U.S. patent application number 10/082933 was filed with the patent office on 2002-08-29 for corner panel of a form system.
This patent application is currently assigned to ECO-BLOCK. Invention is credited to Moore, James D. JR..
Application Number | 20020116890 10/082933 |
Document ID | / |
Family ID | 23037254 |
Filed Date | 2002-08-29 |
United States Patent
Application |
20020116890 |
Kind Code |
A1 |
Moore, James D. JR. |
August 29, 2002 |
Corner panel of a form system
Abstract
A panel connector is disclosed that is used to make a corner in
a wall system and a method of installing that component. The panel
connector defines two channels into which respective portions of
two side panels are inserted, in which the side panels usually
serve as forms or walls in forming concrete wall structures. The
panel connectors form a corner between the two side panels so that
those side panels having a predetermined angle therebetween. It is
noted that this abstract is provided to comply with the rules
requiring an abstract that will allow a searcher or other reader to
ascertain quickly the subject matter of the technical disclosure.
The abstract is submitted with the understanding that it will not
be used to interpret or limit the scope or meaning of the claims
pursuant to 37 C.F.R. .sctn.1.72(b).
Inventors: |
Moore, James D. JR.; (Ft.
Lauderdale, FL) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
ECO-BLOCK
|
Family ID: |
23037254 |
Appl. No.: |
10/082933 |
Filed: |
February 26, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60271827 |
Feb 27, 2001 |
|
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Current U.S.
Class: |
52/578 |
Current CPC
Class: |
E04B 2/8635 20130101;
E04B 2002/867 20130101; E04F 19/02 20130101 |
Class at
Publication: |
52/578 |
International
Class: |
E04C 003/00 |
Claims
What is claimed is:
1. A panel connector, comprising: a. a first channel including a
back wall having two opposed ends and including two side walls
having two opposed edges, in which one edge of each side wall
connects to one respective end of the back wall to form the first
channel that is of a size to receive a portion of a first side
panel therein; b. a second channel including a back wall having two
opposed ends and including two side walls having two opposed edges,
in which one edge of each side wall connects to one respective end
of the back wall to form the second channel that is of a size to
receive a portion of a second side panel therein; and c. means for
positioning the first and second channels adjacent each other.
2. The panel connector of claim 1, wherein the positioning means
comprises integrally connecting a portion of the first channel to a
portion of the second channel.
3. The panel connector of claim 2, wherein the positioning means
comprises one side wall of the first channel also forming the back
wall of the second channel so that the first and second channels
are oriented substantially perpendicular in plan view.
4. The panel connector of claim 1, wherein an intersection of one
end of the back wall and one edge of one respective side wall of
the first channel forms a first channel corner, wherein an
intersection of one end of the back wall and one edge of one
respective side wall of the second channel forms a second channel
corner, and wherein the positioning means comprises a portion of
the first channel corner being attached to a portion of the second
channel corner.
5. The panel connector of claim 4, wherein the back walls of the
first and second channels form an angle in plan view between
approximately 0 and 179 degrees.
6. The panel connector of claim 4, wherein the back walls of the
first and second channels form an angle in plan view between
approximately 30 and 135 degrees.
7. The panel connector of claim 4, wherein the back walls of the
first and second channels form an angle in plan view between
approximately 45 and 90 degrees.
8. The panel connector of claim 4, wherein the first channel corner
is fixedly attached to the second channel corner.
9. The panel connector of claim 4, further comprising first and
second side extensions, wherein the first side extension is
connected to the side wall that is opposed to the side wall that
forms the first channel corner, the first side extension having an
extending portion that extends away from the first channel toward
the second channel and terminates at a distal edge, wherein the
second side extension is connected to the side wall that is opposed
to the side wall that forms the second channel corner, the second
side extension having an extending portion that extends away from
the second channel toward the first channel and terminates in a
distal edge, and wherein the distal edge of the first side
extension contacts the distal edge of the second side
extension.
10. The panel connector of claim 9, wherein the distal edge of the
first side extension is fixedly attached to the distal edge of the
second side extension.
11. The panel connector of claim 9, wherein the first side
extension is substantially linear in plan view and oriented
substantially perpendicular to the back wall of the first channel
and the second side extension is substantially linear in plan view
and is oriented substantially perpendicular to the back wall of the
second channel.
12. The panel connector of claim 9, wherein the extending portion
of the first side extension and the extending portion of the second
side extension form a non-linear angle therebetween in plan view,
in which that angle is supplementary to an angle formed between the
back walls of the first and second channels in plan view.
13. The panel connector of claim 1, wherein the back wall of the
first channel is oriented substantially perpendicular to the two
opposed side walls of the first channel in plan view and wherein
the back wall of the second channel is oriented substantially
perpendicular to the two opposed side walls of the second channel
in plan view.
14. The panel connector of claim 1, further comprising fastening
means associated with at least one of the first and second channels
for detachably holding a portion of the respective side panel
within the respective channel.
15. The panel connector of claim 14, wherein each of the side walls
of the two channels has an engaging surface that faces the opposed
side wall of that channel, and wherein the fastening means
comprises at least one protrusion formed on the engaging surface of
one side wall.
16. The panel connector of claim 15, wherein the protrusion is
sawtooth shaped in plan view.
17. The panel connector of claim 14, wherein the fastening means
comprises at least one protrusion formed on each engaging surface
of the two side walls for the first and second channels.
18. The panel connector of claim 17, wherein the protrusions are
saw-tooth shaped in plan view.
19. The panel connector of claim 1, wherein the first and second
channels are formed of plastic comprising polyethylene,
polypropylene, or acrylonitrile butadiene styrene.
