U.S. patent application number 11/979826 was filed with the patent office on 2009-05-14 for concrete form tie with connector for finishing panel.
Invention is credited to Victor Amend.
Application Number | 20090120027 11/979826 |
Document ID | / |
Family ID | 40409847 |
Filed Date | 2009-05-14 |
United States Patent
Application |
20090120027 |
Kind Code |
A1 |
Amend; Victor |
May 14, 2009 |
Concrete form tie with connector for finishing panel
Abstract
A tie for connecting and maintaining first and second panels of
a concrete formwork in a fixed, spaced relationship during a wall
building process is provided. The tie includes a first connector
connectable to the first panel; and a second connector connectable
to the second panel and connectable to at least one third panel
such that the at least one third panel is spaced from the concrete
surface.
Inventors: |
Amend; Victor; (Toronto,
CA) |
Correspondence
Address: |
SIM & MCBURNEY
330 UNIVERSITY AVENUE, 6TH FLOOR
TORONTO
ON
M5G 1R7
CA
|
Family ID: |
40409847 |
Appl. No.: |
11/979826 |
Filed: |
November 8, 2007 |
Current U.S.
Class: |
52/426 ; 52/565;
52/742.14; 52/745.2 |
Current CPC
Class: |
E04G 17/06 20130101;
E04B 2/8647 20130101; E04B 2/8652 20130101; E04B 2/8617 20130101;
E04B 2/8611 20130101 |
Class at
Publication: |
52/426 ; 52/565;
52/742.14; 52/745.2 |
International
Class: |
E04G 17/06 20060101
E04G017/06; E04B 2/86 20060101 E04B002/86; E04G 21/02 20060101
E04G021/02 |
Claims
1. A tie for connecting and maintaining first and second panels of
a concrete formwork in a fixed, spaced relationship during a wail
building process, the tie comprising: a first connector connectable
to the first panel; and a second connector connectable to the
second panel and connectable to at least one third panel such that
the at least one third panel is spaced from the concrete
surface.
2. The tie of claim 1, wherein the second connector is removably
connectable to the second panel.
3. The tie of claim 1, wherein the second connector is removably
connectable to the at least one third panel.
4. The tie of claim 1, wherein the first connector is embeddable in
the first panel.
5. The tie of claim 4, wherein the first panel is made of
insulating material.
6. The tie of claim 1, wherein the second connector comprises a
second panel connection portion and a third panel connection
portion.
7. The tie of claim 6, wherein the third panel connection portion
is removably connectable to the second panel connection
portion.
8. The tie of claim 6, wherein the second connector comprises at
least one passageway between the concrete surface and the third
panel, for supporting an electrical cable and/or plumbing.
9. The tie of claim 8, wherein at least one of the at least one
passageway is an open-topped passageway.
10. The tie of claim 1, wherein the second connector is dimensioned
to cooperate with a second connector of at least one other tie.
11. The tie of claim 10, wherein the second connector is
dimensioned to be coupled with the second connector of the at least
one other tie.
12. The tie of claim 11, wherein the second connector comprises a
mechanical interlock mechanism for coupling with the second
connector of the at least one other tie.
13. The tie of claim 1, comprising at least one flap pivotably
connected to the second connector for connecting the second
connector to a second panel.
14. The tie of claim 1, wherein the first connector and second
connector are linked by an intermediate portion, the intermediate
portion removably connectable to the first connector.
15. The tie of claim 14, wherein the intermediate portion is
removably connectable to the second connector.
16. The tie of claim 1, wherein the tie is made of plastic.
17. An insulating wall form comprising: the tie of one of claims 1
to 16; a first panel made from an insulating material and connected
to the first connector; and a second panel connected to the second
connector.
18. The insulating wall form of claim 17, wherein the first
connector is embedded in the first panel.
19. The insulating wall form of claim 17, wherein the second
connector is removably connected to the second panel.
20. A method of making a concrete wall comprising; providing a
first panel having an inward facing surface and an outward facing
surface, the first panel made of insulating material; providing a
second panel having all inward facing surface and an outward facing
surface; connecting a first connector of a tie to the first panel
and a second connector of the tie to the second panel wherein the
first and second connectors are separated by an intermediate
portion with a length corresponding approximately to the thickness
of the concrete wall thereby providing a fixed space between the
first and second panels for receiving a charge of the concrete; and
attaching a third panel to the second connector to provide a fixed
space between the concrete surface and the third panel.
21. The method of claim 20, comprising: providing a charge of
concrete into the fixed space between the first and second
panels.
22. The method of claim 21, wherein the charge of concrete is
provided prior to attaching the third panel.
