U.S. patent application number 12/737404 was filed with the patent office on 2011-05-05 for panel interlocking system.
Invention is credited to Roger Saulce.
Application Number | 20110099932 12/737404 |
Document ID | / |
Family ID | 41506607 |
Filed Date | 2011-05-05 |
United States Patent
Application |
20110099932 |
Kind Code |
A1 |
Saulce; Roger |
May 5, 2011 |
PANEL INTERLOCKING SYSTEM
Abstract
A panel interlocking system (100) for locking a panel (102) to
an opposite panel structure (202) via substantially vertical (104)
and horizontal (106) rods positioned generally parallel to a plane
defined by the panel (102) and to be embedded therewith in a filler
material poured adjacent the panel (102) in a direction toward the
panel structure (202). The system (100) includes at least one panel
securing bracket (112) having a body (114) with a first end (116)
for connecting to the panel (102) and a generally opposite second
end (118) for connecting to the rods (104,106). The second end
(118) has a rod opening (120) extending there through for receiving
the vertical rod (104) therein and defines a rod abutting region
(122) adjacent the rod opening (120) toward the first end (116) for
abutment with the horizontal rod (106), such that the horizontal
rod (106) abuts to and between the vertical rod (104) and a
structure rod (204) to be interlocked there between for locking the
panel (102) to the panel structure (202).
Inventors: |
Saulce; Roger; (Montreal,
CA) |
Family ID: |
41506607 |
Appl. No.: |
12/737404 |
Filed: |
July 11, 2008 |
PCT Filed: |
July 11, 2008 |
PCT NO: |
PCT/CA2008/001277 |
371 Date: |
January 11, 2011 |
Current U.S.
Class: |
52/426 ;
52/582.2; 52/745.13 |
Current CPC
Class: |
E04B 2/845 20130101;
E04B 2/8611 20130101; E04C 5/18 20130101; E04B 2/8635 20130101;
E04B 2/847 20130101; E04F 13/0803 20130101; E04B 2/8641 20130101;
E04B 2/8647 20130101; E04C 5/168 20130101 |
Class at
Publication: |
52/426 ;
52/582.2; 52/745.13 |
International
Class: |
E04B 2/86 20060101
E04B002/86; E04B 2/84 20060101 E04B002/84; E04B 1/38 20060101
E04B001/38 |
Claims
1. A panel interlocking system (100) for locking a panel (102) to
an opposite panel structure (202), said system (100) being adapted
to connect to substantially orthogonal first (104) and second (106)
rods positioned generally parallel to a plane defined by the panel
(102), and to be embedded therewith in a filler material poured
adjacent the panel (102) in a direction toward the panel structure
(202), said system (100) comprising: at least one panel securing
bracket (112) having a body (114) with a first end (116) for
connecting to the panel (102) and a generally opposite second end
(118) for connecting to the orthogonal rods (104,106), the second
end (118) having at least one first rod opening (120) extending
therethrough for slidably receiving the first rod (104) therein,
the second end (118) defining a second rod abutting region (122)
adjacent the at least one first rod opening (120) in a direction
toward the first end (116) for being in abutment contact with the
second rod (106), whereby said second rod (106) being adapted to be
in abutment contact to and between the first rod (104) and a
structure rod (204) so as to be interlocked therebetween for
locking the panel (102) to the panel structure (202).
2. The system of claim 1, wherein said first end (716) includes a
first end surface (750) facing substantially away from said second
end (718) for being in abutment contact with a surface (703) of the
panel (702).
3. The system of claim 2, wherein said first end (716) includes a
through opening (752) extending through said first end surface
(750) for receiving a fastener (754) therethrough for connection to
the panel (702).
4. The system of claim 2, further including a generally cylindrical
fastener (754) extending through a through bore (756) of the panel
(702) and having a protrusion (758) extending out of said panel
surface (703), said protrusion (758) defining a circumferential
groove (760) adjacent the panel surface (703), wherein said first
end (716) includes a through opening (752) slidably engaging said
circumferential groove (760) via an opening mouth (752') for
securing the bracket (712) to the panel (702).
5. The system of claim 4, wherein said cylindrical fastener (754)
includes a head (762) adapted to be in abutment contact with a
panel second surface (705) facing generally away from the bracket
(712).
6. The system of claim 4, wherein said cylindrical fastener (754)
includes a head (762) adapted to engage a counter bore (756') of
the panel through bore (756) on a panel second surface (705) facing
generally away from the bracket (712) so as to allow the fastener
head (762) to rest below the panel second surface (705).
7-9. (canceled)
10. The system of claim 1, wherein said body (114) has a generally
V-shape defining an open end and an opposite closed end forming
said first end (116) and said second end (118) respectively, said
open end (116) being securable to the panel (102), said closed end
(118) being rounded so as to form said first rod opening (120).
11. The system of claim 10, wherein said body (114) is made out of
a plate folded to form the V-shape.
12. The system of claim 11, wherein said folded plate (114) defines
a plurality of said bracket (112) being positioned in an end-to-end
configuration with all said first rod openings (120) being in
register with each other for slidably receiving the first rod (104)
therein, said closed end (118) including a plurality of cutouts
(124) extending from the second end (118) toward the first end
(116), each said cutout (124) defining a respective said second rod
abutting region (122) for being in abutment contact with a
respective said second rod (106).