20. A corner panel, comprising: a. a first side panel; b. a second
side panel; c. a first channel including a back wall having two
opposed ends and including two side walls having two opposed edges,
in which one edge of each side wall connects to one respective end
of the back wall to form the first channel that is of a size to
receive a portion of the first side panel therein; d. a second
channel including a back wall having two opposed ends and including
two side walls having two opposed edges, in which one edge of each
side wall connects to one respective end of the back wall to form
the second channel that is of a size to receive a portion of the
second side panel therein; and e. means for positioning the first
and second channels adjacent each other.
21. The corner panel of claim 20, wherein the first and second side
panels are formed of expanded polystyrene.
22. The corner panel of claim 20, wherein the first and second
channels are formed of plastic comprising polyethylene,
polypropylene, or acrylonitrile butadiene styrene.
23. The corner panel of claim 20, further comprising fastening
means associated with at least one of the first and second channels
for detachably holding a portion of the respective side panel
within the respective channel.
24. The corner panel of claim 23, wherein each of the side walls of
the two channels has an engaging surface that faces the opposed
side wall of that channel, and wherein the fastening means
comprises at least one protrusion formed on the engaging surface of
one side wall.
25. The corner panel of claim 24, wherein the protrusion is
saw-tooth shaped in plan view.
26. The corner panel of claim 24, wherein first side panel has an
exterior surface, the exterior surface defining a intention of a
size to complementarily receive one protrusion therein.
27. The corner panel of claim 20, wherein the positioning means
comprises integrally connecting a portion of the first channel to a
portion of the second channel.
28. The corner panel of claim 27, wherein the positioning means
comprises one side wall of the first channel forming the back wall
of the second channel so that the first and second side panels are
oriented substantially perpendicular in plan view.
29. The corner panel of claim 20, wherein an intersection of one
end of the back wall and one edge of one respective side wall of
the first channel forms a first channel corner, wherein an
intersection of one end of the back wall and one edge of one
respective side wall of the second channel forms a second channel
corner, and wherein the positioning means comprises a portion of
the first channel corner being attached to a portion of the second
channel corner.
30. The corner panel of claim 29, wherein the back walls of the
first and second channels form an angle in plan view between
approximately 45 and 90 degrees.
31. The corner panel of claim 29, wherein the first channel corner
is fixedly attached to the second channel corner.
32. The corner panel of claim 29, further comprising first and
second side extensions, wherein the first side extension is
connected to the side wall that is opposed to the side wall that
forms the first channel corner, the first side extension having an
extending portion that extends away from the first channel toward
the second channel and terminates at a distal edge, wherein the
second side extension is connected to the side wall that is opposed
to the side wall that forms the second channel corner, the second
side extension having an extending portion that extends away from
the second channel toward the first channel and terminates in a
distal edge, and wherein the distal edge of the first side
extension contacts the distal edge of the second side
extension.
33. The corner panel of claim 32, wherein the distal edge of the
first side extension is fixedly attached to the distal edge of the
second side extension. and wherein the first side extension is
substantially linear in plan view and oriented substantially
perpendicular to the back wall of the first channel and the second
side extension is substantially linear in plan view and is oriented
substantially perpendicular to the back wall of the second
channel.
34. The corner panel of claim 33, wherein the extending portion of
the first side extension and the extending portion of the second
side extension form a non-linear angle therebetween in plan view,
in which that angle is supplementary to an angle formed between the
back walls of the first and second channels in plan view.
35. A panel connector, comprising: a. a first channel comprising:
i. a first side wall having an edge; ii. a second side wall having
a distal edge and an opposed proximal edge; and iii. a back wall
having opposed ends, one end connected to the edge of the first
side wall and one end connected to the second side wall
intermediate its distal and proximal edges, wherein the back wall,
the first side wall, and a portion of the second side wall of each
channel define a channel of a size to receive of a portion of a
side panel; and b. a second channel comprising: i. a first side
wall having an edge; ii. a second side wall having a distal edge
and an opposed proximal edge; and iii. a back wall having opposed
ends, one end connected to the edge of the first side wall and one
end connected to the second side wall intermediate its distal and
proximal edges, wherein the back wall, the first side wall, and a
portion of the second side wall of each channel define a channel of
a size to receive of a portion of a side panel, wherein the
respective edges of the first side walls of the first and second
channels are connected to each other, wherein the distal edges of
the first and second channels are connected to each other, and
wherein the back walls of the first and second channels form an
angle in plan view that is less than 180 degrees.
36. The panel connector of claim 35, wherein the back wall of the
first channel extends perpendicular to the first and second side
walls of the first channel, and wherein the back wall of the second
channel extends perpendicular to the first and second side walls of
the second channel.
37. The panel connector of claim 35, wherein the angle formed by
the back walls of the first and second channels is approximately 90
degrees.
38. The panel connector of claim 35, wherein the angle formed by
the back walls of the first and second channels is approximately 45
degrees.
39. The panel connector of claim 35, wherein the respective edges
of the first side walls of the first and second channels are
fixedly attached together and the distal edges of the first and
second channels are fixedly attached together.
40. The panel connector of claim 35, further comprising fastening
means associated with at least one of the first and second channels
for detachably holding a portion of the respective side panel
within that channel.
41. The panel connector of claim 35, wherein the first and second
channels are formed of plastic comprising polyethylene,
polypropylene, or acrylonitrile butadiene styrene.