23. The method of claim 20, wherein providing the first and second
panels comprises vertically stacking multiple panels.
24. The method of claim 20, wherein the first panel is moulded and
connecting the first connector to the first panel is performed
during moulding.
25. The method of claim 20, wherein the second connector comprises
at least one passageway, the method further comprising: prior to
attaching the third panel passing electrical cables and/or plumbing
through the passageway.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to forms for concrete walls,
and more particularly to ties for connecting and maintaining first
and second panels of a concrete formwork in a fixed, spaced
relationship during a wall building process.
BACKGROUND OF THE INVENTION
[0002] Conventional formwork for forming walls from pourable
building material such as concrete consist of two opposed,
typically plywood walls connected by a rod, trusswork or other
connecting structure. More recently, it has become desirable to use
insulating material such as expandable polystyrene for the
formwork, in order to provide thermal and acoustic insulation to
the finished wall. In certain applications, particularly those
where it is desired to inhibit the effects of "thermal inertia" of
a concrete wall so as to employ the ability of the concrete to
retain heat for temperature stabilization, it is desirable to
employ formwork with insulated paneling on only one side. The other
side, typically of plywood, may or may not be removed after full or
at least partial curing of die concrete.
[0003] Various insulated formworks and related technologies have
been considered. For example, U.S. Pat. No. 5,845,445 to Blackbeard
discloses an insulated concrete form with a plurality of plywood
boards at an inside surface, and a plurality of insulating foam
panels at an outside surface. The plywood boards and insulating
foam panels are connected by a plurality of elongated vertically
aligned connecting members for retaining the panels in a spaced
apart parallel relationship during the wall building process. The
connecting members are connected to the insulating panels, and ties
are attached to respective connecting members and the plywood
boards. Each tie has a conventional embossed end to engage into a
latch clip on the plywood side. During de-forming, the plywood
boards may be removed by removing the attachment between the ties
and latch clips.
[0004] U.S. Pat. No. 6,314,694 to Cooper et al. discloses a
one-side insulated formwork that includes an insulating panel
connectable to a removable panel by a connecting structure, which
may provide permanent reinforcement embedded in the insulating
panel. The removable panel is attached to the connecting structure
using removable fasteners. The connecting structure maintains a
fixed spaced relationship between the insulating panel and the
removable panel, and according to embodiments disclosed includes
rebar hooks for supporting rebar for embedding in the concrete.
After the concrete has at least partially cured, the removable
fasteners and removable panel are removed, leaving exposed and
flush with the outer surface of the concrete wall a surface of the
connecting structure suitable for flush connection of a finishing
panel.
[0005] U.S. Pat. No. 6,526,713 to Moore, Jr. discloses an insulated
concrete structure for forming walls from a pourable building
material such as concrete. Moore proposed connecting two panels of
a formwork using a web structure, a portion of which is preferably
embedded in an insulating one of the panels. After the concrete has
at least partially cured, one of the panels being now adjacent to
the formed wall, may be removed or remain as part of the
structure.
[0006] Although the above references disclose insulated formwork of
various configurations, improvements are desired. For example, none
of the references discussed above consider the challenges of
installing electrical and/or plumbing after or during the wall
forming process. It is therefore an object of the present invention
to provide a novel wall form, tie and method using the same for
building walls from pourable building material, such as
concrete.
SUMMARY OF THE INVENTION
[0007] According to an aspect, there is provided a tie for
connecting and maintaining first and second panels of a concrete
formwork in a fixed, spaced relationship during a wall building
process, the tie comprising:
[0008] a first connector connectable to the first panel; and
[0009] a second connector connectable to the second panel and
connectable to at least one third panel such that the at least one
third panel is spaced from the concrete surface.
[0010] According to an embodiment, the second panel is made of
plywood and the third panel is made of drywall.
[0011] According to an embodiment, an insulating wall form
comprises the tie, a first panel made from an insulating material
and connected to the first connector; and a second panel connected
to the second connector.
[0012] According to another aspect, there is provided a method of
making a concrete wall, comprising:
[0013] providing a first panel having an inward facing surface and
an outward facing surface, the first panel made of insulating
material;
[0014] providing a second panel having an inward facing surface and
an outward facing surface;
[0015] connecting a first connector of a tie to the first panel and
a second connector of the tie to the second panel, wherein the
first and second connectors are separated by an intermediate
portion with a length corresponding approximately to the thickness
of the concrete wall thereby providing a fixed space between the
first and second panels for receiving a charge of the concrete;
and
[0016] attaching a third panel to the second connector to provide a
fixed space between the concrete surface and the third panel.