13. The system of claim 10, wherein said body (514) is made out of
a rigid wire folded to form a plurality of said V-shape of said
brackets (512) positioned in a side-by-side configuration with two
adjacent said V-shapes (512) being spaced apart from one another by
a respective wire spacing segment (534), the wire forming a
plurality of said second rod abutting region (522) for being in
abutment contact with the second rod (506), each said first rod
opening (520) being for slidably receiving a respective said first
rod (504) therein, said spacing segments (534) of the wire (514)
being securable to the panel (502).
14. The system of claim 13, wherein said spacing segments (534) of
the wire are embedded within the panel (502), whereby said V-shapes
(512) protrude out of said panel (502) for connecting to the first
(504) and second (506) rods.
15. The system of claim 13, including a plurality of said folded
rigid wire (514) positioned in a side-by-side configuration with
each said V-shape (512) being in register with a corresponding said
V-shape of each said rigid wire (514), whereby all registered
second end openings (520) being adapted for slidably receiving a
respective said first rod (504) therein, said plurality of rigid
wires (514) being secured to each other via a plurality of cross
bars (536) spaced apart from one another, whereby said rigid wires
(514) and said cross bars (536) forming a folded wire mesh
(538).
16. The system of claim 15, wherein at least one said cross bar
(536) is located adjacent each said bracket closed second end (518)
of registered V-shapes (512) for being in abutment contact with
corresponding said second rods (506) when corresponding said second
rods (506) are in abutment contact with said first rods (504)
positioned through corresponding said first rod openings (520).
17. The system of claim 1, wherein said body (214) is made out of a
plate having said first end (216) being folded substantially
orthogonally relative to the plate (214) for securing to the panel
(202), said plate (214) having said second end (218) being
arcuately folded to form a saddle facing toward the first end (216)
and defining said first rod opening (220) for slidably receiving
the first rod (204) therein.
18. The system of claim 17, wherein said saddle (220) extends over
at least an angle of about 270 degrees for defining said first rod
opening.
19. The system of claim 17, wherein said plate (214) defines a
plurality of said bracket (212) being positioned in an end-to-end
configuration with all said first rod openings (220) being in
register with each other for slidably receiving the first rod (204)
therein, said plate (214) including a plurality of cutouts (224)
extending from the second end (218) toward the first end (216)
defining adjacent said first rod openings (220), each said cutout
(224) defining a respective said second rod abutting region (222)
for being in abutment contact with a respective said second rod
(106).
20. The system of claim 19, wherein said first ends (216) of said
plate (214) are folded orthogonally relative to the plate (214) in
an alternating configuration in opposite directions.
21-23. (canceled)
24. The system of claim 1, wherein a plurality of said bracket
(712) being positioned in an end-to-end configuration with all said
first rod openings (720) being in register with each other to
slidably receive the first rod (704) therein.
25-29. (canceled)
30. A panel interlocking system (100) for attachment to an opposite
panel structure (202), said system comprising: a panel (102) for
locking to the panel structure (202); at least one first rod (104)
and at least one second rod (106), substantially orthogonal to each
other, positioned generally parallel to a plane defined by the
panel (102); and at least one bracket (112) having a body (114)
with a first end (116) connecting to the panel (102) and a
generally opposite second end (118) connecting to the orthogonal
rods (104,106), the second end (118) having at least one first rod
opening (120) extending therethrough for slidably receiving the
first rod (104) therein, the second end (118) defining a second rod
abutting region (122) adjacent the at least one first rod opening
(120) in a direction toward the first end (116) for being in
abutment contact with the second rod (106), said second rod (106)
being adapted to be in abutment contact to and between the first
rod (104) and a structure rod (204) so as to be interlocked
therebetween for locking the panel (102) to the panel structure
(202), whereby said at least one bracket (112), said first (104)
and second (106) rods and the structure rod (204) being adapted to
be embedded within a filler material poured adjacent the panel
(102) in a direction toward the panel structure (202).
31. A method for interlocking a panel (102) to an opposite panel
structure (202), said panel (102) connecting to a first end (116)
of a body (114) of at least one bracket (112), the bracket (112)
having a generally opposite free second end (118), said method
comprising the steps of: positioning the panel (102) in a
face-to-face configuration with the structure panel (202), with the
at least one bracket (112) extending toward the panel structure
(202); slidably engaging, in a first direction generally parallel
to a plane defined by the panel (102), a first rod (104) into at
least one first rod opening (120) extending through the second end
(118); engaging, in a second direction substantially perpendicular
to the first direction and generally parallel to the panel plane, a
second rod (106) in abutment contact with a second rod abutting
region (122) adjacent the at least one first rod opening (120),
said second rod (106) being located adjacent said first rod (104)
between said first rod (104) and said panel (102); and slidably
engaging, in a direction substantially parallel to the first
direction, a structure rod (204) into at least one rod receiving
structure bracket (212), said second rod (106) being adapted to be
in abutment contact to and between the first rod (104) and the
structure rod (204) so as to be interlocked therebetween for
locking the panel (102) to the panel structure (202).
Description
FIELD OF THE INVENTION
[0001] The present invention relates to composite paneling and the
forming of concrete walls, and more specifically to an interlocking
system for securing forming panels to a panel facing structure via
orthogonal rods that remain within the filler material as
reinforcing structure.
BACKGROUND OF THE INVENTION
[0002] It is well known in the art to have forming panels made out
of wood or other type material that are typically removed after the
concrete has dried. Alternatively, the panels may be of polystyrene
material or the like foam type materials that typically remain part
of the wall construction (stay-in-place type form) along with the
concrete to provide some insulation. To this end a plurality of
intermediate bridging web structure pieces, typically made out of
metallic or plastic type material, allow for relatively quick and
adjustable assembly of the panels to each other, adjacent panels as
well as facing panels. Rebars are typically added to increase the
structural characteristics of the wall.
