U.S. patent application number 11/856528 was filed with the patent office on 2008-07-17 for load bearing wall formwork system and method.
Invention is credited to Pablo Rodriguez Acosta, Fausto Bejarano Castillo, Ronald Jean Degen, Humberto Trimino Vasquez.
Application Number | 20080168734 11/856528 |
Document ID | / |
Family ID | 39616707 |
Filed Date | 2008-07-17 |
United States Patent
Application |
20080168734 |
Kind Code |
A1 |
Degen; Ronald Jean ; et
al. |
July 17, 2008 |
LOAD BEARING WALL FORMWORK SYSTEM AND METHOD
Abstract
A load bearing wall formwork system and method are disclosed.
The load bearing wall formwork system comprises a unique clip
assembly for joining two or more substantially planar structures,
such as a wall panel, in a spaced apart manner and providing a
space there between for placement of a flowable material. The clip
assembly comprises a first clip member having a first side for
attachment to the wall panel, a second side and an opening
positioned between the first and second sides, as well as a second
clip member, engageable with the first clip member, having a first
side for attachment to a second wall panel, a second side and an
opening positioned between the first and second sides. The openings
provided in the first and second clip members are aligned when the
clip members are engaged. A connecting member is insertable into
the aligned openings of the first and second clip members,
connecting the first and second clip members together. A wall
formed by the foregoing components and a method of assembling a
wall formwork are also disclosed.
Inventors: |
Degen; Ronald Jean;
(Santiago, CL) ; Castillo; Fausto Bejarano; (San
Jose, CR) ; Acosta; Pablo Rodriguez; (San Jose,
CR) ; Vasquez; Humberto Trimino; (San Jose,
CR) |
Correspondence
Address: |
DORSEY & WHITNEY LLP;INTELLECTUAL PROPERTY DEPARTMENT
SUITE 1500, 50 SOUTH SIXTH STREET
MINNEAPOLIS
MN
55402-1498
US
|
Family ID: |
39616707 |
Appl. No.: |
11/856528 |
Filed: |
September 17, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60826283 |
Sep 20, 2006 |
|
|
|
Current U.S.
Class: |
52/520 ;
52/220.2; 52/584.1; 52/92.1 |
Current CPC
Class: |
E04B 2/8635 20130101;
Y10T 24/4465 20150115 |
Class at
Publication: |
52/520 ;
52/220.2; 52/584.1; 52/92.1 |
International
Class: |
E04B 2/08 20060101
E04B002/08; E04C 2/52 20060101 E04C002/52; E04B 7/04 20060101
E04B007/04 |
Claims
1. A clip assembly for joining two or more substantially planar
structures in a spaced apart manner, the clip assembly comprising:
a first clip member comprising an attachment member for attachment
to a planar structure, an engagement member attached to the
attachment member having first and second engagement arms; and an
opening positioned in the engagement member; a second clip member
engageable with the first clip member, the second clip member
comprising an attachment member for attachment to a second planar
structure, an engagement member attached to the attachment member
having first and second engagement arms and an opening positioned
in the engagement member, the openings of the first and the second
clip members being aligned when the clip members are engaged; and a
connecting member positioned in the aligned openings of the first
and second clip members.
2. The clip assembly of claim 1, wherein the attachment member
comprises a first longitudinal member and a second longitudinal
member.
3. The clip assembly of claim 2, wherein the first and second
longitudinal members comprise an attachment arm and a raised arm,
wherein the raised arm is in contact with the engagement member and
spaces the engagement member a distance from the attachment to the
wall panel.
4. The clip assembly of claim 3, wherein the first and second clip
members are fastened to the planar structures at the attachment arm
of the attachment member.
5. The clip assembly of claim 1, wherein the clip members are
metal.
6. The clip assembly of claim 1, wherein the connecting member
comprises a rod.
7. The clip assembly of claim 1, wherein the substantially planar
structures comprise panels.
8. A clip assembly comprising: a first clip member having an
attachment member and an engagement member, the engagement member
having a first engagement arm and a second engagement arm, each
engagement arm having an opening; a second clip member having an
attachment member and an engagement member, the engagement member
having a first engagement arm and a second engagement arm, each
engagement arm having an opening, the first and second clip members
engageable at the engagement arms so as to align the openings; and
a connecting member positioned within the aligned openings of the
first and second clip members.
9. The clip assembly of claim 8, comprising more than one opening
in at least one of the clip members.
10. The clip assembly of claim 8, wherein the attachment member
comprises a first longitudinal member and a second longitudinal
member.
11. The clip assembly of claim 8, wherein the first and second
longitudinal members comprise an attachment arm and a raised arm,
wherein the raised arm is in contact with the engagement member,
spacing the engagement member a distance from a position of
attachment.
12. A formwork section for a load bearing wall structure
comprising: a first wall panel and a second wall panel; a first
clip member attached to the first wall panel, the first clip member
having an opening therein; a second clip member attached to the
second wall panel, the second clip member having an opening
therein, the second clip member being engaged with the first clip
member so as to align the opening of the first clip member and the
opening of the second clip member; and a connecting member
connecting the first and second clip members at the aligned
openings.
13. The formwork section of claim 12, wherein the connecting member
is a rod.
14. The formwork section of claim 12, further comprising an
additional structural reinforcement material and two hoisting bar
assemblies.
15. The formwork section of claim 12, further comprising concrete
between the first and second wall panels.
16. The formwork section of claim 12, wherein the wall panels
comprise fiberboard.
17. A clip bracket for a panel assembly comprising: an attachment
member for attachment to a panel; a first engaging arm attached to
the attachment member and spaced a distance from the panel; a
second engaging arm attached to attachment member, parallel with
the first engaging arm and spaced a distance from the panel; an
opening in the first engaging arm; and an opening in the second
engaging arm substantially aligned with the opening in the first
engaging arm.
18. The clip bracket of claim 17, further comprising an additional
opening in at least one of the first and second engaging arms.
19. The clip bracket of claim 18, wherein each of the first and
second engaging arms comprises an additional opening.