[0017] The tie, formwork employing the same, and method for making
a wall provide previously unrealized advantages because they permit
the option, of removal of the second panel after wall construction
prior to attachment of the third panel, while permitting spacing
between the third panel and the concrete surface and/or second
panel for passing electrical wires and/or plumbing and the like.
Thus, the electrical wires and/or plumbing may more easily be
inspected and/or repaired than systems which involve embedding such
utilities in, the concrete wall itself.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Embodiments will now be described more fully with reference
to the accompanying drawings in which:
[0019] FIG. 1 is a perspective cutaway view of a formwork having
first and second panels and a tie;
[0020] FIG. 2 is a perspective cutaway view of an at least
partially set concrete wall of FIG. 1 with a second panel having
been removed and a third panel being connected;
[0021] FIG. 3 is a perspective view of an alternative tie
embodiment;
[0022] FIG. 4 is a side view of a formwork having first and second
panels and the tie of FIG. 3;
[0023] FIG. 5 is a side view of the at least partially set concrete
wall of FIG. 4 with a second panel having been removed and a third
panel connected;
[0024] FIG. 6 is a perspective view of another alternative tie
embodiment;
[0025] FIG. 7 is a perspective cutaway view of a formwork having
first and second panels and an alternative tie embodiment;
[0026] FIG. 8A is a perspective view of a first connector and an
intermediate portion of an alternative tie embedded in a first
panel and connectable to a second panel;
[0027] FIGS. 8B and 8C are perspective views of the intermediate
portion of the alternative tie of FIG. 8A embedded in an at least
partially set concrete wall and connectable to a third panel
connection portion of the tie;
[0028] FIG. 8D is a perspective view of the alternative tie of
FIGS. 8A-8C being connected to a third panel;
[0029] FIG. 8E is a top view of alternative ties as shown in FIGS.
8A-8D embedded in concrete and connected to a third panel;
[0030] FIG. 9 is a perspective view of another alternative tie
embodiment;
[0031] FIG. 10 is a top view of the alternative tie embodiment of
FIG. 9 connected to first, second and third panels; and
[0032] FIG. 11 is a top partial view of an alternative tie being
connected to a second panel.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0033] In the following description, embodiments of a tie for
connecting and maintaining first and second panels of a formwork in
a fixed, spaced relationship during a wall building process, and of
a method of making a concrete wall are provided.
[0034] FIG. 1 is a perspective cutaway view of a portion of a
formwork according to an embodiment. The formwork has at least one
first panel 10, at least one second panel 20 and at least one tie
50. The first panel 10 is an insulating panel made of polystyrene,
and the second panel 20 is made of plywood.
[0035] The tie 50 includes a first connector 52, an intermediate
portion 60, and a second connector 54. As can be seen, the first
connector 52 is embedded in the first panel 10. The second
connector 54 is shown connected to the second panel 20 at a second
panel connection portion 56 by screws or other suitable removable
fasteners. The second connector 54 is removable from the second
panel 20 upon removal of the fasteners. The tie 50 maintains the
first and second panels in a fixed spaced relationship thereby to
provide space between the panels for receiving and holding a charge
of poured concrete 40.
[0036] The second connector 54 of the tie 50 also includes a third
panel connection portion 58 that is spaced from the second panel
connection portion 56 by virtue of the dimensions of the second
connector 54 and the relative positions of the second and third
panel connection portions 56, 58. More particularly, the second
panel connection portion 56 and third panel connection portion 58
are spaced apart such that the third panel 30 when connected to the
third panel connection portion 58 is spaced from the inside surface
of the concrete wall 40. The use of this spacing is illustrated in
FIG. 2. FIG. 2 is a perspective cutaway view of the at least
partially set concrete wall 40 that was poured in FIG. 1 with the
second panel 20 having been removed. A third, or "finishing" panel
30 made of drywall is being connected to the third panel connection
portion 58. With the second panel 20 having been removed, the third
panel 30 connected to the third panel connection portion 58 is
spaced from the inside surface of the concrete wall 40.
Intermediate the second and third panel connection portions 56, 58
are passageways 62 through second connector 54. Passageways 62 are
dimensioned to permit passage of electrical cables/wires 64 and/or
plumbing (not shown) or other utilities being installed along the
wall between the third panel 30 and the inside surface of the
concrete wall 40.
[0037] FIG. 3 is a perspective view of an alternative tie 50A. Tie
50A has a plurality of first connectors 52A and intermediate
portions 60A connected to a second connector 54A. Second connector
54A includes a second panel connection portion 56A connectable to
one or more second panels 20, and a plurality of third panel
connection portions 58A connectable to at least one third panel 30.