[0003] Concrete walls are formed by pouring concrete between forms
facing each other with rebars (horizontal and vertical) in-between
for the construction of buildings/houses. In this case the forms
are typically removed after the concrete is cured/dried.
[0004] In the case the forms are not removed they are of the
stay-in-place form type such as those found in ICF (insulated
concrete form) systems. Many types of insulated forms are on the
market and three main types are found, Lego.TM. type blocks, planks
and narrow panels.
[0005] Systems to link two opposite panels together allow for a gap
between two such panels. This gap or void is being filled with a
filler material made of one or more components usually in a liquid,
semi liquid or paste like material that hardens to become a solid
after the cure is completed. The solid can be a foam type material.
Once it solidifies the result is a composite wall where the two
panels facing each other are part of the resulting wall with the
linking rods embedded inside.
[0006] In conventional reinforced concrete structure such as a wall
the reinforcement is achieved with horizontal and vertical rebars,
these rebars are held together with wire tied around both bars at a
certain angle relative to each other.
[0007] Some devices or parts of these wall structures are discrete
and made of steel or plastic while other linking system
accomplishing the same purpose are not wire made but are built more
like a cage such as in U.S. Pat. No. 7,143,563 where once the bar
is inserted either parallel wise or at a 90 degree angle relative
to each other, a sliding cap is put on to close the cage and locks
the bars together. U.S. Pat. No. 5,893,252 shows a plastic support
where bars are positioned at a 90-degree angle relative to each
other, the top bar is then locked thanks to two clips pivoting over
the top bar and encapsulating said bar.
[0008] Preformed permanent opposite panels attached to each other
via vertical rods are found in U.S. patent application Ser. No.
10/506,465 published on Sep. 22, 2005 under publication No.
2005/0204695A1, but do not allow for horizontal rods to be inserted
for interconnection purposes. Since the panels are molded, they are
expensive to manufacture and limited to relatively small sizes, and
the use of these panels is usually too limiting in term of wall
dimensions with no flexibility in that respect.
[0009] In the case of a liquid becoming a solid foam, the expansion
of the foam will exert a pressure that will push apart the two
facing panels, the spreading apart of the panels is restrained by
the interlocking device composed of the grid made by the horizontal
and vertical bars or rods.
[0010] In the case of concrete walls, the concrete is poured
between the panels (forms), and the hydrostatic pressure of the
liquid or paste like mixture pushes apart the forms.
[0011] Some examples of such foam panel structures are found in
U.S. Pat. Nos. 3,788,020; 4,574,550; 4,730,422; 4,889,310;
6,240,692; 6,247,280; 6,935,081; and 7,082,732.
[0012] Although the insulation panel systems provide some
advantages over more conventional removable wooden plank systems,
they do suffer from a plurality of drawbacks such as the lack of
versatility, the relatively high material cost, the long and costly
(labour) assembly time, non-uniform spacing between adjacent rebars
(both horizontal and vertical), relatively susceptible to blow out
(thereby the need for extensive retaining structure system), small
panels that need to be covered for protection and/or finishing,
etc.
[0013] Accordingly, there is a need for an improved panel
interlocking system.
SUMMARY OF THE INVENTION
[0014] It is therefore a general object of the present invention to
provide an improved panel interlocking system that obviates the
above-mentioned problems.
[0015] An advantage of the present invention is that the panel
interlocking system provides permanent forms or panels linked from
the inside with a device tying the bars together all in one
system.
[0016] An advantage of the present invention is that the panel
interlocking system allows for any size panels to be easily secured
to a facing panel structure using orthogonal rods, bars, rebars or
the like of any cross-sectional shape.
[0017] Another advantage of the present invention is that the panel
interlocking system allows for the panels to be pre-assembled with
securing brackets before installation with other panels or panel
structure, to save on-site working time.
[0018] A further advantage of the present invention is that the
panel interlocking system provides easy customization of the panel
and/or bracket types that may be different than the facing panel,
the panel may also be removable for finishing directly on the
concrete wall or change the panel type after hardening of the
filler material such as the drying of the concrete or the like.
[0019] Still another advantage of the present invention is that the
panel interlocking system allows for simple and rapid
installation.
[0020] Another advantage of the present invention is that the panel
interlocking system is easily adaptable to existing structures for
wall repairs and/or insulation.
[0021] One of the advantages of the present invention is to have a
link between orthogonal bars relative to each other to form a grid.
The grid system can then be linked to the two panels facing each
other also called forms. In the case of an existing wall, only one
panel may be used to create a space between the existing wall and
said panel. With either the panels facing each other or a panel
facing an existing vertical wall, and the bar system in between;
this panel locking system permits a positioning and an interlocking
between bars and facing panels, the space between the two vertical
surfaces can be filled with a filler material made of one or more
compound with a predetermined curing time varying according to the
nature of these compounds and their additives. Once completely
cured the assembly becomes one monolithic block commonly called a
sandwich wall or panel.
[0022] The present invention also advantageously allows the
manufacturing of composite paneling, i.e. two panel (thin skin)
linked together from the inside via a grid made of vertical and
horizontal rods, with the gap between the two skins being filled
with a polyurethane like liquid that foams to form a solid. The
expansion of the foam spreads the two skins apart and exerts a
pressure at the knots between vertical and horizontal rods. These
composite panels can be used as a stand alone wall for separation
of open offices or can be used as non-bearing wall in a
building/house.