42. A form system, comprising: a. a first side panel; b. a second
side panel; c. a first channel comprising: i. a first side wall
having an edge; ii. a second side wall having a distal edge and an
opposed proximal edge; and iii. a back wall having opposed ends,
one end connected to the edge of the first side wall and one end
connected to the second side wall intermediate its distal and
proximal edges, wherein the back wall, the first side wall, and a
portion of the second side wall of each channel define a
three-sided channel that receives a portion of the first side panel
therein; and d. a second channel comprising: i. a first side wall
having an edge; ii. a second side wall having a distal edge and an
opposed proximal edge; and iii. a back wall having opposed ends,
one end connected to the edge of the first side wall and one end
connected to the second side wall intermediate its distal and
proximal edges, wherein the back wall, the first side wall, and a
portion of the second side wall of each channel define a channel
that receives a portion of the second side panel therein, wherein
the respective edges of the first side walls of the first and
second channels are connected to each other, wherein the distal
edges of the first and second channels are connected to each other,
and wherein the back walls of the first and second channels form an
angle in plan view that is less than 180 degrees.
43. The system of claim 42, wherein the first and second side
panels are formed of expanded polystyrene.
44. The system of claim 42, wherein the first and second channels
are formed of plastic comprising polyethylene, polypropylene, or
acrylonitrile butadiene styrene.
45. The system of claim 42, wherein the first and second channels
are substantially a squared U-shaped in plan view and the portion
of the first and second panels received within the respective first
and second channels are also substantially a squared U-shaped in
plan view.
46. The system of claim 42, further comprising fastening means
associated with at least one of the first and second channels for
detachably holding a portion of the respective side panel within
that channel.
47. The system of claim 42, wherein the angle formed by the back
walls of the first and second channels is approximately 90
degrees.
48. The system of claim 42, wherein the angle formed by the back
walls of the first and second channels is approximately 45
degrees.
49. The system of claim 42, wherein the respective edges of the
first sidewalls of the first and second channels are fixedly
attached together and the distal edges of the first and second
channels are fixedly attached together.
50. A method of constructing a form, comprising: a. providing a
panel connector having first and second channels, each channel
comprising: i. a first side wall having an edge; ii. a second side
wall having a distal edge and an opposed proximal edge; and iii. a
back wall having opposed ends, one end connected to the edge of the
first side wall and one end connected to the second side wall
intermediate its distal and proximal edges, wherein the back wall,
the first side wall, and a portion of the second side wall of each
channel define the respective first or second channel that is of a
size to receive a portion of a side panel therein; and b. inserting
a portion of a first side panel into the first channel of panel
connector; and c. inserting a portion of a second side panel into
the second channel of panel connector so that the first and second
side panels from a non-linear angle in plan view.
51. The method of claim 50, wherein the angle is approximately 90
degrees so that the first and second panels are substantially at a
right angle in plan view.
52. The method of claim 50, wherein the angle is approximately 45
degrees.
53. The method of claim 50, further comprising fastening the
portion of the first side panel to the first channel and fastening
the portion of the second side panel to the second channel.
54. A panel connector, comprising: a. a first back wall; b. a first
pair of side walls extending substantially perpendicular from the
first base wall, the first pair of side walls spaced apart from
each other, the first base wall and the first pair of side walls
defining a first channel of a size to complementarily receive a
portion of a side panel therein, one of the side walls of the first
pair of side walls forming a second back wall; and c. a second pair
of side walls extending substantially perpendicular from the second
back wall, the second pair of side walls spaced apart from each
other, the second base wall and the second pair of side walls
defining a second channel of a size to complementarily receive a
portion of a second side panel therein.
55. The panel connector of claim 54, further comprising fastening
means associated with at least one of the first and second channels
for detachably holding a portion of the respective side panel
within that channel.
56. The panel connector of claim 54, wherein the back and side
walls are formed of plastic comprising polyethylene, polypropylene,
or acrylonitrile butadiene styrene.
57. A wall form, comprising: a. right and left panel connectors,
each panel connector comprising: i. a first back wall; ii. a first
pair of side walls extending substantially perpendicular from the
first base wall, the first pair of side walls spaced apart from
each other, the first base wall and the first pair of side walls
defining a first channel of a size to complementarily receive a
portion of a side panel therein, one of the side walls of the first
pair of side walls forming a second back wall; and iii. a second
pair of side walls extending substantially perpendicular from the
second back wall, the second pair of side walls spaced apart from
each other, the second base wall and the second pair of side walls
defining a second channel of a size to complementarily receive a
portion of a side panel therein; and b. four side panels, including
a first, a second, a third, and a fourth side panel, the first side
panel partially disposed in the first channel of the left panel
connector, the second side panel partially disposed in the second
channel of the left panel connector and oriented substantially
perpendicular to the first side panel in plan view, the third side
panel partially disposed in the first channel of the right panel
connector, and the fourth side panel partially disposed in the
second channel of the right panel connector and oriented
substantially perpendicular to the third side panel in plan view,
wherein the right and left panel connectors are spaced apart from
each other.
58. The wall form of claim 57, wherein the first side panel is
oriented substantially linearly with the third panel and the second
and fourth side panels are oriented substantially parallel to each
other in plan view.
59. The wall form of claim 57, further comprising fastening means
associated with at least one of the channels for detachably holding
a portion of the respective side panel disposed within that
channel.
60. The wall form of claim 57, wherein the second and fourth side
panels are spaced apart a predetermined distance, the predetermined
distance corresponding to a width of a cavity of the wall form.
Description
[0001] This patent application claims priority to U.S. Provisional
Application Serial No. 60/271,827, which was filed on Feb. 27,
2001, and which is fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention encompasses a building component used
to form a corner in a wall system and, more particularly, a corner
for a system that is used to construct a concrete wall.
