U.S. patent application number 11/086287 was filed with the patent office on 2005-10-13 for stackable block for insulating concrete form system.
This patent application is currently assigned to Plasti-Fab Ltd.. Invention is credited to Cymbala, Patrick M., Doren, Gregory J..
Application Number | 20050223669 11/086287 |
Document ID | / |
Family ID | 35006271 |
Filed Date | 2005-10-13 |
United States Patent
Application |
20050223669 |
Kind Code |
A1 |
Cymbala, Patrick M. ; et
al. |
October 13, 2005 |
Stackable block for insulating concrete form system
Abstract
A concrete form system comprising a reversibly stackable
insulating form blocks each block having a pair of panels separated
by two or more ties. Each of the top, bottom and side edges of the
panels includes either a tongue or groove so as to engage a
corresponding tongue or groove of a panel of another block stacked
vertically or horizontally adjacent thereto. The panels of each
block are arranged in opposite orientation to each other so as to
enable the block to be stackable in either an upside-down or
right-side-up orientation.
Inventors: |
Cymbala, Patrick M.;
(Calgary, CA) ; Doren, Gregory J.; (Markham,
CA) |
Correspondence
Address: |
MCCARTHY TETRAULT LLP
SUITE 4900, P.O. BOX 48
66 WELLINGTON ST. WEST
TORONTO
ON
M5K 1E6
CA
|
Assignee: |
Plasti-Fab Ltd.
|
Family ID: |
35006271 |
Appl. No.: |
11/086287 |
Filed: |
March 23, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60555956 |
Mar 25, 2004 |
|
|
|
Current U.S.
Class: |
52/426 |
Current CPC
Class: |
E04C 1/41 20130101; E04B
2/8635 20130101; E04B 2002/0204 20130101; E04B 2002/867 20130101;
E04B 2002/0206 20130101 |
Class at
Publication: |
052/426 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A reversibly stackable insulating concrete form block, for use
in a concrete form system, comprising: first and second foam
panels, arranged opposed and parallel to each other and spaced
apart by a predetermined distance; two or more ties extending
perpendicularly between said panels to maintain the panels in said
spaced apart orientation; and each of said panels having top and
bottom edges and left and right ends and including: a first
interlocking means for engaging a respective panel of a block
vertically adjacent thereto; a second interlocking means for
engaging a respective panel of a block located horizontally
adjacent thereto; and at least one tie aligning feature to
vertically align ties of vertically adjacent blocks, wherein said
panels are arranged in opposite vertical and horizontal orientation
with respect to each other whereby said block can be engaged with
other vertically adjacent blocks in either a right-side up or
upside-down orientation.
2. The block of claim 1 wherein said block includes a plane of
symmetry extending from the top of said first panel to the bottom
of said second panel.
3. The block of claim 2 wherein said block includes a plane of
symmetry extending from the top left end of said first panel to the
bottom right end of said second panel.
4. The block of claim 1 wherein said ties includes a plurality of
rebar receiving clips.
5. The block of claim 4 wherein said ties include an axis of
symmetry extending transversely across the mid-point of said
tie.
6. The block of claim 1 wherein said ties include flanges embedded
within each of said panels.
7. The block of claim 6 wherein said flanges extend substantially
across the height of said panels.
8. A reversibly stackable insulating concrete form block, for use
in a concrete form system, comprising: first and second foam
panels, arranged opposed and parallel to each other and spaced
apart by a predetermined distance; and two or more ties extending
perpendicularly between said panels to maintain the panels in said
spaced apart orientation, wherein each panel of said panels
includes a top edge, a bottom edge, and left and right ends; for
said each panel: one of said top and bottom edges includes a first
tongue extending longitudinally along said edge; the other of said
top and bottom edges includes a first groove extending
longitudinally along said other edge and being adapted to receive a
tongue having the dimensions of said first tongue; one of said left
and right ends includes a second tongue extending longitudinally
along said end; the other of said left and right ends includes a
second groove extending longitudinally along said other end and
being adapted to receive a tongue having the dimensions of said
second tongue; two or more projections extending from the edge
having said first tongue; and two or more recesses provided on the
edge having said first groove; and said panels of said block are
arranged in opposite orientation with respect to each other whereby
the top of the first panel faces the bottom of the second panel and
the right end of the first panel faces the left end of the second
panel.