[0023] Furthermore, the present invention permits a positioning and
locking of the rebars usually positioned at a 90-degree angle
between each other, this grid is either self-attached to one form
forming one side of a panel or attached to two forms facing each
other with a variable gap there between, which determines the
thickness of the panel. This present system can use insulated forms
or not and the forms typically stay in place, and can apply to
other medium than concrete to be poured, injected, and foamed
between two panels to form then a composite paneling system. An
advantage of the present invention resides in the positioning and
linking of the rebar which constitutes a mesh or trellis system for
the reinforcement of concrete.
[0024] Advantageously, the permanent form of the present invention
can be made of a thin concrete panel, steel, plastic, reinforced
polypropylene, glass and/or carbon fiber, etc. or even a
combination of several different materials. And the bars can have
any section and be of any material.
[0025] Another advantage of the system over ICF is that if it is
only insulated on the outside of the wall, which is the side
exposed to the elements of nature, the inside of the building can
make full use of the thermal mass of the concrete wall.
[0026] Yet another advantage of the present invention is that panel
connectors can be moulded while the extruded panels can be pierced
or perforated.
[0027] A further advantage of the present invention is that it
enables production of a wall with shotcrete on one or both sides,
such as used for separation walls (with good sound insulation)
between adjacent lands or properties.
[0028] Another advantage of the present invention is that it can be
used where an existing wall (usually old foundation wall) is to be
refurbished and may act as a form; the present interlocking system
therefore including the opposite form.
[0029] When used below grade, a further advantage of the present
invention is that panels, when covered with fiber glass, act as a
waterproof skin on top of the extruded polystyrene, there is no
need to put an additional water proof membrane afterward. Only a
narrow sealing membrane on the joints between adjacent panels and
at the junction between panels and footings may complete the
installation.
[0030] Yet another advantage of the present invention is that it
allows for a precise positioning of the rebar grid. All outside
panels are placed on the perimeter with bracing, then positioning
of the horizontal and vertical rebars, followed by the placement of
inside panels just after cleaning of footings. A short time between
installing inside panels and pouring of concrete minimizes the
chances of further contamination of bottom of concrete footings,
which further allows for a better bond between concrete wall and
footing, with no cold joints.
[0031] According to a first aspect of the present invention, there
is provided a panel interlocking system for locking a panel to an
opposite panel structure, the system being adapted to connect to
substantially orthogonal first and second rods positioned generally
parallel to a plane defined by the panel, and to be embedded
therewith in a filler material poured adjacent the panel in a
direction toward the panel structure, the system comprising at
least one panel securing bracket having a body with a first end for
connecting to the panel and a generally opposite second end for
connecting to the orthogonal rods, the second end having at least
one first rod opening extending therethrough for slidably receiving
the first rod therein, the second end defining a second rod
abutting region adjacent the at least one first rod opening in a
direction toward the first end for being in abutment contact with
the second rod, whereby the second rod being adapted to be in
abutment contact to and between the first rod and a structure rod
so as to be interlocked therebetween for locking the panel to the
panel structure.
[0032] In a second aspect of the present invention, there is
provided a panel interlocking system for attachment to an opposite
panel structure, the system comprising: [0033] a panel for locking
to the panel structure; [0034] at least one first rod and at least
one second rod, substantially orthogonal to each other, positioned
generally parallel to a plane defined by the panel; and [0035] at
least one bracket having a body with a first end connecting to the
panel and a generally opposite second end connecting to the
orthogonal rods, the second end having at least one first rod
opening extending therethrough for slidably receiving the first rod
therein, the second end defining a second rod abutting region
adjacent the at least one first rod opening in a direction toward
the first end for being in abutment contact with the second rod,
the second rod being adapted to be in abutment contact to and
between the first rod and a structure rod so as to be interlocked
therebetween for locking the panel to the panel structure, whereby
at least one bracket, the first and second rods and the structure
rod being adapted to be embedded within a filler material poured
adjacent the panel in a direction toward the panel structure.
[0036] In a further aspect of the present invention, there is
provided a method for interlocking a panel to an opposite panel
structure, said panel connecting to a first end of a body of at
least one bracket, the bracket having a generally opposite free
second end, said method comprising the steps of: [0037] positioning
the panel in a face-to-face configuration with the structure panel,
with the at least one bracket extending toward the panel structure;
[0038] slidably engaging, in a first direction generally parallel
to a plane defined by the panel, a first rod into at least one
first rod opening extending through the second end; [0039]
engaging, in a second direction substantially perpendicular to the
first direction and generally parallel to the panel plane, a second
rod in abutment contact with a second rod abutting region adjacent
the at least one first rod opening, said second rod being located
adjacent said first rod between said first rod and said panel; and
[0040] slidably engaging, in a direction substantially parallel to
the first direction, a structure rod into at least one rod
receiving structure bracket, said second rod being adapted to be in
abutment contact to and between the first rod and the structure rod
so as to be interlocked therebetween for locking the panel to the
panel structure.