[0004] 2. Background Art
[0005] Concrete walls in building construction are often produced
by first setting up two parallel form walls and pouring concrete
into the space between the forms. After the concrete hardens, the
builder then removes the forms, leaving the cured concrete
wall.
[0006] This prior art technique has drawbacks. Formation of the
concrete walls is inefficient because of the time required to erect
the forms, wait until the concrete cures, and take down the forms.
This prior art technique, therefore, is an expensive,
labor-intensive process.
[0007] Accordingly, techniques have developed for forming concrete
walls that use a foam insulating material. The modular form walls
are set up parallel to each other and connecting components hold
the two form walls in place relative to each other while concrete
is poured therebetween. The form walls, however, remain in place
after the concrete cures. That is, the modular walls, which are
constructed of foam insulating material, are a permanent part of
the building after the concrete cures. The concrete walls made
using this technique can be stacked on top of each other many
stories high to form all of a building's walls. In addition to the
efficiency gained by retaining the form walls as part of the
permanent structure, the materials of the form walls often provide
adequate insulation for the building.
[0008] In prior art systems, however, the corners for form systems
have proven to be difficult to manufacture and construct. Often a
specific side panel must be manufactured and used, in which the
side panels are non-linear to form an angle equal to that required
for the building (i.e., 90 degrees). These corner panels necessary
to make a corner structure in the prior art concrete form systems
are expensive which, in turn, increases the cost of the formed
wall.
SUMMARY OF THE INVENTION
[0009] The present invention comprises a panel connector for making
corner structures in building form systems, particularly for
systems used to construct concrete walls. The panel connector
defines two channels into which respective portions of the side
panels are inserted, preferably at the construction site. These
panel connectors are designed to form a corner having a
predetermined angle to which the inserted side panels are
positioned.
[0010] In one exemplary embodiment, the panel connector includes a
first base wall, a first pair of side walls, and a second pair of
side walls. The first pair of side walls extend from the first base
wall and are spaced apart to define a first channel of a size to
complementarily receive a portion of one side panel. One of the
side walls of the first pair of side walls forms a second base
wall, and the second pair of side walls extend from the second base
wall to form the second channel. The second channel is also of a
size to complementarily receive a portion of another side panel.
With this embodiment, the side panels are usually oriented at right
angles to each other in plan view.
[0011] In a second exemplary embodiment, the panel connector
comprises a pair of connected channels. Each channel includes a
first side wall, a second side wall, and a back wall. Both channels
have corners formed between the first side wall and the back wall
and those corners are connected to each other. The side walls for
each channel that do not form the corner of that respective channel
(e.g., the second side panel) may extend beyond the connection
point of the respective back wall to a distal edge. For structural
integrity, it is preferred that the distal edges of the second side
walls of both channels are also connected. In fact, the panel
connector may be formed so that the connected corners of the
channels are coextensive and integral with each other and the
distal edges of the connected channels are also coextensive and
integral with each other.
[0012] In this second embodiment, the back walls of the respective
channels are at an angle with each other in plan view that is less
than 180 degrees. In specific preferred embodiments, the back walls
are at angles of either 45 or 90 degrees and the side panels
accordingly, are at that same angle in plan view.
[0013] The panel connector may also include a fastening means for
forming a stronger connection between the panel connector and the
respective inserted side panels. The fastening means assists in
maintaining the side panels within the respective channels during
the construction process and after its completion.
[0014] The present invention also includes a method of constructing
a portion of a form wall system having at least one panel connector
described herein and at least two side panels.
[0015] These and other features and advantages of the present
invention will become more readily apparent from the following
detailed description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
[0016] FIG. 1 is a perspective view of one embodiment of the
present invention shown being used with an exemplary wall
system.
[0017] FIG. 2 is a perspective side view of a FIG. 1 taken along
line 2-2.
[0018] FIG. 2A is an alternative view of FIG. 2 showing concrete
disposed between the two opposed side panels.
[0019] FIG. 3 is a perspective view of connector shown in FIG.
2.
[0020] FIG. 4 is a perspective view of a first exemplary embodiment
of a panel connector of the present invention.
[0021] FIG. 5 is a top plan view of the panel connector of FIG. 4
having a portion of a respective side panel disposed within each of
the two channels.
[0022] FIG. 6 is a top plan view of T-wall formed using two panel
connectors shown in FIG. 4.
[0023] FIG. 7 is a perspective view of a second exemplary
embodiment of a panel connector of the present invention.
[0024] FIG. 8 is a top plan view of the panel connector of FIG. 7
having a portion of a respective side panel disposed within each of
the two channels, in which the side panels are oriented at an
approximately 45 degree angle to each other.
[0025] FIG. 9 is a top plan view of a panel connector similar to
that of FIG. 7, in which the side panels are oriented at an angle
of approximately 90 degrees instead of at 45 degrees.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention is more particularly described in the
following examples that are intended as illustrative only since
numerous modifications and variations therein will be apparent to
those skilled in the art. As used in the specification and in the
claims, "a," "an," and "the" can mean one or more, depending upon
the context in which it is used. The preferred embodiment of the
present invention is now described with reference to the figures,
in which like numbers indicate like parts throughout the
figures.
[0027] As shown in FIGS. 1-9, the present invention comprises a
corner system 10 used for constructing buildings and the like.
Before describing illustrative embodiments of the present
invention, however, exemplary components that are used to form the
associated concrete form wall are addressed to provide context.
