parallel with one another. Brace elements 310, 312 of panel 302 differ from the brace elements of panel 102 in that each set of brace elements 310, 312 is symmetric about a notional plane 314A, 314B (collectively, notional planes 314) that corresponds to (and extends through) the apex 308 of its corresponding inner surface convexity 306. In the illustrated embodiment, panel 302 comprises a symmetric pair of brace elements 310, 312 for each inner-surface convexity 306. In other embodiments, however, panel 302 may comprise any suitable number of symmetric pairs of brace elements for each inner-surface convexity.
In other respects, panel 302 may be similar to panel 102 described above.
In other respects, panel 332 may be similar to panel 302 described above.
In other respects, panel 342 may be similar to panel 332 described above.
When a formwork comprising panels 362 is filled with concrete, cantilevered inner-surface components 362, 364 may deform outwardly under the outward pressure caused by the weight of liquid concrete—see the outward directions of arrows 162 in
In other respects, panel 360 may be similar to panel 352 described above.
In the illustrated embodiment of
In the illustrated embodiment, panels 370, 380 each comprise one centrally located connector component 304 and a pair of pluralities (e.g. a group of 2 in the case of panel 370 and a group of 3 in the case of panel 380) of inner-surface convexities (374, 376 in the case of panel 370 and 382, 384, 386 in the case of panel 380). In other embodiments, panels similar to panels 370, 380 may be provided with different numbers (e.g. pluralities) of connector components 304, with each connector component 304 located between a pair of pluralities of inner-surface convexities. In such embodiments, a particular plurality of inner-surface convexities may extend transversely between a pair of connector components 304 (rather than between a connector component 304 and one of edges 118).
In other respects, panels 370, 380 may be similar to panel 322 described above.
In other respects, panel 396 may be similar to panel 102 described above.
In the illustrated embodiment of
Panels 402, support members 404 and corner connector members 406 may be fabricated from materials and using processes similar to those described above for panels 102, support members 104 and tensioning members 106.
Panels 402 are elongated in longitudinal directions 420 and extend in transverse directions 422. In the illustrated embodiment, panels 402 have a substantially similar transverse cross-section along their entire longitudinal dimension, although this is not necessary. In general, panels 402 may have a number of features which differ from one another as explained in more particular detail below. The opposing transverse edges 418 of panels 402 comprise complementary connector components 418A, 418B, which connect directly to one another (as opposed to through a support member 404) to provide connections 430 which connect panels 402 in edge-adjacent relationship and to thereby provide wall segments 426, 428 of formwork 400.
In the illustrated embodiment, female engagement portion 492 of connector component 418A comprises a pair of projecting arms 474A, 474B (collectively, arms 474) which are shaped to provide a principal receptacle 471 and hooks 476A, 476B (collectively, hooks 476). In the illustrated embodiment, male engagement portion 496 of connector component 418B comprises a splayed protrusion 469 comprising a pair of projecting fingers 470A, 470B (collectively, fingers 470) which are shaped to provide hooks 472A, 472B (collectively, hooks 472). When connection 430 is made, fingers 470 are inserted into principal receptacle 471 and may project into the concavities of hooks 476. Similarly, arms 474 may project into the concavities of hooks 472. With this configuration, hooks 472, 476 of engagement portions 492, 496 engage one another to form connection 430.
Abutment portion 494 of connector component 418A comprises an abutment surface 482 which is complementary to, and abuts against, abutment surface 480 of abutment portion 498 of connector component 418B when connection 430 is made. In the illustrated embodiment, abutment surface 480 is bevelled at an angle α with respect to exterior surface 414 of its corresponding panel 402 and abutment surface 482 is bevelled at an angle β with respect to exterior surface 414 of its corresponding panel 402. We may define an angle θmax to be the sum of the bevel angles α, β. When connection 430 is made, θmax also represents the interior angle between the exterior surfaces 414 of panels 402, provided that there is no deformation of panels 402 or connector components 418A, 418B. In the illustrated embodiment, α≈135° and β≈45° so that θmax≈180°.
In other embodiments, it may be desirable that the value of θmax be something other than 180°. For example, in some cases where it is desired that panels 402 join together to provide a convex surface (e.g. a curved wall where outer surfaces 414 of panels 402 form a convex surface across connection 430), the value of be less than 180° (e.g. in a range between 160° and 179°). Conversely, in some cases where it is desired that panels 402 join together to provide a concave surface (e.g. a curved wall where outer surfaces 414 of panels 402 form a concave surface across connection 430), the value of θmax be greater than 180° (e.g. in a range between 181° and 200°).