9. The block of claim 8 wherein said block includes a plane of
symmetry extending from the top of said first panel to the bottom
of said second panel.
10. The block of claim 9 wherein said block includes a plane of
symmetry extending from the top left end of said first panel to the
bottom right end of said second panel.
11. The block of claim 8 wherein said projections and recesses
cooperate to cause vertical alignment of said ties.
12. The block of claim 11 wherein said ties include flanges
embedded within each of said panels.
13. The block of claim 12 wherein said flanges extend substantially
across the height of said panels.
14. A reversibly stackable insulating concrete form block, for use
in a concrete form system, comprising: first and second panels,
arranged opposed and parallel to each other and spaced apart by a
predetermined distance; two or more ties extending perpendicularly
between said panels to maintain the panels in said spaced apart
orientation; on a top edge of said first panel, at least one
positive feature for engaging a respective negative feature on a
panel of a block vertically adjacent thereto; on a bottom edge of
said first panel, at least one negative feature for receiving a
corresponding positive feature of said block vertically adjacent
thereto; on a bottom edge of said second panel, a compatible
positive feature to each of said at least one positive feature of
said first panel; and on a top edge of said second panel, a
compatible negative feature to each of said at least one negative
feature of said first panel, wherein said at least one positive
feature, said at least one negative feature, said compatible
positive feature and said compatible negative feature are located
on their respective edges such that said block can be engaged with
other vertically adjacent blocks in either a right-side up
orientation with said at least one negative feature of said first
panel engaging a corresponding positive feature on an adjacent
panel of a block below said block or an upside-down orientation
with said compatible negative feature of said second panel engaging
said corresponding positive feature on said adjacent panel and
wherein one of said at least one positive feature is a tongue
extending longitudinally along said top edge.
Description
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/555,956 filed on Mar. 25, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to concrete form systems and,
more specifically, to systems comprised of stackable foam block
units. More particularly, the invention relates to insulating
concrete form blocks that are reversibly stackable.
BACKGROUND OF THE INVENTION
[0003] In the field of constructing concrete walls, it is commonly
known to use forms normally comprising a pair of panels arranged
parallel to one another and separated by a distance. Concrete is
then poured between the panels and allowed to set. After the
concrete is set, the panels, usually made of wood, are removed. It
is common to have ties extending between the two panels to ensure
that the desired spacing is maintained.
[0004] The advent of insulating concrete form (ICF) systems has
provided an improvement in concrete form systems. In ICF systems,
the panels comprise slabs of insulating foam between which the
concrete can be poured. Once set, the foam panels are left in place
thereby providing both sides of the concrete wall with integral
insulating layers. The foam panels are separated by ties that
normally comprise two flange portions that are embedded in each of
the opposed foam panels and a web portion extending there-between.
The flanges can be embedded by forming the foam panels around them,
by sliding the flanges into slots in the foam, or by any other
manner as will be apparent to persons skilled in the art. The ICF
systems are also available in pre-made blocks of standard
dimensions that can be stacked both vertically and horizontally to
create any desired configuration of form. An example of an ICF
system is provided in U.S. Pat. No. 5,896,714, which shares common
inventors with the present application (the entire disclosure of
U.S. Pat. No. 5,896,714 is incorporated herein by reference). In
this patent, a form block is disclosed having various unique
features. One of the key features is that, once the blocks are
stacked, the tie flanges on each side of the form (and, therefore,
the concrete wall) are vertically aligned. This results in a
vertically continuous nailing surface for securing wall finishing
material such as vapour barriers, additional insulation, wall
boards and the like.
[0005] Other ICF block systems are taught in the following U.S.
Pat. Nos.: 4,229,920; 5,429,933; 6,253,523; 6,401,419; and
6,412,245 (the disclosures of which are incorporated herein by
reference).
[0006] One of the problems associated with some known ICF block
systems is that the blocks can only be used in one orientation.
That is, they cannot be stacked above another block unless they are
positioned in a specific inside/outside, top/bottom manner. This
often results in wastage of product. Such wastage is particularly
faced when a block is cut to a smaller size and the remaining
portion cannot be used since their orientation cannot be
reversed.