Passageways 62 pass from one side to the other of the second
connector 54A.
[0038] FIG. 4 is a side view of a formwork having first and second
panels 10, 20 and the tie 50A of FIG. 3 during pouring of concrete
40.
[0039] FIG. 5 is a side view of the at least partially set concrete
wall 40 of FIG. 4 with the second panel 20 having been removed from
second panel connection portion 56A, and a third panel connected to
third panel connection portion 58A.
[0040] FIG. 6 is a perspective view of another alternative tie 50B.
Tie 50B has a single first connector 52B and intermediate portion
60B connected to a second connector 54B. Second connector 54B
includes a second panel connection portion 56B connectable to one
or more second panels 20, and a plurality of third panel connection
portions 5831 connectable to at least one third panel 30.
Passageways 62 pass from one side to the other of the second
connector 54B. Open-topped channels 63 also pass from one side to
the other of the second connector 54B to ease installation of
electrical cables/wire and/or plumbing or other utilities.
[0041] FIG. 7 is a perspective cutaway view of a formwork having
first and second panels 10, 20 and an alternative tie 50C. Tie 50C
has a single first connector 52C and intermediate portion 60C. A
second panel connection portion 56C is connected to intermediate
portion 60C and is removably connected to second panel(s) 20. A
third panel connection portion 58C is removably connectable to the
second panel connection, portion 56C once second panels 20 are
removed after the concrete 40 has at least partially set.
Connectability between second and third panel connection portions
56C and 58C is by virtue of the dimensions of an extension channel
57C in second panel connection portion 56C suitable for receiving
in interference fit an extension protrusion 59C of third panel
connection portion 58C.
[0042] Multiple ties 50C are stackable by virtue of mechanical
interlock members. These mechanical interlock members include
respective stacking protrusions 66C on the second panel connection
portion 56C and the third panel connection portion 58C. The
stacking protrusions 66C mate in interference fit with respective
corresponding stacking channels (not shown) in adjacent second and
third panel connection portions 56C, 58C of an adjacent tic
50C.
[0043] At the bottom of FIG. 7, a third panel 30 is shown connected
to the third panel connection portion 58C which is in turn,
connected to the second panel connection portion 56C.
[0044] FIG. 8A is a perspective view of a first connector 52D and
an intermediate portion 60D of an alternative tie 50D. First
connector 52D is embedded in a first panel 10 and is connectable to
a second panel 20. For ease of transport, intermediate portion
includes arms 61 which can, due to their pivotability relative to
first connector 52D, fold against the inside surface of the first
panel 10 during transportation. Arms 61 can also fold towards each
other and mate to form the intermediate portion 60D having a second
panel connection portion 56D.
[0045] FIGS. 8B and 8C are perspective views of the intermediate
portion 60D of the tie 50D of FIG. 8A embedded in an, at least
partially set concrete wall 40 and connectable to a third panel
connection portion 58D of the tie 50D. Third panel connection
portion 58D is connected to a third panel(s) 30 after the concrete
40 has been poured and at least partially set and second panel(s)
20 have been removed from second panel connection portion 56D.
[0046] FIG. 5D is a perspective view of the tie SOD of FIGS. 5A-8C
being connected to a plurality of third panels 30, and having an
electrical cable 64 passing through a passageway 62 of the third
panel connection portion 58D.
[0047] FIG. 5E is a top view of a plurality of ties 50D as shown in
FIGS. 8A-8D embedded in the concrete wall 40, and connected to
third panels 30.
[0048] FIG. 9 is a perspective view of another alternative tie 50E.
The tie 50E has an intermediate portion 60E between its first
connector 52E and its second panel connection portion 56E, that is
adjustable in length as shown in FIG. 9. Third panel connection
portion 53E mates with second panel connection portion 56E after
the concrete 40 has been poured and has at least partially set and
second panels 20 have been disconnected from the second panel
connection portion 56E. Third panel connection portion 58E mates
with second panel correction portion 56E by virtue of an
interference fit between an extension channel 57E in second panel
connection portion 56E and an extension protrusion 59F on third
panel connection portion 58E.
[0049] It can be seen in FIG. 9 that depending on the desired
configuration of formwork, second panels 20 can occlude the
extension channel 57E, requiring their removal prior to connection
of the third panel connection portion 58E. Alternatively, if it is
desired to keep second panels 20 while connecting third panels 30,
then they may be attached to the second panel connection portion
56E so as not to occlude the extension channel 57E. In this way,
the third panel connection portion 58E may be connected to the
second panel connection portion 56E while second panels 20 remain
connected to second panel connection portion 56E.
