JP2006521477A - Reusable non-metallic structure forming system - Google Patents

Abstract

A formwork for use with a flow structure material, comprising a base portion having a front surface and a rear surface, and a reinforcing base secured to the rear surface. At least the base portion of the formwork is of a material that is neither metal nor wood.

Description

  This application claims the benefit of US Provisional Application No. 60 / 437,380 (filed December 31, 2002) and US Provisional Application No. 60 / 491,355 (filed July 31, 2003). The entire contents of which are incorporated herein by reference. The present invention relates generally to structure forming systems, and more particularly to a poured forming system that is held using a reusable lightweight plastic form.

  Injection molding systems are well known for forming building structures, including foundations, walls, floors, and roofs. In general, the form is made to receive a cementitious material, such as a flowable hardenable material, most typically concrete. The formwork includes a surface for contacting the flowable material.

  In most cases, the formwork is mainly made from wood. The flowable material generally contacts the flat wooden surface and is cured in the final orientation. However, wood contains oils and fats due to its nature. Oils and fats mix with the flowable material and separate the moisture contained in the flowable material therefrom. The separated moisture is absorbed by the wooden formwork, causing moisture damage to the wooden formwork. Furthermore, before the structure can be completely cured, moisture is stained on the front surface. In addition, the wooden formwork is often broken when separated from the flowable material, but has the advantage of low cost.

  Recently, aluminum formwork has been used instead of wooden formwork. An advantage of an aluminum formwork is that it can have one of a limited number of patterns that are lightly etched into the surface. Thus, when in contact with the etched surface, the flowable material assumes a mirror image of the pattern. However, aluminum molds have some significant drawbacks. For example, the formwork is heavy and difficult to assemble / disassemble and transport. In addition, the etching pattern is reusable but is susceptible to damage, can easily be gouged, or otherwise soiled. This formwork is also very expensive to provide a consistent pattern between the formwork when manufacturing, especially when secured together. Another problem is that only a very limited number of simple, lightly etched patterns can be used, and that pattern only accounts for a small percentage of the total formwork thickness.

  To address the problems of wooden and aluminum formwork, at least one company has created a thin formwork liner that is disposed between the face of a conventional formwork and a flowable material. Formwork liners typically include a lightly etched pattern. After the curing of the material is complete and the mold is removed, the liner is peeled away from the flowable material. Such liners can have several major problems. Due to its limited thickness, the liner easily expands or contracts due to temperature changes. As a result, this liner can only be used within a very limited temperature range without causing damage or abnormalities in the pattern itself. In addition, many flowable materials, such as type 3 concrete with accelerators, produce high temperatures during the curing process and damage the liner even when used at optimum temperatures. The liner is also difficult to fix to the mold surface, resulting in a sub-optimal pattern distribution between the molds. As with aluminum molds, only a limited number of lightly etched patterns can be used. Furthermore, it is often impossible to use a deeper pattern without damaging the liner or at least not significantly distorting the pattern.

  It is to provide a formwork for use with a flowable structural material.

  The formwork includes a base portion having a front surface and a rear surface, and a reinforcement matrix secured to the rear surface. At least the base portion of the formwork is of a material that is neither metal nor wood.

  Referring now to the figures, the same elements are indicated by the same reference numbers throughout the figures, but FIGS. 1A and 2A show the front and rear surfaces 22, 24 of an innovatively constructed form 20 made of a non-metallic material. FIGS. 1B and 2B are a top view and a bottom view of the mold 20 taken along lines 1A-1A and 2A-2A, respectively.

  More specifically, FIG. 1A shows the front surface 22 of the mold 20. A series of cavities 26 extend inwardly from the generally planar front surface 22, usually. However, it will be appreciated that the cavity 26 may extend outwardly from the front surface 22. As will be described in more detail below, the cavity 26 can have a depth. The front surface 22 includes a base portion 28 of the formwork 20. In marked contrast to the prior art, the cavity 26 can extend as much as one-half to three-fourths of the total thickness “T” of the mold 20 or even more. 1B and 2B show examples of the depth of the cavity 26. FIG. The illustrated formwork 20 imitates a rock protruding from the rear surface 24 of the formwork 20.

  The cavity 26 optionally includes a hole 27 that extends from the front surface 22 to the rear surface 24. As a matter of course, the arrangement of the holes 27 is not limited to the inside of the cavity 26, and the holes 27 can be arranged anywhere along the front surface 22 of the mold 20. However, the holes 27 are not always desirable because they affect the appearance of the finished product.