[0007] Some of the prior art patents mentioned above disclose
blocks that may be reversed in orientation. For example, U.S. Pat.
No. 5,896,714 teaches an ICF block that can be stacked in either
orientation when rotated about its vertical axis. That is, the
block does not have 20 a designated inside and outside face.
However, this block has a specific top and bottom, depending on the
first course of the blocks that are laid. U.S. Pat. No. 5,428,933,
on the other hand, does teach a block that is reversible along
either the longitudinal or vertical axis. However, this reference
does not allow for the ties of the block to be aligned once
stacked.
[0008] Thus, there exists a need in the art for a reversible ICF
block that overcomes at least some of the deficiencies of the known
blocks.
SUMMARY OF THE INVENTION
[0009] In one aspect, the present invention provides a concrete
form block for use in a form system, wherein the block is stackable
in either vertical orientation.
[0010] In another aspect, the invention provides an insulating
concrete form block made of a pair of foam panels spaced apart by
two or more ties and wherein the panels are provided with
interlocking means to enable vertically and horizontally adjacent
blocks to engage each other and an alignment means to ensure
vertical alignment of the ties. The interlocking means of each
panel are arranged opposite to the other of the block so as to
allow the block to be reversible, or used in either vertical
orientation.
[0011] In another aspect, the invention provides an insulating
concrete form block comprising a pair of foam panels separated by
two or more ties, wherein each of the panels has an interlocking
means for engaging neighbouring blocks, and wherein the block has a
first plane of symmetry extending diagonally between the top of one
panel to the bottom of the other panel and a second plane of
symmetry extending diagonally between the top right corner to the
bottom left corner of the block. The panels of the block are
provided with an alignment means to ensure vertical alignment of
the ties when the blocks are stacked.
[0012] In another aspect, the invention provides a reversibly
stackable insulating concrete form block, for use in a concrete
form system, comprising: first and second foam panels, arranged
opposed and parallel to each other and spaced apart by a
predetermined distance; and two or more ties extending
perpendicularly between the panels to maintain the panels in the
spaced apart orientation. In each panel, its top and bottom edges
and left and right ends have: a) a first interlocking means for
engaging a respective panel of a block vertically adjacent thereto;
b) a second interlocking means for engaging a respective panel of a
block located horizontally adjacent thereto; and c) a tie aligning
feature for vertically aligning ties of vertically adjacent blocks.
In the block, the panels of the block are arranged in opposite
orientation with respect to each other whereby the block can be
engaged with other vertically adjacent blocks in either a
right-side up or upside-down orientation.
[0013] In another aspect, the present invention provides a
reversibly stackable insulating concrete form block, for use in a
concrete form system, comprising: first and second foam panels,
arranged opposed and parallel to each other and spaced apart by a
predetermined distance; and two or more ties extending
perpendicularly between the panels to maintain the panels in the
spaced apart orientation. Each panel includes a top edge, a bottom
edge, and left and right ends. Also, in each panel: a) one of the
top and bottom edges includes a first tongue extending
longitudinally along the edge; b) the other of the top and bottom
edges includes a first groove extending longitudinally along the
other edge and being adapted to receive a tongue having the
dimensions of the first tongue; c) one of the left and right ends
includes a second tongue extending longitudinally along the end; d)
the other of the left and right ends includes a second groove
extending longitudinally along the other end and being adapted to
receive a tongue having the dimensions of the second tongue; e) two
or more projections extending from the edge having the first
tongue; and f) two or more recesses provided on the edge having the
first groove. The panels of the block are arranged in opposite
orientation with respect to each other whereby the top of the first
panel faces the bottom of the second panel and the right end of the
first panel faces the left end of the second panel.
[0014] In a third aspect, a reversibly stackable insulating
concrete form block, for use in a concrete form system is provided.