[0041] Other objects and advantages of the present invention will
become apparent from a careful reading of the detailed description
provided herein, with appropriate reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Further aspects and advantages of the present invention will
become better understood with reference to the description in
association with the following Figures, in which similar references
used in different Figures denote similar components, wherein:
[0043] FIG. 1 is a perspective view of panel interlocking systems
in accordance with embodiments of the present invention;
[0044] FIG. 2 is a partially broken enlarged top view of the
embodiments of FIG. 1;
[0045] FIG. 3 is a partially broken enlarged perspective view taken
along line 3 of FIG. 1;
[0046] FIG. 4 is a perspective view of other embodiments of panel
interlocking systems in accordance with the present invention;
[0047] FIG. 5 is a partially broken enlarged top plan view of the
embodiments of FIG. 4;
[0048] FIG. 6 is a partially broken enlarged perspective view taken
along line 6 of FIG. 4;
[0049] FIG. 7 is a perspective view of other embodiments of panel
interlocking systems in accordance with the present invention;
[0050] FIG. 8 is a partially broken enlarged top plan view of the
embodiments of FIG. 7;
[0051] FIG. 9 is a partially broken enlarged perspective view taken
along line 9 of FIG. 7;
[0052] FIG. 10 is a perspective view of another embodiment of a
panel interlocking system in accordance with the present
invention;
[0053] FIG. 11 is a broken enlarged side elevation view of the
embodiment of FIG. 10;
[0054] FIG. 12 is a partially broken enlarged perspective view
taken along line 12 of FIG. 10;
[0055] FIG. 13 is a perspective view of other embodiments of panel
interlocking systems in accordance with the present invention;
[0056] FIG. 14 is a partially broken enlarged top plan view of the
embodiments of FIG. 13;
[0057] FIG. 15 is a partially broken enlarged perspective view
taken along line 15 of FIG. 13;
[0058] FIG. 16 is an enlarged partially broken sectioned
perspective view of a bracket fastener connected to the panel of
the embodiment of FIG. 13;
[0059] FIG. 17 is a view similar to FIG. 16 showing another
fastener-panel connection type;
[0060] FIG. 18 is an enlarged partially broken section view of a
double bracket fastener connected to an intermediate panel as in
FIG. 23;
[0061] FIG. 19 is another embodiment of a panel interlocking
system, similar to one of the embodiments of FIG. 13;
[0062] FIG. 20 is a view similar to FIG. 15 showing the embodiment
of FIG. 19;
[0063] FIG. 21 is a partially broken top plan view of other
embodiments of panel interlocking systems in accordance with the
present invention;
[0064] FIG. 22 is a partially broken side elevation view of the
embodiments of FIG. 21;
[0065] FIG. 23 is a perspective view of other embodiments of panel
interlocking systems in accordance with the present invention;
and
[0066] FIG. 24 is a partially broken enlarged top plan view of the
embodiments of FIG. 23.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0067] With reference to the annexed drawings the preferred
embodiments of the present invention will be herein described for
indicative purpose and by no means as of limitation.
[0068] Reference is now made to FIGS. 1 to 3, which show two
embodiments 100, 200 of panel interlocking system in accordance
with the present invention for locking a respective panel 102 or
panel structure to an opposite panel structure, namely the facing
panel 202 in this case; an opposite panel structure can also be an
intermediate wall structure, an existing wall or the like. Each
system 100, 200 is adapted to connect to substantially orthogonal
linking rods 104, 106, 204, bars, rebars (reinforcing bars) or the
like elongated piece, namely respective generally vertical first
rods 104, 204 and common second generally horizontal rods 106, with
all first and second rods being positioned generally parallel to a
plane defined by the panels 102, 202. The orthogonal rods 104, 106,
204 are adapted to be embedded therewith in a filler material such
as concrete or the like hardening or drying mixture (not shown)
that will be poured adjacent and in-between the panels 102, 202,
i.e. in a direction toward the facing panel relative to each
panel.
[0069] Each panel 102, 202 used as a form for a concrete wall may
include elongated channels 108, 208 extending along predetermined
sides of the panel 102, 202 for receiving elongated panel linking
members 110, 210, in the form of `+` shape cross-section bars or
the like, to be positioned between adjacent panels (top side,
bottom side and/or lateral sides) or even partially pre-embedded
into a concrete footing 30 for location and securing of the panel
102, 202 thereon, as shown in FIG. 1.
[0070] As shown more specifically in FIGS. 2 and 3, each system
100, 200 includes at least one, preferably a plurality of panel
securing brackets 112, 212. Each bracket 112, 212 has a body 114,
214 with a first end 116, 216 connecting to the panel 102, 202 and
a generally opposite second end 118, 218 connecting to the
orthogonal rods 104, 106, 204. The second end 118, 218 has at least
one first rod opening 120, 220 extending there through for slidably
receiving the respective vertical first rod 104, 204 therein and to
keep the vertical rod 104 at a predetermined distance from the
panel 102 while preventing it from moving away therefrom, and
defines a second rod abutting region 122, 222 adjacent the first
rod opening 120, 220 in a direction toward the first end 116, 216
adapted to be in abutment contact with the common respective
horizontal rod 106, such that the horizontal rod 106 is so
positioned to be in abutment contact to and between the respective
vertical rods 104, 204 and therefore interlocked there between to
lock the facing panels 102, 202 to each other, especially when the
concrete is being poured between the two facing panels.
[0071] In the first embodiment 100, the body 114 has a generally
V-shape, such as a folded plate or the like, defining an open end
116 and an opposite closed end 118 forming the first and second end
respectively. The open end 116 is secured to the panel 102 by
welding, bonding, embedded in a thin concrete or foam panel or the
like fastening mechanism known in the art, which depends on the
panel and/or bracket materials, or may even include folded ear
pieces (not shown) to abut against and secured the panel internal
surface, and the closed end 118 is essentially rounded to form the
first rod opening.
[0072] Furthermore, in the first embodiment 100, the folded
elongated plate 114 defines a plurality of said brackets 112
positioned in an end-to-end configuration with all the respective
first rod openings 120 being in register with each other for
slidably receiving a common vertical rod 104 therein. The closed
end 118 of the elongated plate 114 includes a plurality of cutouts
124 extending from the second end 118 toward the first open end
116, with each cutout 124 spacing adjacent first rod openings 120
from one another and defining the respective second rod abutting
region 122 that abuttingly support the respective horizontal rod
106.