In some embodiments, it may be desirable to provide θmax with a value that is less than the desired ultimate angle θdesired between outer surfaces 414 of panels 402. This may be accomplished, for example, by providing interior bevel angle β and/or interior bevel angle α of the abutment surfaces at other angles such that the sum of interior bevel angle β and interior bevel angle α (i.e. θmax) is less than the desired ultimate angle θdesired. In some embodiments, θmax (the sum of bevel angles α, β) may be designed to be in a range of 95-99.5% of the value of the desired ultimate angle θdesired. In still other embodiments, θmax may be in a range of 97-99.5% of the value of the desired ultimate angle θdesired. Since θmax represents the sum of the bevel angles α and β, it will be appreciated that selection of a value for θmax may be accomplished by varying either or both of bevel angles α and β.
Obtaining the desired ultimate angle θdesired may involve forcing abutment surfaces 480, 482 into one another or otherwise applying force to panels 402, such that the force causes deformation of panels 402 (or more particularly, connector components 418A, 418B) and so that the interior angle between panels 402 across connection 430 increases from θmax to θdesired. Such force may be applied when support members 404 are connected to panels 402 or by the weight of liquid concrete, for example. Under such forces, the angle between the exterior surfaces 414 of panels 402 changes from θmax to a value closer to the desired ultimate angle θdesired. Accordingly, selecting a value of θmax<θdesired may effectively result in an angle between the exterior surfaces 414 of panels 402 that is closer to θdesired (after the application of force and the corresponding deformation of panels 402 and/or connector components 418A, 418B).
Providing a value of θmax<θdesired may involve an application of force which increases the sealing force between connector components 418A, 418B of panels 402—e.g. pulling the hooks 476 of engagement portion 492 of connector component 418A toward, and into more forceful engagement with, the hooks 472 of engagement portion 496 of connector component 418B, thereby increasing the sealing force between connector components 418A, 418B of panels 492. Further the application of force to cause an increase from θmax to θdesired will include outward components which create torques which tend to push abutment surfaces 482, 480 toward, and into more forceful engagement with one another.
In other embodiments, connector components 418A, 418B may be different than those shown in the illustrated embodiment and may connect to one using techniques other than relative sliding, such as, by way of non-limiting example, deformable “snap-together” connections, pivotal connections, push on connections and/or the like.
Each of the panels 402 of the illustrated embodiment, comprises an outer surface 414 which faces an exterior of its associated formwork wall segment 426, 428 and an inner surface 416 which faces an interior of its associated formwork wall segment 426, 428. In the illustrated embodiment, outer surface 414 and inner surface 416 are respectively substantially similar to outer surface 114 and inner surface 116 of panel 102 described above. Extending between outer surface 414 and inner surface 416, panel 402 comprises a plurality of brace elements 432A, 432B, 434A, 434B, 436A, 436B, 438A, 438B, 440A, 440B. Brace elements 432A, 432B, 434A, 434B, 436A, 436B, 438A, 438B, 440A, 440B of panels 402 may be substantially similar to brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B of panels 102 described above.
Panels 402 of the illustrated embodiment also comprise connector components 419 for connection to complementary connector components 424A at the inner and outer ends 424 of support members 404. In the illustrated embodiment, connector components 419 of panels 402 are located adjacent to connector components 418A and, consequently, connections between panels 402 and support members 404 are located adjacent to connector components 418A. In the illustrated embodiment, connector components 419 comprise female C-shaped connector components for slidably receiving male T-shaped connector components 424A of support members 404. This is not necessary, however, and in other embodiments, connector components 419, 424A may be different than those shown in the illustrated embodiment and may connect to one using techniques other than relative sliding, such as, by way of non-limiting example, deformable “snap-together” connections, pivotal connections, push on connections and/or the like.
Panels 402 also comprise connector component reinforcement structures 421 which reinforce connector components 419 and 418A and provide panels 402 with additional stiffness and resistance to deformation in the region of connector components 419 and 418A. In the illustrated embodiment, connector component reinforcement structures 421 are rectangular shaped comprising inward/outward members 421A, 421B and transverse members 421C, 421D, although this is not necessary. In other embodiments, connector component reinforcement structures 421 could be provided with other shapes, while performing the same or similar function. For example, connector component reinforcement structures 421 could be made to have one or more non-orthogonal and non-parallel brace elements (e.g. similar to brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B described above) or connector component reinforcement structures 421 could be made to have one or more orthogonal and parallel brace elements (e.g. similar to brace elements 334A, 334B, 336A, 336B described above).
Accordingly, formwork 400 differs from formwork 100 in that panels 402 comprise complementary connector components 418A, 418B so as to be able to connect directly to one another in edge-adjacent relationship (i.e. without intervening support members). Furthermore, panels 402 of formwork 400 comprise connector components 419 which connect to complementary connector components 424A of support members 404, so that panels 402 connect to support members 404 at locations away from the transverse edges 418 of panels 404. Still further, panels 402 of formwork 400 comprise connector component reinforcement structures 421 which reinforce connector components 419 and 418A and provide panels 402 with additional stiffness and resistance to deformation in the region of connector components 419 and 418A.