The block comprises first and second panels, arranged opposed and
parallel to each other and spaced apart by a predetermined
distance; and two or more ties extending perpendicularly between
said panels to maintain the panels in said spaced apart
orientation. Further, on the first panel, on its top edge there is
at least one positive feature for engaging a panel of a block
vertically adjacent thereto; on its bottom edge, there is at least
one negative feature for receiving a corresponding positive feature
of the adjacent panel. Also, on the second panel, on its bottom
edge, there is a compatible positive feature to the positive
feature on the first panel; and on its top edge, there is a
compatible negative feature to the negative feature on the first
panel. The features are located on the respective edges such that
the block can be engaged with other vertically adjacent blocks in
either: a right-side up orientation with the negative feature of
the first panel engaging a corresponding positive feature on an
adjacent panel of a block below; or an upside-down orientation with
the compatible negative feature engaging the corresponding positive
feature on the adjacent panel.
[0015] In other aspects various combinations of sets and subsets of
the above aspects are provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The features of the invention will become more apparent in
the following detailed description in which reference is made to
the appended drawings wherein:
[0017] FIG. 1 is a perspective view of a prior art form block;
[0018] FIG. 2 is an end elevation of the prior art block of FIG.
1;
[0019] FIG. 3 is a perspective view of a prior art form constructed
with a plurality of form blocks;
[0020] FIG. 4 is a perspective view of a form block according to an
embodiment of the present invention;
[0021] FIG. 5 is a front elevation of the block of FIG. 4;
[0022] FIG. 6 is a plan view of the block of FIG. 4;
[0023] FIG. 7 is an end elevation of the block of FIG. 4;
[0024] FIG. 8 is a rear elevation of the block of FIG. 4;
[0025] FIG. 9 is a front elevation of a tie used in forming the
block of FIG. 4; and
[0026] FIG. 10 is a perspective view of an embodiment of the
invention for use in a corner.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 illustrates a prior art form block as described, for
example, in U.S. Pat. No. 5,896,714. As shown, the block 10
comprises opposing panels 11 and 12 made of an insulating foam
material as will be known to persons skilled in the art. The panels
11 and 12 are joined together by means of a plurality of ties 13
extending there-between. The panels 11, 12 are maintained in an
aligned and parallel manner, with the ties 13 extending
perpendicularly between the panels. As shown in FIG. 1 and as known
in the art, the facing surfaces of each panel 11 and 12 are
preferably provided with a plurality of grooves so as to form a
stronger bond with the concrete.
[0028] FIG. 2 illustrates an end view of the block of FIG. 1 and
more clearly illustrates the tongues 24 and grooves 26 of the prior
art form block. FIG. 2 also illustrates the ties 13 as known in the
art. The ties comprise a central, planar web portion and two
flanges on opposite ends of the web portion. The flanges are
embedded within the foam panels 11 and 12 and are preferably
designed to extend over the entire height of each panel. In this
way, when the blocks are stacked and the ties vertically aligned,
the flanges provide continuous strips to which fasteners etc. may
be attached.
[0029] FIG. 3 illustrates a partial form constructed with a
plurality of blocks 10 arranged both horizontally and vertically
(i.e. stacked) according to the dimensions of the wall required.
Also illustrated in FIG. 3 is a corner block 20, which has a
similar construction to the linear block 10 but includes a
90.degree. corner. It will be understood that the corner block can
include any desired angle apart from 90.degree.. FIG. 3 also
illustrates at 22, the alignment of the flanges of the ties. As
discussed above, by vertically aligning each tie when the blocks 10
are stacked, the 20 flanges form a continuous vertical strip, as
shown at 22, to which various types of fasteners may be secured for
attaching wall coverings etc. As can also be seen in FIG. 3, the
outer surfaces of the panels may be provided with features such as
embossing or other such indicia as taught in the prior art to
identify the locations of the flanges.
[0030] Returning to FIG. 1 once more, the panels 11 and 12 are
provided with a number of features that enable adjacent blocks to
engage each other so as to ensure that, once the form is erected,
the blocks are maintained in position. These interlocking features
comprise, firstly, a longitudinally extending tongue 24 provided on
the top of each panel 11 and 12 and a longitudinally extending
groove 26 provided on the bottom of each panel. The tongues 24 and
grooves 26 are designed so as to permit the tongues on the tops of
the panels of one block to enter into the grooves on the bottoms of
the panels of an adjacent block when the blocks are stacked. This
engagement serves to restrict adjacent panels from moving with
respect to each other. Further, each end of the panels is provided
with either a tongue or groove to engage the panel of an adjacent
block. However, as shown in FIG. 1, the tongues and grooves on the
sides of the panels are oppositely provided. That is, on one side
of the block, one of the panels, 11, is provided with a tongue 28
while the other panel, 12, is provided with a groove 30.