[0073] The bottom surface of each cutout 124 (cutout depth) defines
a back ridge 126 that extends substantially perpendicularly to the
direction extending between the bracket first 116 and second 118
ends and faces toward the second end 118. The ridge 126, being part
of the horizontal rod abutting region 122, is also used to be in
abutment contact with the horizontal rod 106 to substantially
retain the same against, typically in abutment contact, with the
first rod 104 positioned through the first rod opening 120.
[0074] In the second embodiment 200, the body 214 of each bracket
212 is made out of a plate having its first end 216 folded
substantially orthogonally relative to the plate 214 for securing
to the panel 202 by sliding into a corresponding T-shape channel
228 extending along the panel 202. The plate 214 has its second end
218 arcuately folded to form a saddle facing toward the first end
216 and defining the first rod opening 220 for slidably receiving
the vertical rod 204 therein. The saddle 220 typically extends over
at least an angle of about 270 degrees for defining an almost
closed first rod opening and properly retaining the rod 204
therein.
[0075] Typically, as shown in FIGS. 1 and 3, the plate 214 defines
a plurality of brackets 212 being positioned in an end-to-end
configuration with all the first rod openings 220 being in register
with each other for slidably receiving the common vertical rod 204
therein. Similarly to the above first embodiment 100, the plate 214
includes a plurality of cutouts 224 extending from the second end
218 toward the first end 216, and defining adjacent first rod
openings 220. Each cutout 224 defines a respective second rod
abutting region 222 to support in abutment the respective
horizontal rod 106, along with a back ridge 226.
[0076] Furthermore, the first ends 216 of the plate 214 are folded
orthogonally relative to the plate in an alternating configuration,
in opposite directions, either between adjacent brackets 212 or
between each bracket 212 and adjacent bracket spacing sections of
the plate 214. This alternating configuration of folded first ends
216 allows the plate 214 to fully engage the corresponding T-shape
channel 228.
[0077] For the assembly of the two panel interlocking systems 100,
200 to each other, the first panel 102 is installed onto its
supporting surface 30 (footing for example), and the horizontal
rods 106 are then slidably inserted onto the corresponding rod
abutting regions 122 of the brackets 112 extending from the first
panel 102. The first vertical rods 104 are then slidably inserted
into the corresponding first rod openings 120 of the brackets 112
in front of the horizontal rods 106 to lock the latter in place
between the vertical rods and the panel. It is noted that the
vertical rods 104 could alternatively be installed prior to the
horizontal rods 106. Subsequently, the second panel 202 is
installed facing the first panel 102 with the first rod openings
220 of the brackets 212 extending beyond the horizontal rods 106 to
allow insertion of the vertical rods 204 of the second panel 202 to
be slidably inserted into the corresponding first rod openings 220
and to be locked between the horizontal rods 106 and the first
panel 102, to interlock the two panels 102, 202 to each other.
[0078] Alternatively, if there is enough access from the sides of
the panel systems 100, 200, the first 102 and second 202 panels
could be installed with their respective vertical rods 104, 204
before slidably inserting the interlocking horizontal rods 106
between the vertical rods 104 of the first panel 102 and those 204
of the second panel 202, to lock the vertical rods 104, 204 of one
panel 102, 202 between the horizontal rods 106 and the facing panel
202, 102.
[0079] Now referring more specifically to FIGS. 4 to 6, two other
embodiments 300, 400 of the panel interlocking system in accordance
with the present invention are interlocked to each other, with
respective vertical 304, 404 and horizontal 306, 406 rods, via an
embodiment 90 of an intermediate panel structure allowing for a
thicker concrete wall. In such a case, each panel 302, 402 is
interlocked with the intermediate structure 90 in a similar way
they would directly interlock to one another, which is essentially
the same interlocking system as hereinabove described for the first
two embodiments 100, 200. The intermediate structure 90 is
typically formed of a plurality of vertical members 92 with
corresponding vertical rods 304', 404', each member 92 defining a
plurality of securing brackets 312', 412' having similar
characteristics (first rod opening, second rod abutting region,
etc.) than the second ends 118, 218 of the above-described brackets
112, 212.
[0080] In the third embodiment 300, a plastic type material plate
314 forms a plurality of registered securing brackets 312 in which
the first end 316 substantially has a T-shape for slidably engaging
a corresponding T-shape channel 328 extending along the panel 302
or along a side surface thereof, similar to the above second
embodiment 200.
[0081] In the fourth embodiment 400, the preferably plastic type
material plate 414 forming a plurality of registered securing
brackets 412 includes a shoulder 430 formed at the first end 416 to
be in abutment contact with an edge 432 of the surface 403 of the
corresponding panel 402 facing the intermediate structure 90.
Although not shown, the panel 402 is temporarily secured to the
plate 414 for easy removal after the concrete has dried (typically
facilitated using known in the art release agent covering the
surface of the removable panel facing the concrete), and
replacement by another wall finish (not shown).
[0082] It is noted that in both embodiments 300, 400, each bracket
312, 412 has the second end 318, 418 and the first rod opening 320,
420 and the second rod abutting region 322 are also similar to the
above second embodiment 200.