20. The clip bracket of claim 17, further comprising a base member
in contact with the attachment member and the first and second
engagement arms.
21. A wall comprising: a first panel and a second panel; a first
clip member attached to the first panel, the first clip member
having an attachment member, a first engaging arm and a second
engaging arm, the first clip member also comprising an opening; a
second clip member attached to the second panel, the second clip
member having an attachment member, a first engaging arm, and a
second engaging arm, the second clip member also comprising an
opening, the second clip member being engaged with the first clip
member, wherein the opening of the first clip member and the
opening of the second clip member are aligned; a connecting member
positioned at the aligned openings of the first and second clip
members; and a flowable material in a space between the first panel
and the second panel.
22. The wall of claim 21, wherein the flowable material comprises
concrete.
23. The wall of claim 21, wherein the flowable material surrounds
at least a portion of the clip members and connecting member.
24. The wall of claim 21, wherein the connecting member comprises a
rod.
25. The wall of claim 21, wherein the panel comprises fiberboard.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S.
Provisional Application No. 60/826,823, filed on Sep. 20, 2006,
entitled "Load Bearing Wall Formwork System and Method" by Ronald
Jean Degen, Fausto Bejarano Castillo, Pablo Rodriguez Acosta and
Humberto Trimino Vasquez, the contents of which are incorporated in
by reference.
FIELD OF INVENTION
[0002] This invention relates to concrete forming structures and
bearing walls, ceilings and floors.
BACKGROUND
[0003] Concrete and wall forming systems are known. Such systems
typically include form members secured in place a distance apart,
between which concrete or cement is placed. For instance, in a
concrete forming system, a first form member is secured in position
and a second form member is secured in position a distance from the
first form member. As a result, a space exists between the form
members. Within this space, concrete or cement is placed in a
partially fluid form. Once the concrete sets, the forms are
removed, revealing a wall, floor, or ceiling. In some instances,
forms may be connected by a bridge or structural member spanning
between the forms to hold the forms in place. Likewise, in some
systems, the forms are retained in place and insulating material is
provided between the forms. In building construction, it is common
to include a web or mesh of reinforcing material such as rebar
between the form members prior to adding the concrete, which is
then engulfed by the concrete to provide strength to the hardened
concrete structure along the weak axis of the solidified
concrete.
[0004] The foregoing systems, however, suffer drawbacks. These
structures often comprise numerous components, components that must
be used and discarded, and components which are difficult to
assemble, making assembly of the complete structure both time
consuming and costly. Moreover, concrete wall forming systems that
are connected by a bridge member often-times lack strength to
support a significant load or resist stresses thereon.
[0005] In view of the foregoing, a need exists for a bearing wall
system which is both easy to assemble and has significant
structural strength.
SUMMARY OF THE INVENTION
[0006] A load bearing wall formwork system and method are
disclosed. The load bearing wall formwork system comprises a unique
clip and assembly for joining two or more substantially planar
structures, such as a wall panels, in a spaced apart manner.
[0007] The clip assembly comprises a first clip bracket or member,
and a second clip bracket. The first clip member has a first side
for attachment to the first planar structure, a second side
opposite the first side and a first opening positioned between the
first and second sides. A second clip bracket or member, which is
engageable with the first clip bracket, is also provided having a
first side for attachment to a second planar structure, a second
side opposite the first side, and an opening between the first and
second sides. The openings provided in the engaging sections of the
first and second clip brackets are aligned when the clip brackets
are engaged. A rod or connecting element is insertable into the
aligned openings of the first and second clip brackets, maintaining
the first and second clip brackets in the engaged condition and,
therefore, retaining the first and second planar structures in a
spaced-apart orientation.
[0008] The clip bracket for the panel assembly comprises an
attachment member for attachment to a panel, a first engaging arm
attached to the attachment member and spaced a distance from the
panel, and a second engaging arm attached to attachment member
parallel with the first engaging arm and spaced a distance from the
panel. The first and second engaging arms include openings therein.
These openings are substantially aligned to allow for the insertion
of a connecting element or other device.
[0009] The method for assembly of a load bearing wall including the
foregoing components comprises the steps of providing a first wall
panel and a second wall panel, attaching a first clip member or
bracket having an engagement member and an opening in the
engagement member to the first wall panel, and attaching a second
clip member or bracket having an engagement member and an opening
in the engagement member to the second wall panel. In a preferred
embodiment, a plurality, or more preferably a defined number, of
first clip brackets and second clip brackets are attached to first
and second wall panels. After attaching the clip brackets to the
walls, reinforcing elements may be attached to one or more of the
wall panel(s). The second wall panel is positioned in an opposed
relation to the first wall panel, so that the first and second clip
members face each other. The first and second wall panels with
attached clip members are then moved into engagement, engaging the
first and second clip members at their engagement members.
Subsequently, the openings in the engagement member of the first
and second clip members are aligned. A connecting member, such as a
rod, is inserted into the aligned openings of the clip brackets.
When a plurality of clip brackets assemblies are used, a plurality
of connecting members are inserted into the aligned openings of the
clip bracket rows and/or columns. In a preferred embodiment, the
assembled bearing walls may be transported to the building site,
placed in their corresponding position on the foundation or floor
slabs and attached to each other to conform the designed structural
walls. Finally, a flowable material, such as concrete, is placed
into the space defined between the first and second wall panels and
allowed to harden, forming the wall.
[0010] Other aspects, features and details of the present invention
can be more completely understood by reference to the following
detailed description in conjunction with the drawings, and from the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of the first and second clip
brackets attached to a bearing wall assembly and engaged and
aligned to each other with the connecting rod positioned according
to the preferred embodiment.
[0012] FIG. 2 is a perspective view of a first clip bracket as used
in the assembly shown in FIG. 1.
[0013] FIG. 3 is an end elevational view of the clip bracket shown
in FIG. 2.
[0014] FIG. 4 is a side elevational view of the clip bracket shown
in FIG. 2.
[0015] FIG. 5 is a perspective view of a second clip bracket as
shown in FIG. 1.
[0016] FIG. 6 is an end elevational view of the clip bracket of
FIG. 5.