[0031] As can be seen, particularly in FIG. 1, the block of the
prior art can be rotated about its vertical, or transverse axis and
still be stackable with adjacent blocks. However, as can also be
seen, if the block 10 is rotated about its horizontal, or
longitudinal axis, and stacking of the block on another is
attempted, the required interlocking cannot be achieved. This is
due to the fact that, as described above, the tops and bottoms of
the blocks are structured differently. Specifically, the result of
such stacking would be either two sets of grooves or two sets of
tongues abutting each other.
[0032] As also shown in FIG. 1, the panels of the blocks are
provided with a plurality of projections 32 and corresponding
recesses 34 on the tops and bottoms, respectively, of each panel
11, 12. The projections 32 and recesses 34 are features which serve
to locate vertically adjacent blocks so as to ensure alignment of
the ties 13 when the blocks are stacked. As with the tongues and
grooves described above, the projections and recesses of the prior
art blocks inhibit stacking if the blocks are not oriented in the
same direction. It will be appreciated that the features may be
provided as complementary "positive" and "negative" features formed
to mate with each other. As noted in more detail below, a
"positive" feature, generally, is any outward formation on the edge
of the panel, while a "negative" feature, generally, is any inward
formation on the edge.
[0033] FIGS. 4 to 8 illustrate an embodiment of the present
invention. Referring first to FIG. 4, a foam form block 100 is
shown in perspective. As can be seen, the block has some features
of the prior art block discussed above and as more specifically
described in U.S. Pat. No. 5,896,714 (the entire disclosure of
which is incorporated herein by reference). The block 100 is
comprised of a pair of foam panels 110 and 112, arranged in a
parallel and opposed manner. The panels 110 and 112 are maintained
a specified distance apart by means of a plurality of ties 114
extending there-between. Each block is provided with at least two
ties, and preferably a plurality of ties, with each tie provided
longitudinally spaced along the length of the block as is known in
the art. The ties will be discussed further below.
[0034] It is notable that the panels 110 and 112 have top and
bottom edges and right and left ends, each including either a
tongue or groove, as will be described further below. Each of the
tongues and grooves serve, as described above, to interlock the
panels of one block to panels of other blocks, located vertically
or horizontally adjacent thereto. It will be understood that the
terms "top", "bottom", "right", and "left" are used herein purely
for the sake of convenience in referring to the figures and that
use of such terms is not intended to mean that a block must have
any particular orientation. The tongue can be viewed as a
"positive" feature extending from the surface of an edge, while the
groove can be viewed as a "negative" feature extending into the
surface of an edge.
[0035] As shown in FIGS. 4 to 8, the top longitudinal edge 116 of
panel 110 is provided with a groove 118 extending along the length
of the edge 116. Groove 118 is positioned within the thickness of
the panel 110. However, in other embodiments, it may be positioned
anywhere across the thickness of the panel. Similarly, the bottom
longitudinal edge 120 of the opposite panel 112 is also provided
with a groove 122 that is identical to groove 118 in both
dimensions and position along the width of panel 112.
[0036] The bottom longitudinal edge 124 of panel 110 and the top
longitudinal edge 126 of panel 112 are provided with tongues 128
and 130, respectively, which extend along the lengths of the edges
124 and 126. The tongues 128 and 130 are sized and located so as to
engage the grooves 118 and 122 described above, when blocks are
stacked on top of each other in the process of erecting a form. For
example, the tongue 128 of panel 110 would engage the groove 118 of
a similar panel underneath with a similar engagement taking place
between the tongue 130 of panel 112 and a groove 122 of an adjacent
panel. In this manner, vertically adjacent blocks are secured
together when stacked.