[0083] Now referring more specifically to FIGS. 7 to 9, another
embodiment 500 of the panel interlocking system in accordance with
the present invention has its panel 502 interlocked to a second
embodiment 90a of an intermediate panel structure. In the fifth
embodiment 500, the body 514 is made out of a rigid wire shaped to
form a plurality of V-shape brackets 512, similar to those 112 of
above first embodiment 100, positioned in a side-by-side
configuration with two adjacent V-shape brackets being spaced apart
from one another by a respective wire spacing segment 534 (shown in
dotted lines in FIG. 8). The wire 514 forms a plurality of second
rod abutting regions 522 for being in abutment contact with a
common horizontal rod 506, and each first rod opening 520 slidably
receives a respective vertical rod 504 therein. The spacing
segments 534 of the wire 514 are securable to the panel 502, and
are preferably embedded within the panel 502, such that only the
V-shape brackets 512 protrude out of the panel 502 for connection
to the rods 504, 506.
[0084] The system 500 typically includes a plurality of folded
rigid wire 514 positioned in a side-by-side configuration with each
V-shape bracket 512 being in register with a corresponding V-shape
bracket 512 of each wire 514 such that all registered second end
openings 520 are adapted to slidably receive a respective vertical
rod 504 therein. The plurality of rigid wires 514 are typically
secured to each other via a plurality of cross bars 536 spaced
apart from one another, with the rigid wires 514 and the cross bars
536 forming a folded wire mesh 538 together.
[0085] As better shown in FIG. 8, at least one, preferably two
cross bars 536 are located adjacent each bracket closed second end
518 of registered V-shape brackets 512 to being in abutment contact
with corresponding horizontal rods 506 when they are in abutment
contact with the vertical rods 504 positioned through corresponding
first rod openings 520, and typically form the back ridges 526.
[0086] In FIGS. 7 to 9, the intermediate structure 90a is a similar
folded wire mesh than the above fifth embodiment 500 with accordion
type shape horizontal wires 94 positioned in a side-by-side
configuration and attached to each other via vertical cross bars
96. The accordion type shape wires 94 form alternating second end
openings 98 to receive respective vertical bars 504', with the
cross bars 96 typically forming corresponding back ridges 99 to
abut the respective horizontal rods 506, 506'.
[0087] Now referring more specifically to FIGS. 10 to 12, another
embodiment 600 of the panel interlocking system in accordance with
the present invention is shown. This sixth system 600 includes a
plurality of independent brackets 612 each having a generally
T-shaped first end 616 adapted to slidably engage corresponding
T-shape channel 628 formed along the panel 602. Each bracket 612 is
typically spaced from the adjacent two brackets 612 engaged into
the same channel 628 by generally elongated corresponding bracket
spacers 640 located therebetween and, preferably, also slidably
engaging the same channel 628.
[0088] The abutting region 622 of the bracket 612 forms a recessed
seat 642 that essentially helps positioning and prevents sliding of
the horizontal rod 606 thereon, which proves useful when the
horizontal rods 606 are installed prior to the vertical rods
604.
[0089] Typically, the bracket 612 further includes a top portion of
the vertical rod opening 620 that is a countersunk through hole 644
quite helpful for guiding the corresponding vertical rod 604 when
slidably inserting the vertical rod 604 therein, usually from the
top toward the bottom.
[0090] Optionally, the bracket 612 includes a channel 646 extending
transversally through the body 614 and located between the first
616 and second 618 ends to guide and position a generally
horizontal elongated member 648, such as a plumbing pipe, an
electrical conduit or wire(s), a hollow pipe or the like, that is
abuttingly supported therein.
[0091] Referring more specifically to FIG. 12a, the abutting region
622 of the bracket 612 alternatively includes a generally angled
segment 641 relative to a direction perpendicular to the panel
plane and downwardly toward the bracket first end 616 for
abuttingly receiving the horizontal rod 606 thereagainst. The
angled segment 641 also essentially helps the positioning of the
horizontal rod 606 thereon against the back ridge 626 and prevents
sliding of the rod 606, which proves useful when the horizontal
rods 606 are installed prior to the vertical rods 604.
[0092] Now referring more specifically to FIGS. 13 to 15, other
embodiments 700, 800 of the panel interlocking system in accordance
with the present invention are shown. This seventh system 700
includes a plurality of independent brackets 712 each a first end
716 with a first end surface 750 facing substantially away from the
second end 718 for being in abutment contact with a surface 703 of
the panel 702 facing the brackets 712 and the rods 704, 706.
[0093] The first end 716 typically includes at least one,
preferably two bracket through openings 752 extending through said
first end surface for receiving a fastener 754 therethrough for
connection to the panel 702. To this end, as shown in FIGS. 16 and
17, the system 700 further includes the generally cylindrical
fastener 754 that extends through a through bore 756 of the panel
702 and has a protrusion 758 extending out of the panel surface
703. The protrusion 758 generally defines a circumferential groove
760 adjacent the panel surface 703 such that the through opening
752 slidably engages the circumferential groove 760 via an opening
mouth 752' for securing the bracket 712 to the panel 702.
[0094] In FIG. 16, the fastener 754 typically includes a head 762
adapted to be in abutment contact with the opposite surface 705 of
the panel 702 facing generally away from the bracket 712.
Alternatively, the head 762 adapted to engage a counter bore 756'
of the panel through bore 756 on the panel second surface 705 to
allow the fastener head 762 to rest below, and preferably in
register with, the panel second surface 705, as shown in FIG. 17,
such that the surface 705 and heads 762 are then coverable by a
fiberglass skin or the like.