[0028] As best shown in FIG. 2, side panels 20 are used to form the
wall, in which each side panel 20 has a top end 24, a bottom end
26, a first end 28, a second end 30, an exterior surface 32, and an
interior surface 34. The illustrated side panel 20 has a thickness
(separation between the interior surface 34 and exterior surface
32) of approximately two and a half (21/2) inches, a height
(separation between the bottom end 26 and the top end 24) of
sixteen (16) inches, and a length (separation between the first end
28 and second end 30) of forty-eight (48) inches. The dimensions
may be altered, if desired, for different building projects, such
as increasing the thickness of the side panel 20 for more
insulation. Half sections of the side panels 20 can be used for
footings.
[0029] Referring now to FIGS. 1 and 2, the interior surface 34 of
one side panel 20 faces the interior surface 34 of another side
panel 20 and the opposed interior surfaces 34 are laterally spaced
apart from each other a desired separation distance so that a
cavity 38 is formed therebetween. Concrete--in its fluid state--is
poured into the cavity 38 and allowed to substantially cure (i.e.,
harden) therein to form the wall structure, as shown in FIG. 2A.
The opposed interior surfaces 34 are usually parallel to each
other. The volume of concrete received within the cavity 38 is
defined by the separation distance between the interior surfaces
34, the height of the side panels 20, and the length of the side
panels 20.
[0030] The illustrated side panels 20 are constructed of expanded
polystyrene ("EPS"), which provides thermal insulation and
sufficient strength to hold the poured concrete C until it
substantially cures. The formed concrete wall using expanded
polystyrene with the poured concrete C has a high insulating value
so that no additional insulation is usually required. In addition,
the formed walls have a high impedance to sound transmission.
However, other materials may be used to form the side panels,
including, but not limited to, other polystyrene materials, wood,
plywood, combined steel frame and plywood center (commonly known as
a steel-ply panel), or any other solid material that can be coupled
to either a web member 40 or a connector 50 and can withstand the
forces exerted by the fluid concrete when poured into the cavity 38
without substantial bowing, warping, breaking, or other type of
failure. The opposed side panels may be formed of the same material
or different materials.
[0031] As shown in FIG. 2 and disclosed more completely in U.S.
Pat. Nos. 6,170,220 and 6,336,301 and in U.S. patent application
Ser. No. 09/848,398 (all of which are incorporated herein in their
entireties), each side panel 20 has at least one web member 40
formed into it. Each web member 40 formed within one side panel 20
is usually separated a predetermined longitudinal distance from
other web members 40, which is typically eight (8) inches. Based on
the preferred length of the side panel 20 of forty-eight (48)
inches, six web members 40 are formed within each side panel 20. A
portion of each web member 40 is shown integrally formed within one
side panel 20 and is to be cured within the concrete C so that the
web member 40 strengthens the connection between the side panel 20
and the concrete C. That is, since the web member 40 is an integral
part of the side panel 20, it bonds the side panel 20 to the
concrete C once the concrete is poured and substantially cures
within the cavity 38. However, other designs are contemplated to be
used with the present invention, such as systems in which the web
member is not integrally formed into the side panel and, for
example, the web member is slid into slots precut into the side
panel at the construction site. Still another design with which the
present invention may be used includes systems having the web
members, side panels, and connectors shipped to the construction
site as an integral unit. Such exemplary designs are disclosed in
U.S. Pat. Nos. 4,901,494, 5,390,459, and 5,497,592, which are also
incorporated herein in by reference.
[0032] Referring still to FIG. 2, portions of each web member 40
that extend through the interior surface 34 of the side panel 20
forms one or more attachment points 44. The attachment points 44
are disposed within the cavity 38 and are spaced apart from the
interior surface 34 of the side panels 20. However, as one skilled
in the art will appreciate, the attachment points 44 may take any
of a number of alternate designs formed by or independentl of the
web members 40, including as examples: slots, channels, grooves,
projections or recesses formed in the side panels; hooks or eyelets
projecting from or formed into the side panels; twist, compression
or snap couplings; or other coupling means for engaging cooperating
ends of the connectors.
[0033] The illustrated attachment points 44 of the web members 40
extend into the cavity 38 and the attachment points 44 of each web
member 40 formed within one side panel 20 are spaced apart from the
attachment points 44 of the web members 40 formed within the
opposed side panel 20. Thus, the web members 40 in this
illustrative design do not directly contact each other; instead,
each attachment point 44 independently engages the connector 50
that interconnects the web members 40 and, accordingly, the side
panels 20.
[0034] Referring now to FIG. 3, the illustrated connector 50 has
opposed ends 52 and a length extending therebetween. The ends 52 of
the connectors 50 are each of a shape to engage one attachment
point 44 of two respective web members 40 within opposed panels. In
conjunction, each end 52 of the connector 50 has a track 54 into
which the attachment point 44 is complementarily and slidably
received. Thus, the illustrated connectors 50 engage two attachment
points 44 on opposed web members 40, which position the interior
surfaces 34 of the side panels 20 at a desired separation distance
and support the side panels 20 when the fluid concrete is poured
into the cavity 38. The connector 50 thus makes a two-point
connection with opposed web members 40 because each connector has
two ends 52 that each couple to one attachment point 44, although
it is contemplated making a four-point connection (i.e., each
connector 50 engages four attachment points 44 instead of two as
illustrated in the figures). As also noted above, however, the web
members and connectors can be formed as an integral unit for use
with the present invention.