[0037] In order to assist in securing horizontally adjacent blocks
together, the panels of the blocks are provided with a further
tongue and groove structure, similar to that described above. As
illustrated in FIGS. 4 to 8, the right end 132 of panel 110 is
provided with a groove 134 extending the entire height of the
panel. The left end 136 of panel 110 is provided with a tongue 138
being dimensioned to be received within a groove similar to 134 of
a horizontally adjacent panel. Similarly, the right end 140 of
panel 112 is provided with a tongue 142 while the left end 144 of
panel 112 is provided with a correspondingly dimensioned groove
146. As indicated previously, the combination of tongues 138 and
142 and grooves 132 and 146 allows horizontally adjacent blocks to
be engaged together.
[0038] As shown in FIGS. 4 to 8, the blocks 100 of the invention
are also provided with a plurality of projections (as positive
features) and recesses (as negative features), described further
below, for ensuring that the ties 114 of stacked blocks are
vertically aligned. Referring to FIGS. 4 to 8, the top edge 126 of
panel 112 of the block 100 is provided with a plurality of
projections 148. The projections 148 are preferably elongate and
extend transversely from the tongue 130 to the external face of the
panel 112, the external face being that surface facing away from
panel 110. The projections 148 are provided in pairs, one on each
side of a tie 114. The spacing between adjacent pairs of
projections 148 is preferably greater than the spacing between
respective projections 148 of a pair. The bottom edge 124 of panel
110 is also provided with pairs of projections 150 arranged in the
same manner and having the same dimensions and positioning as
projections 148.
[0039] As shown more clearly in FIGS. 5 and 8, the top edge 116 of
panel 110 and the bottom edge 120 of panel 112 are, in turn,
provided with recesses 152 and 154, respectively, which are adapted
to receive projections 148 and 150 of vertically adjacent panels.
Recesses 152 and 154 are provided in pairs, in the same manner as
the projections, wherein each recess of each pair is located one on
opposite sides of a tie 114. Further, as with the projections, the
recesses 152 and 154 are elongate and extend from the longitudinal
grooves 118 and 122, respectively, to the external faces of the
panels 110 and 112.
[0040] The projections 148 and 150 are adapted to mate and to be
engaged in recesses 152 and 154 when two blocks 100 are stacked
above each other. For example, if a bottom block is provided in the
orientation as shown in FIGS. 4 to 8, that is with the top edge 116
of panel 110 extending upwards, another block positioned above will
have projections similar to projections 150 and will engage the
recesses 152 of panel 110. On the other hand, if block 100 is
provided with the top edge 116 extending downwards, it will be
understood that the next block stacked above it will be similarly
reversed in orientation. The figures illustrate projections 148 and
150 as having a tongue shape and the associated recesses 152 and
154 as having a groove shape. It will be understood that various
modifications of this embodiment will be possible.
[0041] It will be noted that the features of the block 100
described above allow it to be stacked and positioned with other
blocks in a form regardless of whether the "top" edges are directed
upwardly or downwardly. For example, should a first block be
positioned in the orientation shown in FIGS. 4 to 8, the next block
can have the same orientation as the first or can be rotated so
that its "top" edge points downwardly. In such case, the block
would need to be rotated 180.degree. about its vertical axis as
well in order to allow the longitudinal tongues and grooves and the
projections and recesses to engage one another.
[0042] In other words, in one embodiment, the panels of each block
are arranged in an opposite manner with respect to each other so as
to provide the block with two diagonal planes of symmetry. The
first plane extends diagonally across the block from the top of one
edge, through the centre, and to the bottom of the opposite edge.
The second plane similarly extends from the top of one end of the
block, through the centre, and to the bottom of the opposite end.
This orientation allows the block to be rotated about either axis
(i.e. reversible) while still being able to be stacked on another
block.