[0017] FIG. 7 is a side elevational view of the clip bracket of
FIG. 5.
[0018] FIG. 8 is a top plan view of the clip bracket of FIGS. 2 and
5.
[0019] FIG. 9 is a perspective view of the assembly absent a
connecting member.
[0020] FIG. 10 is an end elevational view of an alternative
embodiment of the clip bracket.
[0021] FIG. 11 is an end elevational view of an alternative
embodiment of the clip bracket.
[0022] FIG. 12 is an end elevational view of an alternative
embodiment of the clip bracket.
[0023] FIG. 13 is a perspective view of a hoisting bar assembly
according to one embodiment.
[0024] FIG. 14 is a perspective view of a hoisting bar plate shown
in FIG. 13.
[0025] FIG. 15 is a perspective view of a hoisting bar shown in
FIG. 13.
[0026] FIG. 16 is a perspective view of a hoisting bar assembly
attached to first and second wall panels.
[0027] FIG. 17 is a perspective view of a wall panel assembly
having clip brackets thereon.
[0028] FIG. 18 is a perspective view of adjacent wall panels in an
assembly having clip brackets thereon.
[0029] FIG. 19 is a perspective view of a wall panel assembly of
FIG. 18, having structural steel reinforcements positioned
thereon.
[0030] FIG. 20 is a perspective view showing wall panel assemblies
in an opposed relation for assembly.
[0031] FIG. 21 is a cut away perspective view of the assembly of a
preferred embodiment.
[0032] FIG. 22 in an elevated perspective view of a single wall
panel comprising clip members and a connecting element.
[0033] FIG. 23 is a perspective view of an assembly having clip
members and a connecting element.
[0034] FIG. 24 is a perspective view of a wall assembly of FIG. 21
having flowable material between the wall panels.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] As can be seen from the Figures, a clip assembly 20 for
joining two or more substantially planar structures or wall panels
is provided. While "wall" is used for purposes of discuss herein,
the system and assembly may be applied to walls, floors, ceilings,
or other supporting structures. Likewise, while "panel" and "planar
structure" are used herein, any board or like structure may be
substituted in place of same.
[0036] Specifically, a clip assembly 20 for joining two or more
panels 22, 24 in a spaced apart manner is disclosed. As can be seen
in FIG. 1, the clip assembly 20 includes a first clip bracket 26,
or member, that has a first side 28 for attaching to a panel 22 or
24 and a second side 30 opposite the first side. A second clip
member 28 is also provided. The second clip member 28 or bracket,
has a first side 34 for attachment to a second panel 24 and a
second side 36 opposite the first side. The second clip member 28
is engageable with the first clip member 26. In a preferred
embodiment, the second sides 30, 36 or ends of each clip member 26,
32 overlap in the assembled state. The first clip member 26 and the
second clip member 32 further include an opening 38, 40 positioned
therein. Preferably, each clip member 26, 32 includes at least two
aligned openings 38 or 40. Moreover, the openings 38, 40 in the
first and second clip members 26, 32 are aligned when the clip
members are engaged (see FIG. 9). As a result, an opening, or hole,
passes through the first clip bracket 26 and the second clip
bracket 32. A connecting member 42 or element may be used to attach
the first clip member 26 to the second clip member 32. In a
preferred embodiment, rod 42 may be inserted into the aligned
openings 38, 40 of the first and second clip brackets 26, 32 to
connect or link the brackets. Namely, rod 42 passes through the
opening(s) 38 in the first clip bracket 26 and the opening(s) 40 in
the second clip bracket 32, securing the brackets together. As will
be discussed in further detail herein, the rod 42 may further
comprise an end having a retention means, such as a bend in the rod
or other attached structure. The bend prevents the rod 42 from
sliding from its position in the clip bracket.
[0037] The wall panels 22, 24 or planar structures, discussed
herein may comprise fiber board, wall board, composites, concrete,
cement, masonite, fiber cement, wood, plastic, polyurethane, and/or
combinations thereof. For example, a wall panel comprising an
organic fiber cement asbestos-free board having no crystalline
silica added, which is based upon a mixture of cellulose fibers,
cement and calcium carbonate, with or without ARGF and with or
without impregnator coating may be used for the assembly described
herein. Moreover, the planar structures or wall panels may be of
any size and thickness preferred by the manufacturer or the user.
The clip brackets may comprise a metal material, such as steel,
aluminum, and/or other metals of sufficient rigidity to retain the
wall panels 22, 24 a distance apart and support a load of a desired
weight. However, plastics and other composites and/or materials
meeting the desired characteristics may also be used for the clip
members herein, or portions thereof. The clip brackets may be of
any size and thickness preferred by the manufacturer or the user.
The connecting member 42 preferably comprises a steel rod, such as
a rebar rod, or like structural rod for use in construction, but
other metals, plastics, and/or composites may be used. The rod may
be of any size and thickness preferred by the manufacturer or the
user.
[0038] Referring to FIG. 1, a bearing wall assembly 100 is shown.
Specifically, a clip assembly 20 is attached to a portion of each
of a first 22 and a second 24 wall panel. As can be seen, the clip
assembly 20, generally, fastens a first substantially planar
structure 22 to a second substantially planar structure 24 in a
spaced apart manner and includes a number of open spaces 44 for the
passage of a flowable material, or structural elements. For ease of
reference, only a single clip assembly 20 is shown in FIG. 1, but
more than one clip assembly or clip bracket may be provided on the
wall structure 22 or 24.
[0039] The first clip bracket 26 is attached to a surface or face
46 of the first wall panel 22 and extends outwardly therefrom. A
second clip bracket 32 is attached to a surface or face 48 of the
second wall panel 24 and extends outwardly therefrom. Preferably,
the first and second clip members 26, 32 are provided in an
opposing orientation, so that when assembled, the second ends 30,
36 of each clip bracket are in contact or at least partially
overlap. The first clip bracket 26 and the second clip bracket 32
are further attached or secured together by connecting member 42,
such as the insertion of a rod 42 through aligned openings 38, 40
in the first and second clip members. However, other means of
attaching the first and second clip members 26, 32 may be
acceptable for the purposes provided, such as by fasteners, tongue
and groove assembly, integral clips, adhesive and other attachment
mechanisms. When fully assembled, the combined assembly 20 includes
one or more openings 44 adjacent the wall panel 22 or 24 as well as
within the assembled clip bracket(s) 26, 32. As indicated, these
openings 44 provide additional areas for insertion of structural
members, such as rods, bars or other supports. In addition, these
openings 44 provide areas in which flowable material, such as a
cement, concrete or other building material, can flow through the
structure, thereby substantially filling the space 50 between the
wall panels 22, 24.