In the illustrated embodiment, a slightly different panel 402A is used to provide outside corner 412B.
In the illustrated embodiment, a corner connector member 406 is used to provide inside corner 412A.
Corner connector member 406 also comprises a connector component reinforcement structure 429 which, in the illustrated embodiment, is similar to connector component reinforcement structure 421 described herein, except that connector component reinforcement structure 429 reinforces connector components 423, 425 and 427 of corner connector member 406. Connector component reinforcement structure 429 may have features similar to connector component reinforcement structure 421 described herein. While inside corner 412A is shown as a 90° (orthogonal corner), this is not necessary. Those skilled in the art will appreciate that corner connector member 406 could be modified to provide an inside corner having a different angle.
In operation, formwork 400 is assembled as describe above by connecting panels 402 to one another in edge-adjacent relationships using connector components 418A, 418B; connecting support members 404 to panels 402 using connector components 419, 424A; connecting panels 402, 402A to provide any outside corners 112B; and connecting corner connector members 406, panels 402 and support members 404 to one another to provide any inside corners 112A. Ends of wall segments (e.g. wall segments 426, 428) may be finished with end panels (not shown) which may be similar to support members 404, except without apertures 446, 448 and with connector components 424A on one side only. In other embodiments, such end panels are not required and ends of wall segments may be finished with conventional removable formwork components (e.g. reinforced plywood). Once formwork 400 is assembled, concrete (or some other suitable curable construction material) is introduced into an interior 460 of formwork 400—e.g. between inner surfaces 416 of opposing panels 402 of opposing formwork wall segments 126, 128. Pressure caused by the weight of the liquid concrete in interior region 460 will exert outward force on inner surfaces 416 of panels 402—for example in the directions indicated by arrows 462.
However, the configuration of panels 402 (including the shape of inner surface 416 and the orientations of brace elements 432A, 432B, 434A, 434B, 436A, 436B, 438A, 438B, 440A, 440B) may tend to reduce the deformation of panels 402 (or at least the deformation of outer surfaces 414 of panels 402) relative to that of prior art panels in a manner similar to the shape of inner surface 116 and the orientations of brace elements 132A, 132B, 134A, 134B, 136A, 136B, 138A, 138B, 140A, 140B described above.
Once introduced into interior 460 of formwork 400, the concrete (or other suitable curable construction material) is permitted to solidify. The result is a structure (e.g. a wall) that has its surfaces covered by stay-in-place formwork 400 (e.g. panels 402).
Formwork 500 includes support members 104 that is substantially identical to those described above for formwork 100. Formwork 500 also comprises panels 502 which are similar to panels 402 described above and comprise complementary connector components 518A, 518B at their transverse edges 518 which are similar to complementary connector components 418A, 418B described above and which provide direct connections 530 between edge-adjacent panels 502.
When connection 530 is made, abutment portion 594, 598 abut against one another. More particularly, abutment surface 582 of connector component 518A abuts against abutment surface 580 of connector component 518B when connection 530 is made. Abutment surfaces 580, 582 may comprise features (including bevel angles α, β and their relationship to the maximum angle θmax and the desired ultimate angle θdesired) which are substantially similar to the features of abutment surfaces 480, 482 described herein.
In other respects, formwork 500 may be similar to formworks 100, 400 described herein.
Formwork 600 comprises panels 602 having outer surfaces 614 and inner surfaces 616 and which connect directly to one another by engagement between connector components 618A, 618B. Formwork 600 also comprises support members 604. Formwork 600 differs from formwork 400 in that support members 604 comprise connector components 624A which have hooked shapes for engaging complementary hook-shaped connector components 619 on panels 602. These hook-shaped connector components 624A, 619 may be stronger than those of formwork 400. To accommodate the extra depth of hook-shaped connector components 619, connector component reinforcement structure 621 of panel 602 may have dimensions that are smaller than those of connector component reinforcement structure 421. In other respects, formwork 600 may be similar to formwork 400 described herein.
Although the operations of the method(s) herein are shown and described in a particular order, the order of the operations of each method may be altered so that certain operations may be performed in an inverse order or so that certain operation may be performed, at least in part, concurrently with other operations. In another embodiment, instructions or sub-operations of distinct operations may be in an intermittent and/or alternating manner.
Where a component (e.g. a panel, a support member, 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 accompanying 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:
This application claims priority from U.S. application No. 61/563,594 filed on 24 Nov. 2011. U.S. application No. 61/563,594 is hereby incorporated herein by reference.
Filing Document | Filing Date | Country | Kind |
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PCT/CA2012/050849 | 11/23/2012 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2013/075250 | 5/30/2013 | WO | A |
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