  The rear surface 24 of the mold 20 includes a reinforcing base 30 with an integral honeycomb structure extending from the rear surface 24. The rear surface 24 also includes a base portion 28 of the mold 20. In the illustrated embodiment, the reinforcing substrate 30 includes a plurality of horizontally and vertically extending braces 32, 34 that are integral with the base portion 28 of the mold 20. In some cases, cavity 26 may intersect brace 32 or 34, thereby providing additional structural support to cavity 26. In general, the braces 32 and 34 are arranged at equal intervals. However, as shown in FIG. 2A, the braces 32, 34 are unevenly spaced in areas where rigidity or reinforcement needs to be added to minimize undesirable movement when the formwork 20 is in the installed orientation. May be arranged. In the illustrated embodiment, the braces 32, 34 that form the outer periphery of the formwork 20 have a dimension “A” larger than the inner brace. However, the braces 32 and 34 used as the outer periphery of the formwork 20 may be the same thickness as the inner brace. It is also envisioned that the addition of reinforcement, such as a member extending diagonally between selected horizontal or vertical braces, may be useful in some applications. For example, if a very deep pattern is used, such as a pattern that extends inwardly from the front face 22 to a substantial percentage of the thickness “T” of the entire formwork 20, reinforcement may need to be added. . Another example would be where a particularly complex pattern is desired. Therefore, the thickness, depth, number, and orientation of braces 32 and 34 are all modified as desired to achieve an optimal balance between the weight of the formwork 20 and the required stiffness based on the pattern used. Can do.

  3 and 4 show an alternative embodiment of the present invention. The reinforcement base 30 'of the mold 20' includes a webbing 35 and supports 37, 37 '. The bearings 37, 37 ′ are arranged intermittently between the sections of the band 35. The band 35 includes an orifice 33. In particular, during the assembly and disassembly of the mold 20 ′, when the band 35 may be physically impacted, the orifice 33 provides a buffering action to the band 35, so that the mold 20 can be protected from an accidental side collision. 'Protect. In essence, the orifice 33 absorbs a significant amount of force on the reinforcing substrate 30 '. Furthermore, the weight of the mold 20 ′ can be reduced by the band portion 35. As shown in the figure, the band portion 35 may be disposed in the immediate vicinity of another band portion 35 so as to further provide a buffering action. Furthermore, if desired, the mold 20 'can be divided into subunits (not shown) by placing the two strips 35 in close proximity to each other. Thus, each subunit can include at least one band 35. 3 and 4 illustrate an orifice 33 that varies in size, it should be noted that the orifice 33 may be uniform in size.

  FIG. 5 shows a formwork 20 'having staggering vertical perimeters. The staggered vertical perimeter of the formwork 20 'helps the user when joining two or more formwork 20' together. If the outer peripheries of the molds 20 ′ are staggered, the adjacent molds 20 ′ can be arranged more easily than the linear outer peripheries 20. Furthermore, when the molds 20 'are secured together, the staggered outer perimeter of the molds 20' provides a greater holding force for the molds 20 '. FIG. 6 shows adjacent molds 20 'arranged to form interlocking units. The fixing of the molds 20 and 20 'will be described in detail below. The present invention illustrates alternate vertical perimeters, but can also be implemented with alternate horizontal perimeters. It should also be noted that the reinforcing base 30 ′ of the formwork 20 ′ may be replaced with the reinforcing base 30 of the formwork 20. Further, the reinforcing substrate 30 'performs substantially the same function as the reinforcing substrate 30 and provides the same advantages as the reinforcing substrate 30 and the additional advantages described above.

  As best shown in FIGS. 3, 4, 5, 6, 12, 13, and 15, the outer vertical braces 34 of the formwork 20 are spaced apart between the upper end 44 and the lower end 46 of the formwork 20. A plurality of openings 40 are included. The opening 40 is disposed between recesses 45. The recess 45 will be described in detail below. Further, the horizontal braces 32 associated with the upper end 44 and the lower end 46 of the mold 20 may also include openings 40 and recesses 45 spaced along each horizontal brace 32.