[0040] In a preferred embodiment, the base clip assembly 20
comprises two clip brackets 26, 32 or members. Referring to FIGS.
2-11, each clip bracket 26 or 32 includes an attachment member 52
for attachment to a wall panel 22 or 24 and an engaging or
engagement member 56. The engaging member 56 has first 58 and
second 60 engaging arms that are attached to the attachment member
52 of each bracket 26, 32. The engaging arms 58, 60 are preferably
planar and positioned horizontally in the assembly 20 for a
vertical wall structure. In this arrangement a rod 42 can be easily
inserted vertically during assembly. The second engaging arm 60 is
parallel with the first engaging arm 58, forming a C-shaped clip
bracket. An opening 38 or 40 is provided in the first engaging arm
58 and an opening 38 or 40 is provided in the second engaging arm
60. These openings 38 or 40 are substantially aligned. As a result
of this alignment, a rod 42 or bar may be inserted through the
openings. An additional opening 62 may be provided in each of the
engaging arms 58, 60 to permit the flow of material or insertion of
additional structures as described above. In a preferred
embodiment, as can best be seen in FIGS. 3 and 6, the attachment
member 52 spaces the engagement member 56 a distance away from the
face 46, 48 of the panel 26, 32.
[0041] In the preferred embodiment, the attachment member 52
comprises a pair of longitudinal members 54 for attaching to the
wall panel 22, 24. As can be seen from FIGS. 1-8, preferably, the
longitudinal members 54 have a first arm 64 for attachment directly
to the panel 22 or 24. The first arm 64 is in contact with the
panel 26 or 32 and may include one or more openings 68 there
through for the insertion of a fastening device 70, such as a
screw, a nail, a rivet, a bolt or comparable device. Alternatively,
the first arm 64 may be welded or molded integral with the panel or
may be attached by adhesive. Preferably, a plurality of openings 68
are provided in the first arm 64, through which a threaded member
70, such as a screw, is inserted to secure the arm 64 on a first
face 46 or 48 of the panel 26 or 32. The longitudinal member 54
also includes a second, raised arm 66 which connects the first arm
64 to the engaging member 56. Preferably, the second arm 66 is
raised a distance W, or extends at an angle 72 away from the face
46, 48 of the panel so that the engaging member 56 is raised a
distance from the attachment to the panel 26, 32. The second arm 66
is approximately positioned at an angle 72 of 90.degree. from the
first arm 64 and the face 46, 48, but such an angle is not
necessary, as other positions of the arm 66 and angles 72 would be
acceptable for the purposes described herein.
[0042] As can be seen in FIGS. 2 and 5, a second parallel
longitudinal member 54 is provided, and is a mirror image of the
first longitudinal member. In the preferred embodiment, the second
longitudinal member 54 is spaced a distance from the first
longitudinal member 54. With the exception of orientation, as can
be seen in FIGS. 1 and 8, the structures are substantially
identical. Therefore, the second longitudinal member 54 will not be
described in further detail herein.
[0043] Referring to FIGS. 2, 5 and 8, connected to the attachment
member 52, and extending between the first and second longitudinal
members 54, and between the first and second engaging arms 58, 60,
is a base member 74. The base member 74 is attached, or in contact
with, the lower portion, and preferably the lower edge 76 of the
first and second engaging arms 58, 60. The base member 74 extends
the width of the first and second engaging arms 58, 60, and spans
the distance from the first longitudinal member 54 to the second
longitudinal member 54. The base member 74 is, thus, both in
contact with, or attached to, the attachment member 52 at the
second raised arm(s) 66, and engagement member 56 at the first and
second engagement arms 58, 60. In a preferred embodiment, the base
member 74 is attached by welding to each of the aforementioned
components. Alternatively, a clip bracket may be formed by die or
mold cutting as a single unit that is later bent into the shape and
arrangement desired. Other means of attachment would be acceptable
for purposes provided herein, including, but not limited to,
adhesive or fasteners. The base member 74 preferably has an opening
78 therein to permit flow of material or insertion of components,
such as support rods, bars or other structure.
[0044] Accordingly, the clip bracket 26 or 32 attached as described
above is in contact with the wall panel 22 or 24 and has a portion
separated a distance from the wall panel to provide additional
space or openings to the assembly.
[0045] Referring to FIGS. 2-7, in a preferred embodiment, the clip
assembly 20 comprises two clip brackets 26, 32 having different
dimensions. However, brackets equivalent in size would not depart
from the overall scope of the invention. Preferably, a first clip
bracket 26 (FIGS. 2-4) has engaging arms 58, 60 that extend a first
distance X. The engagement arms of the second clip bracket 32
(FIGS. 5-7) extend a second distance Y. Distance X is greater than
distance Y in a preferred embodiment. As a result, when assembled
the first clip bracket 26 extends across a greater portion of the
distance Z (see FIG. 9) between first wall panel 22 and second wall
panel 24. Moreover, the aligned openings 38, 40 of the first and
second clip brackets are positioned in close proximity to the
second wall panel 24, thereby allowing the insertion of a rod 42 in
close proximity to the second wall panel 24. One of skill in the
art would understand that variations in dimension of the first and
second clip brackets 26, 32 may vary the positioning of the aligned
openings 38, 30 between the first wall panel 22 and second wall
panel 24. For instance, where the first bracket 26 and second
bracket 32 are symmetrical, and of equivalent dimensions, the rod
42 may be centered or positioned at a midpoint between the first
wall panel 22 and the second wall panel 24.