[0035] Referring now to FIGS. 2 and 3, the connectors 50 also
define an aperture 56 of a size to complementary receive a re-bar
(not shown) therein. The re-bar provides reinforcing strength to
the formed wall. The diameter of the re-bar can be one-quarter
(1/4) inch or other dimension as required for the necessary
reinforcement, which depends on the thickness of the concrete wall
and the design engineering requirements. The connectors 50 usually
have two or more apertures 56 and re-bar can be positioned in any
of the apertures 56 before the concrete is poured into the cavity
38. The apertures 56 can be designed so that the re-bar is
securably snapped into place for ease of assembly.
[0036] To alter the width of the cavity 38 (i.e., the separation
between the interior surfaces 34 of the opposed side panels 20),
different connectors 50 can have varying lengths. The width of the
cavity 38 can be two (2), four (4), six (6), eight (8) inches or
other separation. Different connectors 50 are sized accordingly to
obtain the desired width of the cavity 38. Also, as one skilled in
the art will appreciate, the fire rating, sound insulation, and
thermal insulation increase as the width of the cavity 38, which is
filled with concrete, increases. One skilled in the art will
appreciate that the cavity 38 may only be partially filled with
concrete, but such an embodiment is usually not desired.
[0037] The web members 40 and connectors 50 are usually constructed
of a thermoplastic, but other materials may be used. Factors used
in choosing the material include the desired strength of the web
member 40 and connector 50, the compatibility with the material
used to form side panels 20 and with the concrete, and cost.
Another consideration is that the end plates of the web members
(positioned adjacent the exterior surface of the side panel 20)
should be adapted to receive and frictionally hold a metal
fastener, such as a nail or screw, therein, thus providing the
"strapping" for a wall system that provides an attachment point for
gypsum board (not shown), interior or exterior wall cladding (not
shown), or other interior or exterior siding (not shown).
[0038] Referring back to FIGS. 1 and 2, one skilled in the art will
appreciate that a plurality of side panels 20 can be longitudinally
aligned to form a predetermined length and be vertically stacked to
form a predetermined height. For example, the first end 28 of one
side panel 20 abuts the second end 30 of another side panel 20 and
the bottom end 26 of one side panel 20 is disposed on the top end
24 of another side panel 20. Thus, a series of side panels 20 can
be aligned and stacked to form the concrete system into which
concrete C is poured to complete the construction of the wall. One
consideration, however, is that the side panels 20 are not
vertically stacked too high and filled at once so that the pressure
on the bottom side panel 20 is greater than the yield strength of
the web members 40 or side panels 20. Instead, the stacked wall of
panels 20 can be filled and cured in stages so that the static and
dynamic pressures are not excessive on the lower side panels
20.
[0039] Still referring to FIGS. 1 and 2, the side panels 20 are
optionally provided with a series of projections 35 and
indentations 37 that complementarily receive offset projections 35
and indentations 37 from another side panel 20 (i.e., a
tongue-and-groove-type system) to facilitate the stacking of the
components. The projections 35 and indentations 37 in the adjacent
side panels 20 mate with each other to form a tight seal that
prevents leakage of concrete C during wall formation and prevents
loss of energy through the formed wall.
[0040] In the context of these exemplary components, the present
invention is disclosed, which comprises a panel connector 60 that
is used to form a corner of the wall structure. The panel connector
60, which is shown in FIGS. 1 and 4-9, joins or interconnects two
or more side panels 20 in a fixed or stationary relationship
relative to each other. As noted above, the interconnected side
panels 20 can employ any design used in the art, ranging from
plywood panels to the illustrative EPS panels illustrated in the
Figures.
[0041] In a preferred embodiment, the panel connector 60 comprises
first and second channels 70, 80, both of which have a back wall
72, 82 and two side walls 74, 84. For each of the first and second
channels 70, 80, the back wall 72, 82 has two opposed ends 73, 83
and each side wall 74, 84 has two opposed edges 75, 85, in which
one edge 75, 85 of each side wall 74, 84 connects to one respective
end 73, 83 of the back wall 72, 82. Together the two spaced apart
side walls 74, 84 and interconnected back wall 72, 82 form one
respective channel 70, 80. The first and second channels 70, 80 are
preferably of a size to receive a portion of a side panel 20
therein. As discussed below, the channels 70, 80 may also include a
fastening means to assist inkeeping the side panel 20 retained
within to the respective channel once interconnected.
[0042] It is also preferred that the back and side walls 72, 74,
82, 84 are substantially planar and it is further preferred that
the side walls 74, 84 are both oriented substantially perpendicular
to the back wall 72, 74 in plan view (i.e., top or bottom view).
Thus, the channel 70, 80 is substantially a squared U-shape in plan
view, which matches the profile of the portion of the illustrated
side panels 20 inserted into that channel. Of course, the shape and
orientation of the channels 70, 80 may be varied as desired; for
example, the two opposed side walls 74, 84 could be oriented
inwardly (not shown) to form an acute angle relative to the back
wall 72, 82 and such an alternative channel design could still
receive a portion of the respective side panel therein.
[0043] For purposes of discussing the present invention, the first
channel 70 will be disclosed as receiving a first side panel 20A
and the second channel 80 as receiving a second side panel 20B. The
illustrated first and second side panels 20 are of the same design,
but one skilled in the art will appreciate that the first side
panel 20A may be an EPS panel and the second side panel 20B formed
of a different material. Similarly, the first and second side
panels 20A, 20B may have different widths between their respective
interior and exterior surfaces 32, 34.
[0044] The present invention also preferably includes a means for
positioning the first and second channels 70, 80 adjacent to each
other. It is preferred that the positioning means comprises
integrally connecting a portion of the first channel 70 to a
portion of the second channel 80. More specifically, it is
preferred that the panel connector 60 be formed or extruded so that
the first and second channels 70, 80 are fixedly attached to each
other (i.e., coextensive and integrally formed together) along a
potion or their entire heights, which extends between the top and
bottom of the channel. However, the two channels may be
interconnected using other means, such as fusing, welding,
chemically bonding such as with glue, mechanically attaching such
as with nails, screws, or rivets, or other techniques known in the
art.