  As shown in the figures, the opening 40 helps to build an overall wall forming system 50 according to various embodiments of the present invention. The wall forming system 50 includes a plurality of molds 20. The molds 20 are arranged so that the openings 40 of the adjacent molds 20 are aligned with each other when the molds 20 are assembled to the wall forming system 50. The openings 40 do not have to be arranged at regular intervals. In practice, as best shown in FIG. 7, the openings 40 are arranged at intervals close to each other in the center of the mold 20, and are arranged at wider intervals near the upper end 44 and the lower end 46 of the mold 20. It turns out to be most beneficial.

  A series of male members, such as bolts 52, can be used to secure the formwork 20 together while assembling the formwork 20 to the wall forming system 50. Bolts 52 can be inserted through mating openings 40 in adjacent molds 20 and then secured. Conventionally, the bolt 52 is threaded and a nut (not shown) can be screwed there. However, using such conventional fasteners can take time to assemble and disassemble.

  7 and 8 show an embodiment of the present invention. A friction-based securing member, shown as a friction-based wedge member 54, is used as part of the retention mechanism 56. The holding mechanism 56 further includes a bolt 52. The wedge member 54 is wedged between the base portion 28 of the mold 20 and the bolt 52. Generally, the wedge stop member 54 is thinnest at one end and thickest at the opposite end so as to form a ramp-like member. As shown, the wedge stop 54 is wider at the thicker portion and narrower at the thinner portion. A force is applied to the upper end of the wedge stop member 54 in a direction generally perpendicular to the desired movement between the bolt 52 and the mold 20 so that the thicker portion of the wedge stop 54 is removed from the bolt 52 and the mold 20. Hang in between. The shape and design of the wedge member 54 allows a person on site to easily identify the correct orientation of the wedge member 54 for mounting. However, on the other hand, the design of the wedge stop member 54 does not prevent the wedge stop member 54 from being attached when the wedge stop member 54 rotates 180 °. If it is desired to have the wedge member 54 in such an orientation, the installer need only support the wedge member 54 in place while it is struck with a hammer. The wedge stopper 54 is concave so as to be easily inserted between the bolt 52 and the base portion 28 of the mold 20. When the wall forming system 50 is to be dismantled, the concave shape of the wedge member 54 makes it easy to apply a force to the lower end portion of the wedge member 54 and remove it. The wedge-fastening member 54 can be formed of a material that has the property that it can be shrunk under a load without damaging the mold 20 or the bolt 52. In an alternative embodiment, the wedge members 54 may be formed from the same material as the mold 20, and the bolts 52 are generally made of metal, preferably from an iron-based material. In other alternative embodiments, the wedge member 54 may be made of metal to minimize damage from the bolts 52 that occurs on the wedge member 54 during assembly of the wall forming system 50. The formwork 20 provides a compression capability that further assists in holding the bolts 52 and wedge members 54. Further, as shown in the figures of the present invention, the braces 32, 34 are offset from the opening 40 and the reinforcement mechanism 56 so that a wedge stop 54 or a conventional threaded connection can be used.

  FIG. 9 illustrates an alternative retention mechanism 56 'that can be implemented in accordance with the present invention. As shown in the figure, the wedge stop member 54 ′ is integral with the mold 20. In order to avoid interference with the bolts 52, the wedge members 54 ′ are disposed only on the common side of each mold 20. The retaining mechanism 56 'includes an opening 58 that is generally equidistantly spaced from the upper end 60 and the lower end 62 along the lateral extent of the wedge stop member 54'. The diameter of the outer periphery of the opening 58 is preferably smaller than that of the bolt 52 to be inserted so that appropriate friction is generated when the wedge stopper member 54 ′ is inserted into the bolt 52. The material on both sides of the opening 58 provides resistance and support for the opening 58 and facilitates retention of the bolt 52. As a matter of course, the present invention is not limited to the holding mechanism disclosed above, and can be implemented by other methods for assembling the wedge stopper 54 ′ to the mold 20. For example, the portion of the wedge member 54 'adjacent to the opening 40 may be thinner than the portion spaced from the opening 40 along the path along which the bolt 52 moves. Of course, the wedge member 54 'is assembled to the mold 20 and friction is utilized to hold the bolts 52, but the wall forming system 50 is wedged as long as it can be easily removed when disassembled. The stop member 54 ′ may be assembled with the formwork 20 in any form.