[0046] As is shown in FIGS. 10-12, alternative embodiments of the
clip bracket may include variations in dimensions, shapes and
openings of the engagement members, as well as the attachment
members. FIG. 10 shows an engaging member 56 of FIG. 3, absent an
additional opening 62. Alternatively, an attachment member 80 may
be provided that eliminates the opening or distance between the
base member 74 and the attached planar structure or wall panel (see
FIGS. 11 and 12). FIG. 11 shows a clip bracket having attachment
arms 82 in the same plane as the base member 74 of the clip
bracket, while having second raised arms 84 extending at an angle
86 from the outside edge of the attachment arm 82. FIG. 12
illustrates a clip bracket having only attachment arm(s) 88. The
arms, shapes, and number of openings illustrated in the Figures are
for purposes of example only and one of skill in the art would
understand that various dimensions and shapes would be acceptable
for purposes of the present clip and assembly.
[0047] FIG. 17 shows an assembly 90 having a plurality of clip
brackets 26 or 32 fastened to the wall panel 22 or 24. Preferably,
the clip brackets 26 are spaced apart in an equal relation, but any
spacing would be acceptable for the purposes provided. Additional
wall structures or panels 92 may be attached. The additional panels
92 may optionally contain additional clip brackets 26 or 32
attached thereto. (See FIG. 14). Various means of connecting 94
adjacent wall structures are known in the art, any of which would
be acceptable for the purposes provided herein. In addition, in the
preferred embodiment, the joint between walls consists in a tongue
and groove arrangement. As can be seen in FIG. 19, as is common in
the assembly of concrete structures, a web or mesh 96 of support
rods, such as rebar, may also be provided, which in the fully
assembled structure, is surrounded by concrete and provides
additional structural strength to the assembly. This web 96 of
structural support rods may be attached by fastening clamps 97 or
other means commonly known in the art.
[0048] Referring to FIGS. 13-16, preferably, the wall panel 22, or
assembled wall structures 90 may further contain one or more
hoisting bar receiving plates 99. The hoisting bar receiving plate
99 comprises a metal plate with a central protruding metal cylinder
101. While metal is specifically disclosed, other materials are
contemplated for the purposes provided herein. The facing wall
panel 24 or assembly of wall panels 98 may also have one or more
hoisting bar receiving plates 99 attached thereto with identical
form and dimensions, and positioned facing the corresponding plate
99 in the first wall panel 22. The central metal cylinders 101
receive the first end 103 and second end 105 of a hoisting bar 108.
The hoisting bar 108 may comprise metal or other rigid material of
sufficient strength to support the weight of an assembled wall. In
a preferred embodiment, the hoisting bar receiving plates 99 are
attached to the wall panel 22, 24 by means of fasteners 110
extending through openings 112 in the plate 99, such as threaded
screws. However, alternative means of attachment are also
contemplated herein, including but not limited to, nut and bolt,
adhesive, tongue and groove, integral molding, and the like. The
combination of hoisting bar receiving plates 99 and hoisting bar
108 forms a hoisting bar assembly 114, which when fastened to the
wall panel assembly, may be engaged by a tool (not shown) to lift
and move the assembled structure.
[0049] Referring to FIGS. 17 through 24, wall panels 22, 24 having
a plurality of clip brackets 26 or 32 positioned thereon are
provided. The first wall panel 22 has a first clip bracket 26, or a
plurality of same. As discussed above, the first wall panel 22 may
also comprise one, two or more hoisting bar receiving plates 99. In
a preferred embodiment, two hoisting bar receiving plates 99 are
provided on the first wall panel 22. Second wall panel 24 is
provided with a second clip bracket 32, or a plurality of same.
Similar to the first wall panel 22, one, two or more, and
preferably two hoisting bar receiving plates 99 are provided,
attached thereto. First wall panel 22 and second wall panel 24 are
arranged in an opposing relation so that the first clip bracket(s)
26 and, if included, the hoisting bar receiving plates 99 of the
first wall panel assembly 90 face the second clip bracket(s) 32
and, if included, the hoisting bar receiving plates 99 of the
second wall panel assembly 98 (see also FIG. 16). If needed,
hoisting bars 108 may be placed into the cylinder 101 of each of
the hoisting bar receiving plates 99 of the first and/or the second
wall assembly 90, 98. The first clip bracket(s) 26 and the second
clip bracket(s) 32 are moved together as assemblies 90 and 98 are
moved toward each other. Also, during this step, the hoisting
bar(s) 108, when placed on assembly 90 will move toward the
cylinder(s) 101 of the hoisting bar receiving plate(s) 99 of the
facing wall assembly 98. This results in engaging, and preferably
slidably engaging, the engagement members 56 of the respective
first and second clip brackets 26, 32 and also, when applicable,
the engaging of the hoisting bar assemblies 114. The openings 38,
40 in the first and second clip brackets are aligned throughout the
combined assembly 20, 100 and a rod 42 is inserted through the
openings 38, 40, thereby connecting the first wall panel assembly
90 to the second wall panel assembly 98 and forming an area 102
between the wall panels 22, 24 that can be filled with a flowable
material. Moreover, as indicated above, the size of the clip
members 26, 32 may vary. Thus, the width of the space 50, 102
between the wall panels 22, 24, and therefore the size or thickness
of the wall, may be varied to greater or lesser dimensions.
[0050] In the fully assembled wall structure, as shown in FIG. 21,
a plurality of clip brackets 26, 32 and clip assemblies 20 are
provided between a pair of wall panels 22, 24 or a plurality of
wall panels. This structure may also include hoisting bar
assemblies 114. These fully assembled wall structures may be
transported to a building site for final positioning and assembly
of the walls.