[0045] Similar to the exemplary web members and connectors
described above, the panel connectors 60 may be formed of plastic,
more preferably high-density plastic such as high-density
polyethylene or high-density polypropylene, although other suitable
polymers may be used. Other contemplated plastics include
acrylonitrile butadiene styrene ("ABS") and glass-filled
polyethylene or polypropylene. Likewise, other materials that may
be used are other plastics and thermoplastics (including polyvinyl
chloride (P.V.C.), polytetrafluoethylene (P.T.F.E.), polyamides
such as nylon), metal, and natural and other synthetic materials.
Factors used in choosing the material include the desired strength
of the panel connector 60, the compatibility with the material used
to form side panels 20 and with the concrete C, and cost.
[0046] In the first exemplary embodiment of the present invention
shown in FIGS. 4-6, the positioning means comprises one side wall
74 of the first channel 70 also forming the back wall 82 of the
second channel 80 so that the first and second channels 70, 80 are
oriented substantially perpendicular in plan view. Stated
differently, this illustrated embodiment comprises a first back
wall 72 and a first pair of side walls 74 extending from the first
base wall 72 to define the first channel 70. One of those two side
walls 74 of the first channel 70 forms a second back wall 88. The
second pair of side walls 84 extend substantially perpendicular
from the second back wall 88. Similar to the first set of side
walls, the second pair of side walls 84 are also spaced apart from
each other to define the second channel 80. The first and second
channels 70, 80 receive respective first and second side panels
20A, 20B, as shown in FIGS. 5 and 6, so that the side panels
interconnected by this embodiment are oriented substantially
perpendicular to each other in plan view.
[0047] Referring now to FIGS. 1 and 7-9, a second exemplary
embodiment of the present invention is shown, in which the two
channels are interconnected at one of their respective corners.
Specifically, for the first channel 70, the intersection of one end
73 of the back wall 72 and one edge 85 of one respective side wall
84 forms a first channel corner 76, and, similarly for the second
channel 80, the intersection of one end 83 of that back wall 82 and
an edge 85 of one respective side wall 84 forms a second channel
corner 86. The positioning means in this embodiment comprises a
portion of the first channel corner 76 being attached to a portion
of the second channel corner 86. As noted above, the first and
second channel corners 76, 86 preferably are fixedly attached to
each other along the entire height of the panel connector 60, but
other designs of the positioning means are contemplated as
mentioned above.
[0048] It is preferred that that the back walls 72, 82 of the first
and second channels 70, 80 form an angle .theta. in plan view
between approximately 0 and 179 degrees, more preferably between 1
and 170 degrees, still more preferably between 30 and 135 degrees,
and most preferably between and including 45 and 90 degrees. The 45
degree embodiment is illustrated in FIGS. 1, 7, and 8 and the 90
degree embodiment is illustrated in FIG. 9. As one skilled in the
art will appreciated, the angle .theta. between the first and
second side panels 20A, 20B interconnected by a panel connector 60
form the same sized angle in plan view as the angle formed by the
back walls in the illustrated embodiments.
[0049] Although not required, it is preferred for structural
strength of the panel connector 60 of this second exemplary
embodiment that the channels interconnect at another point besides
the first and second channel corners 76, 86. One contemplated
embodiment includes one or more extension members (not shown)
extending between the back walls of the first and second channels
70, 80 to stationarily position the back walls relative to each
other. Such an extension may, for example, interconnect the opposed
corners of the channels so that the two ends of one back wall are
either directly or indirectly connected to corresponding ends of
the other back wall. This extension may be substantially planar,
arcuate, or other shape that is preferably aesthetically
pleasing.
[0050] In another embodiment illustrated in FIGS. 7-9, the channels
include respective first and second side extensions 90, 94. The
first side extension 90 is connected to the side wall 74 that is
opposed to the side wall that forms the first channel corner 76
(i.e., the corner not connected to the second channel 80) and,
likewise, the second side extension 94 is connected to the side
wall 84 that is opposed to the side wall that forms the second
channel corner 86. Both the first and second side extensions 90, 94
have extending portions that extend away from the first channel 70
toward the second channel 80 and terminate at a respective distal
edge 92, 96. As illustrated, the distal edge 92 of the first side
extension 90 contacts the distal edge 96 of the second side
extension 94 and, more preferably, the two distal edges 92, 96 are
fixedly attached together.
[0051] Referring still to FIGS. 7-9, the first side extension 90 is
substantially linear in plan view and oriented substantially
perpendicular to the back wall 72 of the first channel 70.
Likewise, the second side extension 94 is substantially linear in
plan view and is also oriented substantially perpendicular to the
back wall 82 of the second channel 80. The extending portion of the
first side extension 90 and the extending portion of the second
side extension 94 form a non-linear angle .PHI. therebetween. That
angle .PHI. between the first and second side extensions 90, 94 is
preferably supplementary to the angle .theta. formed between the
back walls 72, 82 of the first and second channels 70, 80 (i.e.,
collectively the angles (.theta.+.PHI.) total 180 degrees). This
embodiment is presently preferred because the exterior surface of
the formed wall is aesthetically pleasing and provides a contiguous
mounting surface when covered, such as with stucco or the like. As
noted above, however, other embodiments are contemplated, such as
arcuate shapes, to address all architectural designs.