[0043] As such, if on a first panel, its top edge has an
arrangement of positive features on its face (e.g. one or more
longitudinal tongues, one or more transverse tongues, one or more
blocks, domes, nodules, pikes, poles, etc.), then on the bottom
edge of that panel, there should be a complementary set of negative
features on its face (e.g. depressions, gaps, grooves,
indentations, notches, slots, etc.) to receive and mate with each
of the positive features. It will be appreciated that there may be
additional negative features on the bottom edge. For the second
panel, on its top edge, there should also be a similar arrangement
of complementary negative features on its face to receive and mate
with each of the positive features on the top edge of the first
panel. For the bottom edge of the second panel, there should be
another set of positive features, as provided on the top edge of
the first panel. It will be appreciated, however, in order to allow
stacking of a block either in a right-side up or upside down
orientation to its neighbour below, full symmetry of all positive
features on the cross-corner longitudinal edges is not always
necessary. On a first panel, one edge can have a set of positive
features, while the cross-corner edge on the other panel needs to
have only at least one of the positive features located in a
mirrored location on the cross-corner edge of the other panel. As
such, if the block is turned 180 degrees about its longitudinal
axis, then the edge having the lesser number of positive features
will still mate with the corresponding negative features in the
neighbouring block.
[0044] In other embodiments, a longitudinal top edge of the first
panel may have both positive and negative features. On the bottom
edge of that panel, there would be a complementary arrangement of
negative and positive features to mate with the corresponding
opposing feature on the top edge. Meanwhile, on the second panel,
the top edge would have the same complementary arrangement of
negative and positive features as on the bottom of the first panel.
Also, the bottom edge of the second panel would have the same
arrangement of positive and negative features of the top edge of
the first panel. In other embodiments, the bottom edge of the
second panel would have simply at least a sufficient subset of the
features of the top edge of the first panel to provide that when
the block is turned 180 degrees about its longitudinal axis, the
block can mate either "right-side up" or "upside-down" with another
stacked block.
[0045] It will be appreciated that in one embodiment, the positive
and negative features mate such that there is a reasonably tight
coupling of at least some surfaces of the positive features with at
least some surfaces of the negative features. However, in other
embodiments, there may be a looser coupling or fitting of the
positive features to the negative features, such that the negative
features are larger in size than the positive features. For
example, if a top edge has two or more positive features thereon,
then in a loose coupling arrangement, the corresponding negative
features on the bottom edge be one large feature which is sized to
accept both positive features therein. In other embodiments, the
positive features on one top edge of one panel may be copied on the
bottom edge of the other panel. Similarly, the negative features on
the bottom edge of one panel may be copied on the top edge of the
other panel. In other embodiments, the features on the transverse
edge of the other panel may not be a copy, but would still be of a
compatible form to mate with the corresponding features of the
neighbouring panel. As such, there does not necessarily have to be
perfect symmetry of features from one edge of a panel to its
corresponding transverse edge of the other panel. However, there
should be sufficient compatibility of the features, in size, number
and position such that if the form is stacked either right-side up
or upside down, then the positive or negative features on the
bottom edges of both panels, in either orientation, should be
engaged with the corresponding features on the top edges of the
panel underneath and the panel should lie flat thereagainst.
[0046] Therefore, the block of the invention is capable of being
stacked over another block in either an upside-down or
right-side-up orientation. This feature maximizes the number of
orientations in which the block, or sections of block can be used
thereby minimizing waste. For example, in some cases, a block would
need to be cut to a desired length. In such cases, the portion of
the block not used would normally need to be discarded since, in
order to use it, a similar section of block with the same
orientation of tongues/grooves would be needed. However, with a
block of the present invention, the entire block or a section of
the block can be rotated about either the vertical or horizontal
axis and still be used in creating the concrete form.
[0047] FIG. 9 illustrates an embodiment of the ties 114 as used in
the block of the invention. As shown, the ties 114 include a
central, generally planar web portion 156 comprising a plurality of
co-planar, intersecting members 157. As known in the art, ties 114
can be made of any type of generally rigid material and are
preferably made of a plastic, such as high density polyethylene or
polypropylene. The web portion has an upper end 158 and a lower end
160 as well as opposing sides 162 and 164. Each side 162 and 164 of
the web portion 156 includes a flange 166. Each flange 166
comprises a generally flat element that lies perpendicular to the
plane of the web 114. The flanges 166 are designed to engage the
foam panels (described above). The flanges 166 are generally
embedded within respective foam panels and this may be achieved by
causing such foam to form around the flange or by inserting the
flange into pre-cut slots in the foam panel. As indicated above,
the flanges 166 preferably have a length that generally corresponds
to the height of the panels 110 and 112. In this manner, the
flanges 166 extend across substantially the entire height of the
block 100. The web portions 156 of the ties 114 are provided with a
plurality of apertures or clips 168 for receiving rebar and the
like. As will be known to persons skilled in the art, rebar is used
to reinforce the concrete that is provided between the panels of
the block. The rebar clips 168 are either provided on or formed as
part of transverse members 169 of the web 156.