[0095] Referring back to FIGS. 13 to 15, the bracket second end 718
has a U-shape with the base wall of the U-shape forming the back
ridge 726 abuttingly receiving the horizontal rod 706, and one of
the two, generally parallel, side walls of the U-shape forming the
rod abutting region 722. At least one, preferably both side walls
of the U-shape having the first rod openings 720 of the brackets
712 extending there through.
[0096] Furthermore, when a plurality of panels 702 are positioned
side by side, a series of brackets 712 preferably secure to two
adjacent panels 702, with each one of the bracket through openings
752 slidably engaging a fastener 754 of a respective adjacent panel
702, to retain the panels adjacent to one another. Such an
interlocking system is essentially used on one side of the wall
only since the assembly of brackets 712 on a second facing panel is
more complex.
[0097] This eighth system 800 includes a plurality of independent
plates 814 each including a plurality registered brackets 812. All
bracket first ends 816 of a common plate 814 have an H-shape with
each open cavity 864 of the H-shape being adapted to slidably
receive a panel side edge. As illustrated, the panels 802,
preferably forming an internal side of the concrete wall, are
typically corrugated with horizontal corrugations (see FIG. 13) to
allow a thinner concrete wall for a same resistance and inwardly or
internally curved (see FIG. 14) to provide for empty spaces between
the panels 802 and internal boards (such as plasterboards (known as
Gyproc.TM. panel) or the like--not shown) to extend power grid
wirings, plumbing hardware or the like (not shown) therein. The
inward curve of the panels 802 allow to transfer the outward load
from the concrete to the plates 814 that are retained to the
horizontal rods 706 and the back panels 702 via vertical rods
804.
[0098] FIG. 18 shows an alternate embodiment 754' of a fastener
used with an intermediate panel structure (90d as shown in FIG. 23)
or panel and having one protrusion 758 with corresponding
circumferential groove 760 extending from a respective surface of
the panel structure 90d.
[0099] Now referring more specifically to FIGS. 19 and 20, another
embodiment 700a of a panel interlocking system in accordance with
the present invention is shown, which is similar to the seventh
embodiment 700. The main difference is that the bracket 712a has a
generally cylindrical-shaped body 714a with first end 716a that
directly extends through the panel bore 756 and includes a head
762' to abut the panel opposite surface 705. Similarly to the
fastener 754, the bracket 712a includes a circumferential groove
760a adjacent the panel surface 703 to allow a panel link (between
adjacent bores 756 of adjacent panels 702)/stiffener bar 766
(between adjacent bores 756 of a same panel 702). Although not
shown, such panel bar 766 could be angled to connect adjacent
panels angled relative to one another. Each bracket second end 718a
includes a diametric transversal channel 768 adapted to receive the
horizontal rod 706a therein, and a first rod through opening 720a
extending generally orthogonally to the channel 768 to slidably
receive the vertical rod 704a therein.
[0100] Now referring more specifically to FIGS. 21 and 22,
alternate embodiments 700b, 700c of the panel interlocking system
700 in accordance with the present invention are shown, in which
the respective brackets 712b, 712c essentially differ from bracket
712 and are secured to corresponding vertical rods 704b, 704c and
horizontal rod 706. Brackets 712b, 712c each are of a generally
L-shape with the base wall of the L-shape forming the bracket first
end 716b, 716c, and the free end of the elongated wall of the
L-shape having the first rod opening 720 extending there through
and the adjacent second rod abutment region 722 (bracket 712c only
in this case) to form the bracket second end 718. The first end of
the bracket 712b has an opening 752 with a mouth 752' to slidably
engage the corresponding fastener 754 protruding from the panel
702b, similar to bracket 712. On the other side, the bracket 712c
simply includes a through closed opening 752c adapted to be engaged
by a screw-type fastener 754c or the like when the securing is done
onto an existing wall 702c or the like (not accessible from both
sides or simply too thick).
[0101] Now referring more specifically to FIGS. 23 and 24, another
embodiment 90d of an intermediate panel structure using vertical
members 92d similar to the members 92 of FIGS. 4 to 6 but having
opposed longitudinal side channels 93 adapted to be engaged by a
respective edge wall 42 of an adjacent intermediate panel 40. The
intermediate panel 40 typically includes fasteners 754' slidably
receiving brackets 712b (with a squared second end 718b), 712d on
back and front side of FIG. 23 respectively (or top and bottom side
of FIG. 24 respectively). Brackets 712d, of panel interlocking
system 700d in accordance with the present invention, have a
generally U-shape with the base wall of the U-shape forming the
bracket first end 716d and having a through opening (not shown)
with a side mouth (not shown) to engage the corresponding
protrusion 758 of the fastener 754'. The brackets 712b, 712d and
the vertical members 92d are in register with each other to connect
to respective horizontal 706b, 706d and vertical 704b, 704d rods.
This embodiment is the most suitable to use when shotcrete
(concrete shot under pressure using a gun or the like) is
considered, to form an insulated sandwich panel (not shown).
[0102] Depending on the type and material of the panel that is
considered, the different components of the present panel
interlocking system could be made out of numerous materials such as
metal, plastic, or the like type materials using a wide variety of
manufacturing processes.
[0103] All plates described hereinabove are typically weight
relieved mainly to allow a better flow of concrete when poured
thereon as well as a better adherence of the concrete onto the
plate to preserve a unitary strong concrete wall.
[0104] Although the present invention has been described with a
certain degree of particularity, it is to be understood that the
disclosure has been made by way of example only and that the
present invention is not limited to the features of the embodiments
described and illustrated herein, but includes all variations and
modifications within the scope and spirit of the invention as
hereinafter claimed.
* * * * *