[0052] As noted above, the present invention may optionally further
comprise a fastening means associated with at least one of the
first and second channels 70, 80 for detachably holding a portion
of the respective side panel 20 within that respective channel. The
embodiment of the fastening means shown in FIGS. 4, 5, and 7-9
comprises at least one protrusion 100 that engages the side panel
20 inserted into the channel. As illustrated, each of the side
walls 74, 84 of the two channels has an engaging surface that faces
the opposed side wall 74, 84 of that channel and the protrusions
100 are formed on the engaging surfaces of the side walls 74, 84.
The illustrated protrusion 100 is saw-tooth shaped in plan view, in
which the saw-tooth shape has opposite steep and gradual sides. The
gradual side generally faces the front of the side wall 74, 84 and
the steep side generally faces the respective back wall 72, 82 of
that channel 70, 80.
[0053] It is also contemplated that the side panels 20 include an
indentation 39 or detent in their respective exterior surfaces 32
of a size to receive one respective protrusion 100 therein when the
side panel 20 is fully inserted into the channel. In use, when the
side panel 20 is inserted into the respective channel, at least one
indentation 39 within the interior and/or exterior surface of the
side panel 20 engages the steep side of the protrusion 100 to
secure the received side panel 20 to the respective channel. There
may be a plurality of spaced-apart protrusions 100 on the mating
surface of each side wall 74, 84 and corresponding indentations 39
to engage each protrusion 100.
[0054] Additionally, each side wall 74, 84 has a lateral height
extending between the top surface and the bottom surface of the
respective side wall. Each protrusion 100 may extend substantially
the lateral height of the side wall, which is greater than half the
lateral height, more preferably greater than three-quarters of the
lateral height, and most preferably substantially the entire
lateral height. Further, each protrusion 100 may extend
substantially parallel to the back edge 75, 85 of the side
wall.
[0055] Other fastening means are also contemplated. One example of
an alternative fastening means may comprise at least one orifice
(not shown) in each of the side walls of the first and the second
pairs of side walls and a plurality of fasteners (not shown). After
the first and second side panels 20A, 20B are inserted into the
respective first and second channels 70, 80, a fastener may be
inserted through the orifice into the received side panel 20. In
another design, the fastening means may comprise at least one
starter indentation (not shown) in each of the side walls of the
first and the second pairs of side walls and a plurality of
fasteners (not shown) so that one fastener may be driven through
the starter indentation and into the received side panel. It is
also contemplated that the fastening means may include chemical
adhesives as well as other types of mechanical fasteners such as
rivets, nails, screws, bolts and the like if the materials allow
(i.e., when using plywood side panels).
[0056] Referring back to FIGS. 4 and 5, one of the side walls 74 of
the first pair of side walls and one of the side walls 84 of the
second pair of side walls each may define a laterally extending lip
78 formed at the front edge of the respective side wall. As one
skilled in the art will appreciate, when the first side panel 20A
is received into the first channel 70 and when the second side
panel 20B is received into the second channel 80, the defined lips
78 extend outwardly away from the interior surface 34 of the
respective received side panels 20 so that a portion of the panel
connector 60 extends into the cavity 38 to be substantially cured
within the concrete C. Since the lips 78 are an integral part of
the panel connector 60, the lip, assists in "locking" the panel
connector 60 to the concrete C once the concrete is poured and
substantially cures within the cavity 38 around the exposed
portions of the panel connector 60.
[0057] As illustrated in FIG. 1, multiple panel connectors 60 can
be used in conjunction with each other to form the wall structure.
Another example is the formation of a T-wall, which is illustrated
in FIG. 6. There are two panel connectors shown: a right panel
connector 60R and a left panel connector 60L. The embodiment of the
panel connector 60 illustrated in FIGS. 4 and 5 is shown, but one
skilled in the art will appreciate that other panel connector
designs may similarly be used, including the embodiment shown in
FIG. 9. This T-wall system also uses four side panels, including a
first, a second, a third, and a fourth side panel, in which the
first and second side panels 20A, 20B are inserted into the left
panel connector 60L and the third and fourth side panels 20C, 20D
are inserted into the right side panel connector 60R. To form the
T-wall, the right and left panel connectors 60L, 60R are spaced
apart from each other. Also, the first side panel 20A is oriented
substantially linearly with the third panel 20C and the second and
fourth side panels 20B, 20D are oriented substantially parallel to
each other. The second and fourth side panels 20B, 20D are spaced
apart a predetermined distance, in which the predetermined distance
preferably corresponds to the width of the cavity 38. As further
disclosed in U.S. patent application Ser. No. 09/848,398 (which is
incorporated by reference herein in its entirety), flexible linking
members 62 and extenders 64 can be used to interconnect the side
panels 20 and to assist in preventing bowing when fluid concrete
fills the cavity 38.
[0058] Although the present invention has been described with
reference to specific details of certain embodiments thereof, it is
not intended that such details should be regarded as limitations
upon the scope of the invention except as and to the extent that
they are included in the accompanying claims. For example, as noted
above, the present invention is described with reference to a
system incorporating the depicted concrete form system, it will be
understood by those skilled in the art that the present invention
is applicable to other types of concrete form systems utilizing one
or more form panels or other concrete retaining and/or molding
elements retained in position by one or more connectors or other
relative position-fixing elements. Also, although the present
invention is described with reference to a system, method and
components thereof for use in the forming of concrete building
components, the present invention may also find application in the
formation of various other types of products of concrete and/or
other moldable and curable materials such as, for example,
structural and nonstructural building components and consumer
products of concrete, plastics, and other synthetic and natural
materials.
* * * * *