[0051] The clip brackets 26, 32 may have connecting members or
elements, such as rods 42, inserted therein which results in a
plurality of parallel aligned rods 42 in the assembly which add
support to the overall assembly 100. Referring specifically to
FIGS. 22 and 23, the rods 42 may further comprise an end having a
retention means, such as a bend 116 in the rod or other structure
attached to the rod 42. While not required, in a preferred
embodiment, the rod 42 comprises a 90.degree. angle 118 bend 116 at
one end 120. While a 90.degree.angle 118 is specifically disclosed,
various angles would be acceptable for the purposes provided
herein. The bend 116 prevents the rod 42 from sliding from its
position in the clip bracket. In a preferred embodiment, the bend
116 reaches outwardly, allowing for the connection of the rod at
the retention means 116 to other structural elements in an
assembly, or in a corresponding floor assembly to which the wall
assembly is attached. Additionally, in a preferred embodiment, the
rod(s) 42 are inserted vertically downward, which assists in the
ease of assembly, although other orientations of the rod(s) would
not depart from the overall scope of the present invention.
[0052] As indicated above, a flowable material 104 may be inserted
into the space 102 between the wall panels 22, 24 as shown in FIG.
24. The flowable material may comprise concrete, cement,
insulation, liquid, gas, or other substance, or any combination
thereof. Preferably, the flowable material is a cement or concrete
that includes a plasticizer which eliminates the need of vibration
to settle the concrete into the load bearing wall assembly.
Therefore, the mixture placed within the assembly is fluid during
its introduction into the space 102 between the wall panels to
allow ease of flow within the openings of the assembled structure
100. The concrete comprises an aggregate size and fluidity suitable
for these purposes. The plasticizer may evaporate, leak-out or
remain in the hardened concrete. In a preferred embodiment, the
system uses a self-compacting concrete having a maximum aggregate
diameter of 20 millimeters that requires strict grading control.
The concrete admixture is formulated with plasticizers and
additives to permit a low water-to-cement ratio, insuring free flow
throughout the assembly. Preferably, the concrete has a capacity of
flowing and compacting without the aid of vibration, thereby
ensuring significant homogeneity of the hardened concrete. For
instance, a self-compacting low-viscosity concrete or cement with a
water-to-cement ratio of less than 0.55 and a characteristic cube
strength of approximately 35 N/mm.sup.2 or 350 kg/cm.sup.2, a
minimum slump of 150 mm and a granulometry having a maximum grain
diameter of 22 mm may be acceptable for use. While a specific
concrete is described herein, the flowable concrete used herein may
comprise a wide variety of known and currently used commercial
concretes having the properties needed for the purposes desired by
the assembler and/or manufacturer. Likewise, the concrete
formulation will vary depending upon local cement or concrete
characteristics which may define the types and quantities of
air-entrapment and plasticizing additives. Moreover, the
granulometry and characteristics of the available aggregate may
influence the formation. Local conditions, such as temperature and
moisture at the time of pouring may also have influence on the
concrete formation. Accordingly, the concrete is prepared to meet
the applicable conditions.
[0053] Accordingly, a wall assembly is formed having a plurality of
wall panels 22, 92 adjacently aligned and attached to a second set
of wall panels 24, 106, spaced a distance Z therefrom by the clip
assembly 20 described hereinabove. The area 102 between the wall
panels 22, 92, 24, 106 is filled with a concrete mixture 104 that
cures and hardens to form a complete wall structure as shown in
FIG. 24, having panels 22, 24, clip assembly 20, the rebars or
connecting rods 42, the structural reinforcements, if required by
the design, and concrete 104 in a combined assembly. In this
assembly, it is not necessary to remove the wall panels 22, 24 as
in other concrete forming systems. Furthermore, the wall panels 22,
24 and assembly itself contribute to the structural strength and
rigidity of the wall. As a result of the combined assembly, the
wall is able to bear or support a significant load.
[0054] The method of assembling the bearing wall system using the
foregoing components will now be discussed in further detail in
reference to FIGS. 9 and 13-24. Preferably, a first wall panel 22
is attached to a plurality of first clip members 26 or brackets. A
second wall panel 24 is, likewise, assembled with a plurality of
second clip brackets 32. The brackets may be attached by fasteners
70 inserted through openings 68 in the longitudinal members 54 of
the clips, or by other means discussed herein. The clip brackets
26, 32 are positioned on the respective first wall panel 22 and
second wall panel 24, so that when assembled, the first clip
bracket(s) 26 are opposed and aligned with the second clip
bracket(s) 32 (see FIGS. 9 & 20). Opposing faces 46, 48 of the
first and second wall panels 22, 24 therefore have attached
brackets. Once the brackets are attached to the panels, the panels
22, 24 are brought together to engage the first clip bracket(s) 26
with the second clip bracket(s) 32, resulting in the engagement of
the engagement members 56 at the engagement arms 58, 60 (see FIGS.
9 & 21). Turning to FIG. 21, after the clip members 26 and 32
are engaged, the openings 38 and 40 are aligned and a connecting
member is used to connect the clip brackets. In a preferred
embodiment, rod 42 is inserted through the aligned openings 38, 40,
which when a plurality of clip brackets are used, results in the
insertion through a plurality of clip brackets. Namely, a plurality
of parallel rods 42 may be inserted through adjacent aligned clip
brackets and/or a single rod 42 may be inserted through a plurality
of openings in a plurality of aligned clip brackets, both of which
can be see in FIG. 21.
[0055] Using the aforementioned method, an assembly 20 or 100 is
formed which has numerous openings 44, 62 in the assembly and
between the first wall panel 22 and the second wall panel 24. The
openings 44, 62 are capable of receiving a flowable material 104
and/or additional structural elements, including, but not limited
to, connector bars placed in the foundation and/or floor slab on
which the bearing wall will be placed that will provide structural
integrality between the walls and the foundation. Thus, once the
assembly 20, 100 is created, cement or concrete 104 is poured into
the space 50, 102 between the wall panels 22, 24 and substantially
surrounds the clip members 26, 32 and rods 42. The concrete 104
cures and hardens in the space, forming a complete wall structure
having two wall panels, attached clip assemblies, and concrete,
which structure has significant strength and rigidity. The wall
assembly may be further integrated to the foundation and/or floor
slab. Moreover, due to the option of varying the size of the clip
members 26, 32, the width of the space 50, 102 between the wall
panels 22, 24, and therefore the size or thickness of the wall, may
be varied to greater or lesser dimensions. Additionally, as shown
in FIG. 19, additional structural support members 96 such as rebar,
may be added prior to introduction of the flowable substance to
further strengthen the wall.