[0050] FIG. 10 is a top view of the alternative tie 50E of FIG. 9
connected to first, second and third panels 10, 20, 30.
[0051] FIG. 11 is a top partial view of an intermediate portion 60F
and a second connector 54F of an alternative tie. Adjacent third
panel connection portion 58F of second connector 54F are flaps 55F
pivotably connected to the second connector 54F. Flaps 55F are at
least a portion, of the height of the third panel connection
portion 58F (i.e. extend into the page in FIG. 11). Other means of
pivotably connecting flaps 55F to second connector 54F may be used.
Flaps 55F pivot away from second panels 20 in order to permit
insertion of spacer boards S against second panels 20 and second
connector 54E Once the spacer boards S are in place as shown in
FIG. 11, flaps 55F are pivoted back against the spacer boards and
at least one respective fastener F is passed through flap 55F into
the respective spacer board S. The spacer board S is thereby held
against a respective second panel 20 and maintains the fixed
formwork during pouring of the concrete 40. Upon at least partial
setting of the concrete, the fasteners F, spacer boards S and
second panels 20 may be removed, and a Gird panel 30 then connected
to the third panel connection portion 58F of the second connector
54. It will be understood that an embodiment employing such flaps
may be used without spacer boards where at least a part of second
panel 20 is thick enough to interact with the flaps suitably to
permit second panel to be held in place by the flaps as
described.
[0052] In order to make a wall from pourable building material such
as concrete, a first panel made of an insulating material is
provided. The first panel has an inward facing surface facing
towards the interior of the building, and an outward facing surface
facing towards the exterior of the building. A second panel, also
having an inward facing surface and an outward facing surface, and
preferably of plywood, is also provided. The first connector of the
tie is connected to the first panel. It will be understood that
this may be done upon manufacture of the first panel where the
insulating material is expandable polystyrene or the like such that
the first connector is thereby embedded in the panel during
moulding. The second connector of the tie is then connected to the
second panel using fasteners such as screws and/or some alternative
or combined mechanical connection. When the first and second panels
are connected to the tie as described, the first and second
connectors are separated by an intermediate portion with a length
corresponding approximately to the thickness of a wall being made.
A fixed space between die first and second panels for receiving a
charge of the concrete is thereby provided. A charge of concrete is
then provided into the fixed space between the first and second
panels. The electrical cable and/or plumbing may be passed through
passageways 62 prior to connection of the third panel, preferably
made of drywall.
[0053] It will be understood that, in some embodiments, the third
panel may be connected prior to pouring of the concrete into the
fixed space between the second and third panels. If electrical
cable and/or plumbing are required, then this of course is
installed prior to connection of the third panels. In some cases,
the second panels would remain part of the finished wall, albeit
hidden from view inside the building by the third panels.
Furthermore, the second panels may remain part of the finished wall
whether or not the third panels were connected prior to or after
pouring of the concrete. This is left to the preference of the
builder, and the suitability of the second panel remaining part of
the wall. Indeed, some described embodiments of ties described
herein require removal of the second panel prior to connection of
the third panel, and some do not.
[0054] Depending particularly upon the required height of the
concrete wall being built, first and second panels may be
vertically stacked upon each other to provide a formwork having a
suitable height.
[0055] Embodiments of ties have been shown for use in construction
environments in which a second panel is desired to be disconnected
from the tie prior to connection of a third panel, and also in
which the second panel may remain while a third panel is being
connected.
[0056] While embodiments have been shown hereby ties are stacked
using a mechanical interlock mechanism, other configurations are
possible. For example, second connectors of two adjacent ties may
cooperate with each other to connect to second and/or third panels
without interlocking. In such an embodiment, two second connectors
of two ties may have second panel connection portions that do not
mechanically interlock or even touch, but align to both receive a
common second panel. In other or complementary embodiments, the
first portion of a tie may span the entire height of a first panel,
while intermediate portions and/or second portions do not. Various
combinations and modifications within the scope of the invention
are possible.
[0057] While embodiments have been shown that have the third panel
spaced from the second panel, it will, be understood that second
panels may be provided that are dimensioned and configured with
respect to a tie so that there is little or no space between the
third and second panels. It will be understood that in such
embodiments, the second panel is intended to be disconnected from
the formwork prior to connection of a third panel, such that the
third panel is in fact spaced from the concrete wall surface
thereby permitting passage of electrical cables/plumbing and the
like between the third panel and the concrete wall surface.
[0058] Although embodiments have been described, those of skill in
the art will appreciate that variations and modifications may be
made without departing from the spirit and scope thereof. As
defined by the appended claims.
* * * * *