[0048] As shown in FIG. 9, the web portion 158 preferably includes
a line of symmetry, M, which separates the tie into two mirror
image sections. This allows the tie 114 to be used in either
vertical orientation. As will be noted, each of the mirror image
sections includes at least two rows of rebar clips 168, the two
rows being provided in a "face up" and "face down" orientation.
This arrangement allows the rebar clips 168 to be easily accessible
regardless of the vertical orientation chosen.
[0049] Various other features and variations of the ties 114 will
be apparent to persons skilled in the art. For example, although
the above embodiment has described ties that are unitary in
structure, it is known, for example, for the web portion of the
ties to comprise a separate piece, thereby enabling the block to be
assembled on site. It is also known in the art to minimize the area
occupied by the intersecting members of the web so as to reduce
inhibition of concrete flow there-through. However, in other
embodiments, the tie can include various other intersecting members
in order to impart additional strength to the block. Further, it
will be understood that the spacing between the panels of the block
will depend upon the length of the web of the tie.
[0050] Referring once more to FIGS. 5 and 8, the external faces of
each panel 110, 112 of the block is provided with a plurality of
indicia, in the form of vertical lines or the like, to identify the
locations of each tie. As known in the art, and as specifically
taught in U.S. Pat. No. 5,896,714, such indicia may comprise
embossing, printing, depressions, or any other such visible
markings to facilitate the engagement of the protrusions (148, 150)
with corresponding recesses (152, 154) and, therefore, enable
stacking of blocks above each other. As mentioned above, the
specific placement of protrusions and corresponding recesses serve
to positively locate each block so as to align the ties. As
illustrated in FIG. 3, it is preferred to stack the blocks in a
staggered manner so as to avoid a continuous joint between adjacent
blocks. This is a standard practice and is also taught in U.S. Pat.
5,896,714. It will be understood that to facilitate the
reversibility of the block as discussed above, the indicia would
preferably be provided on both panels.
[0051] FIG. 10 illustrates another embodiment of the invention,
which comprises a corner block 200. As shown, the corner block 200
includes panels 210 and 212 as before. The structure of each panel
is essentially the same as that of the panels 110 and 112 described
above. Panels 210 and 212 include respective tongues 214, 216 and
grooves 218, 220. As described above, each tongue and groove
interacts with a corresponding other in vertically adjacent blocks
so as to positively engage each other. The panels 210 and 212 also
include respective projections 222, 224 and corresponding recesses
226, 228. Generally, the projections and recesses are provided in
pairs as described above. However, in the corner portion of the
corner block, additional projections 230 are provided without
corresponding to ties but still serve to position vertically
adjacent blocks. Further, on the inner panel 210, the corner
portion is provided with only one projection 232 and recess 234 for
each tie. The embodiment shown in FIG. 10 can comprise either an
inside or outside corner, depending upon the positioning of the
linear blocks described above. For example, the block 200 of FIG.
10 would comprise an outer corner block if the remaining blocks of
the form are arranged with top directed projections (that is
projections on the "top" end of the block) on the outer facing
panel. If, on the other hand, the blocks of the form are arranged
with the top directed projections provided on the inner facing
panel, the block 200 of FIG. 10 would be used for inside
corners.
[0052] It will be understood that another embodiment of the corner
block, panel 210 would include top directed projections while the
opposite panel 212 would include top directed recesses, which is
the opposite orientation of the embodiment shown in FIG. 10.
[0053] Although the corner block of FIG. 10 is illustrated with a
90.degree. bend, it will be understood that any desired angle can
be provided.
[0054] Although the invention has been described with reference to
certain specific embodiments, various modifications thereof will be
apparent to those skilled in the art without departing from the
spirit and scope of the invention as outlined in the claims
appended hereto. The entire disclosures of all references mentioned
above are incorporated herein by reference.
* * * * *