[0056] The installation and assembly of a wall with the foregoing
components requires minimal time and effort as the assembler must
simply attach the clip brackets to the wall panel, align the wall
panels, and insert a connecting member into the aligned openings of
the clip brackets. Assembled bearing walls may be placed in
transporting racks and transported to a building site. They can be
hoisted by means of the hoisting bars and placed in their
corresponding position on the foundation or floor slab, which may
have embedded therein, the connecting rods 42 to integrally connect
the walls with the foundation or floor slab. A leveling prop
connector for attaching a prop for retaining the formwork wall
section leveled on a building site may also be attached to the
assembled bearing wall for use in assembly at the construction
site. A transportable wall assembly may comprise a plurality of
bearing wall panels with clip brackets and structural elements
included. In a preferred embodiment these panels are transported to
the building site and hoisted into the specific desired position.
Subsequently, concrete is introduced into the area between the
panels. As result, the assembly and method described herein save
significant time, effort and cost in the construction of a load
bearing structure.
[0057] In the foregoing system and devices, wall panels are
assembled by means of a unique anchoring system which may have a
variety of dimensions according to the requirements of the site,
the manufacturer and or the user, permitting great versatility in
the design. The formwork walls formed by the system and method
described comprise a high performance and efficient building
solution that is capable of safely withstanding strains produced by
static and dynamic loads acting on structural walls.
[0058] Although various representative embodiments of this
invention have been described above with a certain degree of
particularity, those skilled in the art could make numerous
alterations to the disclosed embodiments without departing from the
spirit or scope of the inventive subject matter set forth in the
specification and claims. All directional references (e.g., upper,
lower, upward, downward, left, right, leftward, rightward, top,
bottom, above, below, vertical, horizontal, clockwise,
counterclockwise, x-axis, y-axis, and z-axis) are only used for
identification purposes to aid the reader's understanding of the
embodiments of the present invention, and do not create
limitations, particularly as to the position, orientation, or use
of the invention unless specifically set forth in the claims.
Joinder references (e.g., attached, coupled, connected) are to be
construed broadly and may include intermediate members between a
connection of elements and relative movement between elements. As
such, joinder references do not necessarily infer that two elements
are directly connected and in fixed relation to each other.
[0059] In some instances, components are described with reference
to "ends" having a particular characteristic and/or being connected
with another part. However, those skilled in the art will recognize
that the present invention is not limited to components which
terminate immediately beyond their points of connection with other
parts. Thus, the term "end" should be interpreted broadly, in a
manner that includes areas adjacent, rearward, forward of, or
otherwise near the terminus of a particular element, link,
component, part, member. In methodologies directly or indirectly
set forth herein, various steps and operations are described in one
possible order of operation, but those skilled in the art will
recognize that steps and operations may be rearranged, replaced, or
eliminated without necessarily departing from the spirit and scope
of the present invention. It is intended that all matter contained
in the above description or shown in the accompanying drawings
shall be interpreted as illustrative only and not limiting. Changes
in detail or structure may be made without departing from the
spirit of the invention as defined in the appended claims.
[0060] The following paragraphs enumerated consequently from 1
through 39 provide for various aspects of the present invention. In
one embodiment, in a first paragraph (1), the present invention
provides a clip assembly for joining two or more substantially
planar structures in a spaced apart manner, the clip assembly
comprising: a first clip member comprising an attachment member for
attachment to a planar structure, an engagement member attached to
the attachment member having first and second engagement arms; and
an opening positioned in the engagement member; a second clip
member engageable with the first clip member, the second clip
member comprising an attachment member for attachment to a second
planar structure, an engagement member attached to the attachment
member having first and second engagement arms and an opening
positioned in the engagement member, the openings of the first and
the second clip members being aligned when the clip members are
engaged; and a connecting member positioned in the aligned openings
of the first and second clip members.
[0061] 2. The clip assembly of paragraph 1, wherein the attachment
member comprises a first longitudinal member and a second
longitudinal member.
[0062] 3. The clip assembly of any of paragraphs 1 or 2, wherein
the first and second longitudinal members comprise an attachment
arm and a raised arm, wherein the raised arm is in contact with the
engagement member and spaces the engagement member a distance from
the attachment to the wall panel.
[0063] 4. The clip assembly of any of paragraphs 1 through 3,
wherein the first and second clip members are fastened to the
planar structures at the attachment arm of the attachment
member.
[0064] 5. The clip assembly of any of paragraphs 1 through 4,
wherein the first clip member includes more than one opening.
[0065] 6. The clip assembly of any of paragraphs 1 through 5,
wherein the engagement arms are planar.
[0066] 7. The clip assembly of any of paragraphs 1 through 6,
wherein the clip members are metal.
[0067] 8. The clip assembly of any of paragraphs 1 through 7,
wherein the clip members comprise a material having a rigidity
comparable to metal.
[0068] 9. The clip assembly of any of paragraphs 1 through 8,
wherein the connecting member comprises a rod.
[0069] 10. The clip assembly of any of paragraphs 1 through 9,
wherein the substantially planar structures comprise panels.
[0070] 11. A hoisting assembly for engaging a hook required to
hoist an assembled formwork for a load bearing wall structure
comprising: a first hoisting bar receiving plate comprising a metal
plate for attachment to a first planar structure, the first
hoisting bar having a protruding centered hollow cylinder for
engaging a first end of a hoisting bar; a second hoisting bar
receiving plate comprising a metal plate for attachment to a second
planar structure, the second hoisting bar having a protruding
centered hollow cylinder for engaging a second end of the hoisting
bar; the hoisting bar placed in contact with the first and second
hoisting bar receiving plates, each end of the hoisting bar
positioned in contact with each one of the protruding centered
hollow cylinders of each hoisting bar receiving plate.