  FIG. 10 shows another alternative embodiment of a retention mechanism 56 "that can be implemented in accordance with the present invention. The retention mechanism 56" includes a wedge member 54 "and a bolt 52. The wedge member 54" As shown in FIG. 8, it can be wedged between the base portion 28 of the mold 20 and the bolt 52, or as shown in FIG. 9, the wedge member 54 "can be integrated with the mold 20. Wedge member 54 "is similar to wedge member 54 and wedge member 54 ', but wedge member 54" further includes a lip 55 at the thicker portion. Lip 55 is a wedge. Forms a surface that is wider than the stop members 54 and 54 'to apply force during installation.

  The wall forming system 50 shown in each figure is often utilized for retaining walls of the type shown in FIG. FIG. 11 shows the finished wall 80 where the material to be retained forms the opposite half of the mold for the flowable material. The wall forming system 50 is assembled, the flowable material is poured between opposing molds and cured in the wall 80, and then the wall forming system 50 is disassembled. The pattern shown in FIG. 11 is a rock projecting from the base and is a clearer and more detailed pattern than that formed by the conventional system. However, it should be noted that the pattern in FIG. 11 is for illustration purposes and the wall forming system 50 may be a different pattern. For example, FIGS. 12 and 13 show other patterns that can be used in accordance with the present invention.

  As noted above, the molds 20 are positioned adjacent to each other in the wall forming system 50. However, the formwork 20 does not necessarily have to be adjacent. 12 and 13 show how the mold 20 and the holding mechanism 56 form a wall forming system 50 of adjacent molds 20 according to the present invention. In addition, spacers 66 are often placed between adjacent molds 20 to help properly place the molds 20 to create the wall forming system 50. The spacers 66 are generally incorporated into the finished wall 80, keeping the pair of opposing molds 20 generally equidistant from each other. The spacer 66 may serve the additional function of forming a mold for receiving the flowable material between which it is cured to the finished wall 80. The first and second ends 74 and 76 of the spacer 66 are configured to receive the holding mechanism 56. Accordingly, the first and second end portions 74 and 76 are provided with holes 75 for slidingly engaging with the bolts 52 of the holding mechanism 56 outside the boundary of the formwork 20. Furthermore, the first and second ends 74, 76 of the spacer 66 are placed in the recess 45 of the mold 20. Therefore, when the molds 20 are arranged adjacent to each other, the molds 20 are substantially flush with each other. Thus, the depth of each recess 45 is generally half the depth of the first and second ends 74, 76. The recess 45 is between adjacent molds 20 and helps to minimize seams that may appear on the finished wall 80. Note that staggering the formwork 20 ′ further helps to hide seams that may appear on the finished wall 80 because the seams become discontinuous along horizontal or vertical lines. .

  When the mold 20 is disassembled, the first and second ends 74, 76 of the spacer 66 remain outside the boundary of the completed wall 80. In order to facilitate removal of the first and second ends 74, 76 of the spacer 66 after construction, a score line may be provided at the boundary line 72 of the spacer 66. The position of the boundary line 72 depends on the thickness of the completed wall 80. That is, the boundary line 72 separates the portion of the spacer 66 that remains embedded in the completed wall 80 from the portion of the spacer 66 that protrudes from the completed wall 80. However, as a matter of course, the boundary line 72 may be arranged at an arbitrary position along the spacer 66, or may be an arbitrary number of cut lines. To remove the first and second ends 74, 76 of the spacer 66 from the finished wall 80, it is only necessary to tap the first and second ends 74, 76 with a scissors.

  14 and 15 show an alternative spacer 90 according to the present invention. Conventional spacers are generally flat or entirely round. Flat spacers generally allow for easier assembly of the mold 20, and round spacers can be more durable. In addition, round spacers are generally more aesthetically preferred. This is because once the construction is complete, the portion of the round spacer that remains in the finished wall 80 is less noticeable on the surface of the finished wall 80. However, it is generally more difficult to insert a bolt into a round spacer. As shown in FIGS. 14 and 15, the spacer 90 is a new spacer that has the advantages of the conventional spacer and does not include the corresponding disadvantages. The spacer 90 has both a flat portion 92 and a round portion 94. The flat portion 92 further includes a hole 96 for receiving the bolt 52 of the retention mechanism 56. The rounded portion 94 of the spacer 90 is generally incorporated into the finished wall 80 and the flat portion 92 remains outside the boundary of the finished wall 80. Similar to the first and second ends 74, 76 of the spacer 66, the flat portion 92 of the spacer 90 is placed in the recess 45. Further, in order to facilitate removal of the flat portion 92 after construction, a score line may be provided at one or more boundary lines 98 of the spacer 90. The position of the boundary line 98 depends on the thickness of the completed wall 80. That is, the boundary line 98 separates the portion of the spacer 90 that remains embedded in the completed wall 80 from the portion of the spacer 90 that protrudes from the completed wall 80. To remove the flat portion 92 of the spacer 90, it is only necessary to tap the flat portion 92 with a hammer. FIG. 15 shows the spacer 90 in a mounting position within the wall forming system 50.

  The spacer 90 can be manufactured using any conventional technique for forming metal parts. For example, a round metal piece may be used for the round portion 94 of the spacer 90. A flat piece of metal may be welded to the round metal piece to create a flat portion 92 of the spacer 90. However, the preferred method of manufacturing the spacer 90 is to utilize a progressive stamping operation on a flat metal piece. The flat portion 92 of the spacer 90 maintains the shape of the flat metal piece, while the round portion 94 of the spacer 90 can be machined from the flat metal piece by progressive tooling techniques.

  As noted above, FIGS. 3, 4, 5, 6, 12, 13, and 15 show a plurality of openings 40 along the upper and lower outer horizontal braces 32 of the mold 20. Thus, the formwork 20 can also be stacked vertically along the horizontal brace 32 and is not limited to connection along the outer vertical brace 34. The holding mechanism 56 for holding the molds 20 stacked vertically is the same.

  Further, under certain circumstances, such as when the opening 40 is not accessible and the opposing mold 20 must be held in place, the spacer 90 'can be used for the hole 27. it can. In the simple embodiment shown in FIG. 16, a threaded bolt acts as a spacer 90 'passing through the mating hole 27 of each opposing mold 20, and a nut 99 is optionally engaged with the rear surface 24. Thus, each mold 20 is maintained in a fixed direction with respect to the spacer 90 ′. When the mold 20 is used up, the nut 99 that engages the rear surface 24 can be removed. The spacer 90 'can be scored in a manner similar to that described above to remove the portion of the spacer 90' that extends outwardly from the completed wall 80. Alternatively, the spacer 90 'can be used as a fastener for screwing the part to the finished wall 80, such as a stud.

  Road curbs can also be manufactured using curb mold 100 which is similar in concept to mold 20 and substantially incorporates the features and advantages of form 20. FIG. 17 shows the curb mold 100. The curb mold 100 includes a front portion 102 and a rear portion 104. The front portion 102 includes a tapered panel 106. The tapered panel 106 can be designed according to governmental or industry regulations for road curb structures. The rear portion 104 includes a solid surface 108 and a reinforcing grid 110. The reinforcing grid 110 is generally similar to the reinforcing base 30 of the formwork 20. Further, the reinforcing grid 110 performs substantially the same function as the reinforcing base 30 and provides the same advantages as the reinforcing base 30. It should also be noted that the reinforcing grid 110 is similar to the reinforcing base 30 'of the formwork 20' and can perform substantially the same function and provide the same advantages.

  The curb mold 100 includes an opening 112 for engaging a spacer and a retention mechanism. Similar to the formwork 20, the curbwork formwork 100 can be joined together by a retention mechanism to create a plurality of connected curbwork formwork 100, depending on the desired length of the finished road curb. Similarly, spacers 66 or 90 may be used to properly position the first and second portions 102, 104 of the curb mold 100 and may be integrated into the finished road curb. When the first and second portions 102, 104 of the curb mold 100 are connected by spacers 66 or 90, a flowable material is poured between the first portion 102 and the second portion 104. The fluid material is then cured into a finished road curb.

  There are many advantages to manufacturing at least the major components of the mold 20 and the mold 100 from materials that are not wooden or metal, such as plastic. The molds 20, 100 are very light and can be quickly moved, assembled and disassembled at the construction site. Furthermore, because the molds 20, 100 are not made of metal, they are much more resistant to light impacts that would otherwise foul a metal mold with an etched pattern. If the molds 20, 100 are damaged, they may be repaired in-situ using a “well known” plastic repair kit in the art without having to recreate the entire pattern. Further, since the pattern is incorporated into the base portion 28 of the molds 20, 100, the pattern is undesirable for the rest of the molds 20, 100 as opposed to using conventional thin liners. No more moving.

  In a preferred embodiment of the present invention, the entire molds 20, 100 are fully integrated and formed as one piece. In one embodiment, the major components of the molds 20, 100 are created using a molding process. In one alternative embodiment, the mold forms 20, 100 are created by computer numerical control (CNC) machining. By CNC machining, the molds 20, 100 can have custom shapes and sizes. In another alternative embodiment of the present invention, the molded material is a polypropylene copolymer, such as that sold under the trade name Pro-fax ™. Thus, the molds 20, 100 can be manufactured at a very low cost, and many different molds can be created with various patterns depending on the desired application. This material includes various fillers, such as glass fiber strands, while still minimizing weight and providing flexibility to potential cuts or bruises while providing formwork 20, 100 Stiffness can be added. For example, the flowable material used to make the finished wall 80 does not stick to the material of the molds 20, 100 during the curing process. Thus, the molds 20, 100 require minimal cleaning after the flowable material is cured and the molds 20, 100 are removed. Furthermore, the flowable material and the holding mechanism 56 make minimal contact, if any. Accordingly, rusting of the metal components of the retention mechanism 56 can be significantly reduced over time.

  Furthermore, the molds 20, 100 are not permeable like wood and therefore do not absorb moisture from the flowable material. Therefore, the molds 20 and 100 do not need to be coated with a coating before use in order to prevent moisture absorption, and do not deteriorate over time due to moisture damage. In addition, the holes 27 in the molds 20, 100 allow the flowable material to vent and thus allow excess air and moisture retained in the flowable material to be discharged. As a result, the completed wall 80 can have a finer surface than when a conventional formwork is used. In line with this same policy, the molds 20, 100 can be used to create a finished wall 80 that is colored without compromising the reusability of the mold. The molds 20, 100 can be coated with powder or acid and the powder or acid can be mixed with the flowable material to produce a colored flowable material. As noted above, unlike conventional molds, the molds 20, 100 are not permeable and therefore do not absorb the color of the flowable material. Thus, the formwork 20, 100 can be used to make a finished wall 80 having a plurality of different colors without affecting the color of the finished wall 80 or the reusability of the formwork 20, 100. .

  Forms 20 and 100 are not limited to the creation of a generally planar finished wall 80, as shown in FIG. 8, but can produce curved, radial and fillers. A corner for the completed wall 80 can also be created. Therefore, the molds 20 and 100 may be molded so as to form a completed wall including the corners without using an additional mold for the corners. Furthermore, the molds 20, 100 can be modified so that the full size molds 20, 100 can be used in areas that should not fit properly. Depending on the material properties of the molds 20, 100, the molds 20, 100 can also be cut off during work at the construction site without affecting the quality or formation of the finished wall 80. On the other hand, the molds 20, 100 may be joined together to form any irregular shape or size of the finished wall 80. Although the molds 20, 100 are shown as joined to form a generally rectangular wall, the molds 20, 100 divide the seams that may be present on the finished wall 80, and as much as possible. Note that they may be joined as staggered units for concealment.

  The embodiments disclosed herein have been described so that the reader can better understand the novel aspects of the present invention. While the preferred embodiment of the invention has been illustrated and described, many changes, modifications and substitutions can be made in the art without departing from the spirit and scope of the invention as set forth in the following claims. Engineers can do it.

It is a front view of the formwork by this invention. FIG. 2 is a cross-sectional plan view of the mold, taken along line 1A-1A in FIG. It is a rear view of the formwork by this invention. FIG. 3 is a cross-sectional plan view of the mold, taken along line 2A-2A in FIG. FIG. 6 is a perspective view of an alternative embodiment of a formwork according to the present invention. FIG. 6 is a perspective view of an alternative formwork according to the present invention. FIG. 6 is a perspective view of another alternative embodiment of a formwork according to the present invention. FIG. 5 is a perspective view of another alternative formwork according to the present invention. 1 is a rear view of a wall forming system according to the present invention. FIG. 1 is a perspective view of a wall forming system showing a portion of a retention mechanism according to the present invention. FIG. FIG. 6 is a perspective view of a wall forming system showing an alternative embodiment of a retention mechanism. FIG. 6 is a perspective view of a wall forming system showing another alternative embodiment of a retention mechanism. FIG. 3 is a perspective view of a wall completed using the formwork system of the present invention. 1 is a perspective view of a hollow wall forming system that uses pairs of opposing molds spaced apart by spacers to receive a flowable material. FIG. FIG. 13 is a different perspective view of the system of FIG. FIG. 6 is a perspective view of a single alternative spacer according to the present invention. FIG. 6 is a perspective view of a wall forming system showing an alternative spacer in the installed position. FIG. 6 is a side view of another alternative spacer that uses an opening through the face of an opposing mold according to the present invention. It is a perspective view of the curb mold according to the present invention.

Claims (27)

A base portion having a front surface and a rear surface;
A reinforcing base fixed to the rear surface,
A formwork for use with fluid structural materials, wherein at least the base portion is formed from a material that is neither metal nor wood.   The formwork of claim 1, wherein the base portion and the reinforcing base are formed as a single piece.   The mold according to claim 2, wherein the material that is neither metal nor wood is plastic.   The formwork of claim 3, wherein the plastic comprises glass fiber strands.   The formwork of claim 1, wherein the reinforcement base comprises a series of integral braces.   The formwork of claim 1, wherein the front surface of the base portion further comprises a tapered panel.   The formwork of claim 1, wherein the front surface further comprises a pattern.   The formwork of claim 7, wherein the cavity associated with the pattern includes at least one hole extending from the front surface to the rear surface of the base portion.   9. The formwork of claim 8, wherein the cavity associated with the pattern can extend more than about one half of the total thickness of the formwork.   The formwork of claim 9, wherein the cavity can extend more than about three quarters of the total thickness of the formwork.   11. The formwork of claim 10, wherein the reinforcement base comprises a series of integral braces, and the cavity intersects one of the braces to provide additional structural support. A plurality of molds each having a front face, a rear face, and a plurality of openings through the mold form;
A reinforcing base fixed to the rear surface of the plurality of molds;
At least one holding mechanism having a male member and a fixing member;
Comprising at least one spacer tie,
The wall forming system, wherein the plurality of molds are made of a material that is neither metal nor wood, and the holding mechanism fixes the two of the molds to each other.   The wall forming system of claim 12, wherein the formwork includes at least one opening, and the male member of the holding mechanism passes through the opening.   The wall forming system of claim 13, wherein the spacer tie comprises the male member of the retaining mechanism.   14. The spacer tie has at least one hole, and the male member of the retaining mechanism engages the hole and the opening when the hole and the opening are in a mated arrangement. A wall forming system as described in.   The openings of the two molds are aligned with each other, the male member of the holding mechanism is inserted through the two openings of the plurality of molds, and the fixing member frictions the male members. The wall forming system according to claim 15, wherein the wall forming system is a wedge-holding member held by a hook.   The wall forming system according to claim 16, wherein the fixing member of the holding mechanism is integral with one of the plurality of molds.   16. The retention of claim 15, wherein the spacer tie includes opposing flat portions and rounded portions disposed therebetween, and the at least one hole extends through each of the flat portions. mechanism.   19. The spacer tie includes the score line to facilitate its separation along a score line, the score line separating the rounded portion from the plurality of flat portions. Wall forming system. A plurality of base portions each including a front surface and a rear surface;
A reinforcing base fixed to each of the rear surfaces;
Holding mechanism,
Each of the plurality of base portions and the reinforcing base is molded as a partial piece, the plurality of base portions are plastic, and the holding mechanism fixes two of the plurality of base portions to each other. Wall forming system for use with.   21. The wall formation according to claim 20, wherein the plurality of base portions further include a plurality of holes, and two of the base portions are arranged next to each other such that the holes of the base portions are arranged in a row. system.   The holding mechanism includes a male member and a fixing member, the male member passes through the holes arranged in the row of the adjacent base portions, and the fixing member holds the male member. The wall forming system according to claim 21.   The wall forming system of claim 21, wherein the retention mechanism further includes braces disposed between the base portions to properly position the base portions. A base portion having a front surface and a rear surface including a pattern and formed from a plastic material;
A formwork for use with a flow structure material comprising a series of integral braces and a reinforcement base secured to the rear surface, wherein the base portion and the reinforcement base are formed from a single material.   25. The formwork of claim 24, wherein a cavity associated with the pattern includes at least one hole extending from the front surface to the rear surface of the base portion.   25. A formwork according to claim 24, wherein the cavity associated with the pattern can extend more than about one half of the total thickness of the formwork.   25. A formwork according to claim 24, wherein the cavity can extend more than about three quarters of the total thickness of the formwork.

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