[0071] 12. A clip assembly comprising: a first clip member having
an attachment member and an engagement member, the engagement
member having a first engagement arm and a second engagement arm,
each engagement arm having an opening; a second clip member having
an attachment member and an engagement member, the engagement
member having a first engagement arm and a second engagement arm,
each engagement arm having an opening, the first and second clip
members engageable at the engagement arms so as to align the
openings; and a connecting member positioned within the aligned
openings of the first and second clip members.
[0072] 13. The clip assembly of paragraph 12, comprising more than
one opening in at least one of the clip members.
[0073] 14. The clip assembly of either of paragraphs 12 or 13,
wherein the first and second clip members have more than one
opening.
[0074] 15. The clip assembly of any of paragraphs 12 through 14,
wherein the attachment member comprises a first longitudinal member
and a second longitudinal member.
[0075] 16. The clip assembly of any of paragraphs 12 through 15,
wherein the first and second longitudinal members comprise an
attachment arm and a raised arm, wherein the raised arm is in
contact with the engagement member, spacing the engagement member a
distance from a position of attachment.
[0076] 17. A formwork section for a load bearing wall structure
comprising: a first wall panel and a second wall panel; a first
clip member attached to the first wall panel, the first clip member
having an opening therein; a second clip member attached to the
second wall panel, the second clip member having an opening
therein, the second clip member being engaged with the first clip
member so as to align the opening of the first clip member and the
opening of the second clip member; and a connecting member
connecting the first and second clip members at the aligned
openings.
[0077] 18. The formwork section of paragraph 17, wherein the
connecting member is a rod.
[0078] 19. The formwork section of either of paragraphs 17 or 18,
further comprising an additional structural reinforcement material
and two hoisting bar assemblies.
[0079] 20. The formwork section of any of paragraphs 17 through 19,
further comprising concrete between the first and second wall
panels.
[0080] 21. The formwork section of any of paragraphs 17 through 20,
wherein the wall panels comprise fiberboard.
[0081] 22. A clip bracket for a panel assembly comprising: an
attachment member for attachment to a panel; a first engaging arm
attached to the attachment member and spaced a distance from the
panel; a second engaging arm attached to attachment member,
parallel with the first engaging arm and spaced a distance from the
panel; an opening in the first engaging arm; and an opening in the
second engaging arm substantially aligned with the opening in the
first engaging arm.
[0082] 23. The clip bracket of paragraph 22, further comprising an
additional opening in at least one of the first and second engaging
arms.
[0083] 24. The clip bracket of paragraph 23, wherein each of the
first and second engaging arms comprises an additional opening.
[0084] 25. The clip bracket of any of paragraphs 22 through 24,
further comprising a base member in contact with the attachment
member and the first and second engagement arms.
[0085] 26. The clip bracket of any of paragraphs 22 through 25,
wherein the base member comprises an opening.
[0086] 27. A fully assembled formwork section for a load bearing
wall comprising:
[0087] a first panel and a second panel; a first clip member
attached to the first panel, the first clip member having an
attachment member, a first engaging arm and a second engaging arm,
the first clip member also comprising an opening; a second clip
member attached to the second panel, the second clip member having
an attachment member, a first engaging arm, and a second engaging
arm, the second clip member also comprising an opening, the second
clip member being engaged with the first clip member, wherein the
opening of the first clip member and the opening of the second clip
member are aligned; a connecting member positioned at the aligned
openings of the first and second clip members; a leveling prop
connector for attaching a prop for retaining the formwork wall
section leveled on a building site; a structural reinforcement
material; and a hoisting bar assembly attached to the first and
second wall panels.
[0088] 28. The fully assembled formwork of paragraph 27, wherein a
flowable material is added to the formwork section between the
first and second wall panels.
[0089] 29. A wall comprising: a first panel and a second panel; a
first clip member attached to the first panel, the first clip
member having an attachment member, a first engaging arm and a
second engaging arm, the first clip member also comprising an
opening; a second clip member attached to the second panel, the
second clip member having an attachment member, a first engaging
arm, and a second engaging arm, the second clip member also
comprising an opening, the second clip member being engaged with
the first clip member, wherein the opening of the first clip member
and the opening of the second clip member are aligned; a connecting
member positioned at the aligned openings of the first and second
clip members; and a flowable material in a space between the first
panel and the second panel.
[0090] 30. The wall of paragraph 29, wherein the flowable material
comprises concrete.
[0091] 31. The wall of either of paragraphs 29 or 30, wherein the
flowable material surrounds at least a portion of the clip members
and connecting member.
[0092] 32. The wall of any of paragraphs 29 through 31, wherein the
connecting member comprises a rod.
[0093] 33. The wall of any of paragraphs 29 through 32, wherein the
panel comprises fiberboard.
[0094] 34. A method for assembly of a formwork for a load bearing
wall comprising:
[0095] providing a first panel and a second panel; attaching a
first clip member having an engagement member and an opening in the
engagement member to the first panel; attaching a second clip
member having an engagement member and an opening in the engagement
member to the second panel; attaching a leveling prop connector to
the first or second panel; attaching additional structural
reinforcement material to at least one of the first and second
panels; attaching a hoisting bar receiving plate to a wall panel
and a hosting bar to the hoisting bar receiving plates; positioning
the second panel in an opposed relation to the first panel so that
the first and second clip members face each other; moving the first
panel towards the second panel, both having attached clip members,
into engagement; engaging the first and second clip members at
their engagement members; engaging the hoisting bar with the
hoisting bar receiving plates; aligning the openings in the
engagement members of the first and second clip members; inserting
a connecting member into the aligned openings.
[0096] 35. The method of paragraph 34, wherein a plurality of first
clip members, a plurality of second clip members, and a plurality
of connecting members are provided.
[0097] 36. The method of either of paragraphs 34 or 35, further
comprising placing a flowable material into a space defined between
the first and second panels.
[0098] 37. The method of any of paragraphs 34 through 36, wherein
the flowable material comprises concrete.
[0099] 38. The method of any of paragraphs 34 through 37, further
comprising allowing the concrete to cure, which when hardened forms
a wall.
[0100] 39. The method of any of paragraphs 34 through 38, wherein
the connecting member comprises a rod.
[0101] Although the present invention has been described with
reference to preferred embodiments, persons skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *