JP3974533B2 - Improved stackable structural panel system - Google Patents

Description

  The present invention relates generally to a stackable wall form of the type having opposed pairs of panels for receiving a flowable material such as concrete. In particular, the present invention relates to improvements in such wall frames.

  There are currently many different systems and methods for making isolation frames that cast concrete walls. Often these systems have a pair of opposing foam panels made entirely of a rigid foam such as polystyrene, with a cavity for receiving concrete between them. Define. These pairs of foam panels are placed one on the other to form a wall frame assembly. Once the concrete is solidified, the assembled wall frame remains in place to isolate the walls. Prior to concrete pouring, the opposed foam panels are typically maintained in a spaced apart parallel relationship by connectors each having a pair of parallel and lateral attachment flanges embedded in each foam panel. .

  Such stacking of panels is accomplished at a construction site. On the one hand, it is possible to provide a wall frame that can be easily and very quickly stacked without any loss of time, and on the other hand, can be stably and securely stacked without accidental disassembly prior to concrete pouring. Desirable in this field. As can be readily appreciated, as soon as concrete is poured, the chances of the stack being folded or disassembled are greatly reduced.

  By way of example, both the wall frame and the structural form panel discussed above are shown in US Pat. Other examples of the separation structure panel are shown in Patent Documents 3, 4, 5, 6, 7, 8, and 9.

Canadian Patent Application No. 2,292,865

Canadian Patent Application No. 2,312,158

US Pat. No. 3,895,469

U.S. Pat. No. 4,229,920

U.S. Pat. No. 4,704,429

U.S. Pat. No. 4,884,382

U.S. Pat. No. 4,885,888

U.S. Pat. No. 4,894,969

US Pat. No. 5,428,933

  It is an object of the present invention to provide an improved stackable foam panel that allows stable solid stacks to be easily constructed.

According to a first aspect of the present invention, there is provided a connector for integrally joining opposing foam panels in a parallel relationship spaced apart along a longitudinal direction to form a frame for receiving a flowable material. ;
Each planned pair of elongated anchor members to be longitudinally embedded inside a corresponding one of the foam panels, each of the anchor members having two opposing ends, A head part projecting along the longitudinal direction from each of the head parts, each head part having a laterally extending terminal surface;
A connecting member for integrally connecting the pair of anchor members in the longitudinal direction;
The head parts of each anchor member are mirror-symmetric with respect to each other;
Each head component has an L-shaped cross section having a transverse arm that defines the terminal surface and a longitudinal arm that connects the transverse arm to the distal end of an anchor member from which the head component protrudes. A connector is provided.

This aspect of the invention further comprises a wall frame that receives the flowable material:
Comprising a pair of foam panels each having opposing top and bottom wall surfaces;
A connector for integrally joining the foam panels in a spaced apart parallel relationship along the longitudinal direction, said connector being designed to be embedded longitudinally inside one of the corresponding foam panels; A pair of elongated anchor members, each of the anchor members having two opposing end portions and a head component projecting longitudinally from each of the end portions; Each connector has a terminal surface extending laterally and along a corresponding part of the top and bottom wall surfaces of the corresponding foam panel, and the connector integrally connects the pair of anchor members in the longitudinal direction. It further comprises a connecting member for:
Each head component is formed such that its terminal surface is suitable for extending along either the top wall surface or the bottom wall surface;
The head parts of each anchor member are mirror-symmetric with respect to each other;
Each head component has an L-shaped portion having a transverse arm defining the terminal surface and a longitudinal arm connecting the transverse arm to the distal end of an anchor member from which the head component protrudes. It is related with the wall frame characterized by this.
In one aspect of the above-mentioned formwork, the top wall surface and the bottom wall surface of each foam panel are provided with protrusions and recesses alternately, and the head component is embedded in one of the protrusions.
In one form of the above formwork, for each foam panel, each protrusion on the top wall faces the recess on the bottom wall, and each recess on the top wall faces the protrusion on the bottom wall.
The wall frame assembly of the present invention includes a plurality of the above-mentioned wall frames, and the wall frames are stacked in the vertical direction.
In one embodiment of the above formwork assembly, the terminal surface extending along the bottom wall surface of the upper wall frame foam panel is adjacent to the lower wall frame foam panel for the adjacent upper wall frame and lower wall frame. It contacts the terminal surface extending along the top wall surface.

According to a second aspect of the invention, an installation device for installing an end panel to a wall frame to receive a fluidizable material, the wall frame being spaced apart and parallel along the longitudinal direction. A pair of foam panels opposite the relationship, the pair of foam panels having aligned end portions:
First and second engaging members for detachably engaging each side end portion of the pair of foam panels;
Installation means for longitudinally installing the end panel between the first and second engaging members when engaged with the end portions of the pair of foam panels;
Comprising:
An installation device is provided wherein the first and second engagement members each define a sleeve for wrapping a side end portion of the corresponding foam panel.

  As part of a second aspect, the present invention further provides an end panel assembly for a wall frame for receiving a flowable material, wherein the wall frame is spaced apart along a longitudinal direction and in a parallel relationship. A pair of opposing foam panels, the pair of foam panels being provided with an end panel assembly having aligned end portions. The end panel assembly includes an installation device as defined above and an end panel that is installable between engagement members of the installation device.

A wall frame for receiving a flowable material:
A pair of opposing foam panels spaced along the longitudinal direction and in a parallel relationship, the pair of foam panels having aligned side end portions;
With end panels;
A mounting device having first and second engaging members for removably engaging each side end portion of the pair of foam panels, and the end panel between the first and second engaging members; Installation means for longitudinal installation;
Each foam panel is provided with elongated ridges extending along the inner surface therein, and a wall frame is also provided, the inner surface facing the opposing foam panel.

Finally, according to a third aspect of the present invention, an improvement of a wall frame for receiving a flowable material is provided, the wall frame having corners formed by longitudinally adjacent foam panel portions. is doing. This improvement provides that the wall frame includes a reinforcing connector for reinforcing the corners. The connector has a pair of elongated anchor members each embedded within one of the corresponding longitudinal sides of the foam panel portion;
The connecting member extends to the inside of the corner and the wall frame. The connecting member connects the pair of anchor members together in the longitudinal direction;
The connection member is detachably connected to a pair of anchor members.

  Other aspects and objects of the present invention will become more apparent from the description according to the preferred embodiment provided by way of example only with reference to the accompanying drawings and how the invention can be put into practical use.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION The present invention relates to a stackable structural system that uses a wall frame made of parallel foam panels to receive a flowable material such as concrete. The following is a description of a preferred embodiment of such a wall frame. However, it will be understood that the following description is given by way of example and that the present invention can be applied to wall frames having different characteristics.

Referring to describe Figure 1 of the preferred embodiment of the wall frame, have wall frame assembly (10) is shown, make a frame (form) for receiving a flowable material, such as those concrete or similar Suitable for The assembly (10) is made up of plastic panels (14A, 14B) comprising a stack of spaced apart horizontal rows of wall frames (11), each being coplanar and substantially rectangular. It has been. The panels (14A, 14B) of adjacent wall frames (11) abut against each other along their horizontal and vertical sides.

  Each of the wall frames (10) includes a first foam panel (14A) and a second foam panel (14B) that are provided in a spaced apart and parallel relationship and are joined together by a plurality of connectors (16). I have. The foam panels (14A, 14B) are located in a spaced apart and expanded position so that the foam panels (14A, 14B) form a wall frame as shown in FIG. ) For the purpose of movement of the foam panels (14A, 14B) close to each other and collapsed.

  In use, once the wall frame assembly that receives the flowable material is installed using a stacked horizontal row of wall frames, the empty cavities that exist between the panels (14A, 14B) are either concrete or Filled with cement-based grout. After the filling material has hardened, a composite wall is obtained with a separating panel secured to the inner wall of the concrete by a connector.

  The foam panels (14A, 14B) each have a top wall (15) facing the bottom wall (17), each preferably having a projection (18) and a recess (19) having a similar complementary shape. ) Any one of the median rows (13). This middle row (13) is provided between two coplanar end faces (50) that make up the boundaries of the ends of the panels (14A, 14B). These coplanar end faces (50) preferably have a sufficiently large width to provide increased stability between the interconnected panels (14A, 14B).

  The protrusion (18) or the recess (19) of the top wall surface (15) of one panel (14A) is opposed to the recess (19) or the protrusion (18) of the bottom wall surface (17) of the same panel (14A). And when the pair of panels (14A, 14B) are in the expanded position shown in FIG. 1, each recess (19) or protrusion (15) on the top side (15) of the other panel (14B) 18) facing. In this way, it can be seen that a pair of panels (14A, 14B) is advantageously interconnected with a similar pair of panels having opposing wall surfaces (15, 17) acting as top or bottom wall surfaces. .

  In the preferred embodiment, mainly because of the manufacturing process, the protrusion (18) and the recess (19) are substantially rectangular. However, other shaped projections and depressions such as circles, rectangles, squares, etc. can also be used. Furthermore, in order to prevent the deterioration of the protrusion (18), the present invention prefers the use of the protrusion (18) with rounded corners. Nevertheless, protrusions (18) having rectangular corners or other shapes are still effective. Preferably, each protrusion (18) and recess (19) includes two opposing substantially convex cross sections (52, 53) that facilitate insertion of the protrusion (18) into the recess (19). )have.

  2, 3 and 4, the components of the connector (16) according to the preferred embodiment of the present invention are shown in more detail. The connector (16) includes a pair of anchor members (20A, 20B) embedded in the first and second foam panels (14A, 14B). Each anchor member (20A, 20B) has an elongated flange plate (22) extending deeply in the longitudinal direction and inside the corresponding foam panel (14A or 14B), and an elongated shape connected in the longitudinal direction of the flange plate (22). And a link element (24). The link element has a protruding end (26) coming out of the foam panel (14A, 14B). Preferably, the protruding end (26) of each anchor member (20A, 20B) is parallel to the flange plate (22) and when embedded therein as shown in FIG. 14A or 14B) with a stabilizing plate (28) extending to the same height as the inner surface (30).

  The stabilization plate (28) of each anchor member (20A, 20B) preferably has an upper end (54) and a lower end (56), which are anchor members (20A or 20B). ) Is connected to an anchor member (20A or 20B) which is a pair of adjacent wall frames (11). More preferably, the fixture (58) is a four-nail type fixture that is molded into the stabilization plate (28) so as to protrude from the corresponding end of the stabilization plate (28). It is. The fixture (58) at the upper end (54) of a given stabilization plate (28) is preferably mirror-symmetrical with the fixture (58) at the lower end (56) of the stabilization plate (28). 2 and 4, which is best shown in FIGS. 2 and 4 and has sides with sharp teeth suitable for coupling with the sharp teeth of the paired anchor members (20A, 20B). is doing. Advantageously, this embodiment allows the connectors (16) used at both the top or bottom end to greatly facilitate the handling of the wall frame at the building site.

  To lighten the foam panel assembly, the linking element (24) is preferably provided with a plurality of holes (25) along it. However, the link element (24) may be a solid plate. Speaking from the fact that the anchor members (20A, 20B) are embedded in the foam panels (14A, 14B), those skilled in the art will know that in the production of the foam panels (14A, 14B) in the manufacturing plant, the panels (14A, 14B) 14B) is preferably injected to surround the anchor members (20A, 20B), thereby anchoring the panels (14A, 14B) and the foam panels (14A, 14B). It will be noted that it will be understood to strengthen the bond between the anchor members (20A, 20B) acting as parts. More particularly, plastic foam material, preferably polystyrene or any other material known to those skilled in the art of plastic foam, is injected to surround the anchor members (20A, 20B).

  The connector (16) further comprises a web-shaped connecting member (32) extending between the foam panels (14A, 14B). This connecting member (32) formed of a relatively flexible plastic material has a central portion (44) formed to receive and hold a metal rod used to reinforce concrete. Yes. The connecting member (32) further includes a first elongate side end (34A) hingedly connected to the protruding end (26) of the first anchor member (20A), and a first elongate side end ( 34A) and a second elongate side end (34B). The second elongated side end (34B) is hingedly connected to the protruding end (26) of the second anchor member (20B). The foam panels (14A, 14B) are therefore primarily stacked with the expanded position shown in FIG. 1 where the foam panels (14A, 14B) are spaced apart to form the wall frame (11) and the foam panels (14A, 14B). It is possible to move between the folded-up positions (not shown) which are close to each other for the purpose.

  The connecting member (32) is preferably symmetrically shaped to receive and hold the metal rod used to reinforce the concrete at the reversible position of the wall frame (11). Therefore, the wall frame (11) can be turned upside down and can still be used to receive and hold the metal rod in the top groove of the connecting member (32).

  A plurality of connecting elements (64) are preferably provided on the protruding end (26) of each anchor member (20A, 20B) for hinged connection of the connecting member (32) to the anchor member (20A, 20B). It is provided on the stabilization plate (28). Each of these connecting elements (64) is shaped to form two aligned ridges (66) protruding from the stabilization plate (28), the space between them being an elongated sleeve (68). ). A coupling pin (70) may be provided on the sleeve (68). Holes (71) for receiving pins are preferably provided in the ridges (66) for this purpose, each hole (71) facing the inside of the sleeve (68). The connecting member (32) is preferably made of a plastic mold and the connecting pin (70) is therefore permanently provided on the ridge (66).

  In order to cooperate with the connecting element (64), each elongated side end of the connecting member (32) defines a corresponding number of arms (72). For example, three arms (72) can be used for the symmetrical connecting member (32). Each arm (72) has a distal end (74) connected to a corresponding coupling pin (70) so as to be rotatable about an axis defined by the coupling pin (70). The purpose is to provide the distal end (74) of the arm (72) to be rotatable about the coupling pin (70), or to allow the coupling pin (70) to rotate itself within the pin receiving hole (71). It can be easily seen that this is achieved by providing it. Preferably, the distal end (74) of each arm (72) has a hole (76) for receiving one of the pins (70).

  As can be readily understood by those skilled in the art, the connecting element (64) can be formed directly by molding during the manufacture of the anchor members (20A, 20B). In the embodiment shown in FIGS. 2 and 3, the protrusion (78) is produced by molding on both sides of the ridge (66).

  Although the connecting element (64) is shaped to form aligned ridges (66), the present invention is not limited to other types such as open slotted knuckles, as will be apparent to those skilled in the art. It can be understood that the connection element is adopted. In this alternative embodiment, the connecting member (32) is advantageously removed from the corresponding anchor member (20A or 20B). Such an embodiment is shown, for example, in FIG. 6 and will be described below in connection with a corner connector. In order to hingely connect the connecting member (32) to the anchor member (20A, 20B), the connector (16) has a plurality of aligned open slotted tube shapes arranged on the stabilizing plate (28). Each tube-type knuckle (360) is provided with a pair of opposing elongate ends defining a slot (365) that is properly mated with a slot in the other knuckle (360). An inner tube having a portion is formed. The connecting member (32) includes a pair of elongated side ends that each define an enlarged end (370) slidably inserted into an open slotted tube knuckle, and an enlarged end (370). And a strip portion (375) connecting the central portion of the connecting member (32) to the central portion.

Connector Improvements Still referring to FIGS. 2, 3 and 4, and according to the first embodiment of the present invention, each anchor member (20A, 20B) has two opposing end portions (90, 92). From there, the head part (35) extends along the longitudinal direction. Preferably, the head component (35) is connected to the upper and lower ends (90, 92) of the flange plate (22) of the corresponding anchor member (20A or 20B). The head component (35) has a laterally extending terminal surface (36). Preferably, each head part (35) has an L-shaped part forming a transverse arm defining a terminal surface (36) and the end of an anchor member (20A, 20B) from which the head part (35) protrudes. And an elongated arm (38) connecting the transverse arm (36) to the section.

  When the connector (16) is embedded in the foam panels (14A, 14B) to form the wall frame (11), each head component (35) is preferably as shown in FIG. Aligned and embedded in the panel protrusion (18), the best one covers half of the upper and lower edges (90, 92) of the foam panel (22) as shown in FIG. The other half of the end of the foam panel (22) corresponds to the recess (19). Preferably, the surface (36) of the head part (35) extends flush with the top and bottom wall surfaces (15, 17) of the projection (18).

  Preferably, the head component (35) at the upper end (90) of the predetermined member is the head component (35) at the lower end (92) of the flange plate (22) and the flange plate (22) of the other anchor member. ) And mirror-symmetrical with the head component (35) provided at the upper end (90). Thus, the connector (16) can be flipped over or rotated in any direction and used properly if properly positioned between the protrusion (18) and the recess (19). it can.

  The head part (35) serves two main purposes. First, the head component (35) helps support the weight of the entire frame wall assembly (10) when concrete is poured into the frame wall assembly (10). In fact, experiments show that without the head part (35), the frame wall assembly (10) has a tendency to flex in height up to 2 inches after concrete is poured.

  Second, the head component (35) facilitates stacking one of the wall frames (11) on top of the other. In fact, without the head component (35), it is difficult for the operator to push the first wall frame (11) on top of the second wall frame (11) to make their proper connection. Having equipment for the head part (35), the operator strikes or pushes on the terminal surface (36) of the head part (35) to more easily assemble the wall frame (11).

End Panel Assembly Referring to FIG. 5, a second aspect of the present invention is shown. The end panel assembly (101) is provided to provide an end panel (102) at the side end of the wall frame assembly (10). The end panels are, for example, completely used to block the side ends of the wall frame assembly (10) and, when injected, include the concrete in the structure defined by the wall frame. Advantageously, the end panel (102) is also used as a wall stud for structures such as windows, door frames and the like.

  The end panel assembly (101) comprises an end panel (102) and a mounting device (103) for providing the end panel (102) on the side wall frame (11). . The end panel (102) is preferably made of wood, for example a set of wood stacked one on top of the other and extends through the entire height of the wall frame assembly (10). The foam panels (14A, 14B) of the wall frame (11) have aligned side edges (108A, 108) to which the mounting device (103) is secured. The mounting device includes first and second engaging members (100A, 100B) that are detachably engageable with the side end portions (108A, 108B) of the panel (14A, 14B). Preferably, the first and second engaging members (100A, 100B) each define a sleeve for wrapping the side ends (108, 108B) of the corresponding foam panels (14A, 14B), such as plastic. Made of flexible elastic material. Preferably, the engagement members (100A, 100B) are shaped to conform to the shape of the side ends (108, 108B) of the foam panels (14A, 14B). In the disclosed embodiment, each foam panel (14A or 14B) has an elongated ridge (110) extending along (112) on its inner surface. That is. Each face facing each foam panel (14A or 14B) and each engaging member has a corresponding channel (14) engageable with each ridge (110).

  The mounting device (103) also has an end between them when the first and second engaging members (100A, 100B) are engaged with the side ends (108A, 108B) of the pair of foam panels. An installation means for installing the part panel (102) in the longitudinal direction is provided. For example, the installation means is embodied by first and second support portions (104A, 104B) that protrude from the first and second engaging members to the inside of the foam panels (14A, 14B), respectively. As shown in FIG. 5, the two supports (104A, 104B) define a track for slidably receiving the end panel (102). A screw (106) or other suitable type of fixture preferably secures the end panel (102) to the support (104A, 104B). However, the installation means of the present invention is not limited to the embodiments described above. For example, instead of defining a track, the first and second protrusions may simply define a wall to which the end panel is fixedly secured. In other embodiments, instead of two supports, a single connection article joining two engagement members together can be provided to define either the wall or the track.

Reinforced corners Referring to FIGS. 5-7, a third embodiment of the invention with a wall frame used as a corner is shown. The corner is defined by two longitudinally adjacent foam panel portions (14A, 14A ′). In the embodiment of FIGS. 5 and 6, the foam panel portions (14A, 14A ′) form a right angle, and in the embodiment of FIG. 7, they form a 45 degree angle. Of course, other suitable angular openings between the two foam panel sections (14A, 14A ′) can be considered within the scope of the present invention.

  In order to strengthen and reinforce the corner walls, the connector (16) is arranged inside the corners as shown. The connector (16) includes a pair of anchor members (20A, 20B) embedded in the longitudinal direction in one of the foam panel portions (14A, 14 '). The connection member (32) integrally connects the two anchor members (20A, 20B) in the longitudinal direction. The anchor members (20A and 20B) and the connecting member (32) may have the same structure as the connector (16) described above, or alternatively, connectors having different structures can be used.

  In the preferred embodiment, as described above, the connecting member (32) is preferably hinged to the corresponding anchor member (20A or 20B) using a tubular knuckle (360) in the open slot. It is connected. This embodiment has the advantage that the connecting member (32) is easily removed to put the wall frame in its folded position and the rear part is connected at the construction site. Other types of connections such as hinges or otherwise are used as well. The connecting member (32) can be removed from or anchored firmly to the anchor members (20A, 20B).

  In this respect, advantageously, as shown in FIGS. 5 and 7, the corner wall frame comprises a connector having a removable connecting member on only one side of the corner, and on the other side of the connector, It should be noted that it has a connecting member that is hinged as shown, for example, in FIGS. This particular embodiment limits the number of tubular knuckles with open slots that are more effective to manufacture, although it is still possible to place the corner wall frame in a folded position for shipping.

  Although preferred embodiments of the present invention have been described in detail herein and shown in the accompanying drawings, the present invention is not limited to these specific embodiments, as defined in the claims. It will be understood that various modifications and changes may be made thereto without departing from the purpose and scope of the invention.

1 is a partial perspective view of a frame wall assembly according to a preferred embodiment of the present invention. FIG. FIG. 3 is a perspective view of a connector according to a preferred embodiment of the present invention, with the right anchor member and web member portions removed. FIG. 3 is a partial perspective side view of a portion of the connector of FIG. 2. FIG. 2 is a side cross-sectional elevation view of the frame wall assembly of FIG. 1. FIG. 3 is a plan view of a 90 degree corner of a frame wall assembly according to a preferred embodiment of the present invention. The enlarged view of the side part edge part of the wall frame of FIG. FIG. 6 is an enlarged plan view of a portion of a corner of the frame wall assembly shown in FIG. 5. FIG. 4 is a plan view of a 45 degree corner of a frame wall assembly according to a preferred embodiment of the present invention.

Claims (6)

A connector for integrally joining opposing foam panels in a parallel relationship spaced along the longitudinal direction to form a frame for receiving flowable material;
Each planned pair of elongated anchor members to be longitudinally embedded inside a corresponding one of the foam panels, each of the anchor members having two opposing ends, A head part projecting along the longitudinal direction from each of the head parts, each head part having a laterally extending terminal surface;
A connecting member for integrally connecting the pair of anchor members in the longitudinal direction;
The head parts of each anchor member are mirror-symmetric with respect to each other;
Each head component has an L-shaped cross section having a transverse arm that defines the terminal surface and a longitudinal arm that connects the transverse arm to the distal end of an anchor member from which the head component protrudes. A connector characterized by that. A wall frame for receiving a flowable material:
Comprising a pair of foam panels each having opposing top and bottom wall surfaces;
A connector for integrally joining the foam panels in a spaced apart parallel relationship along the longitudinal direction, said connector being designed to be embedded longitudinally inside one of the corresponding foam panels; A pair of elongated anchor members, each of the anchor members having two opposing end portions and a head component projecting longitudinally from each of the end portions; Each connector has a terminal surface extending laterally and along a corresponding part of the top and bottom wall surfaces of the corresponding foam panel, and the connector integrally connects the pair of anchor members in the longitudinal direction. It further comprises a connecting member for:
Each head component is formed such that its terminal surface is suitable for extending along either the top wall surface or the bottom wall surface;
The head parts of each anchor member are mirror-symmetric with respect to each other;
Each head component has an L-shaped portion having a transverse arm defining the terminal surface and a longitudinal arm connecting the transverse arm to the distal end of an anchor member from which the head component protrudes. A wall frame characterized by   The wall frame according to claim 2, wherein the top wall surface and the bottom wall surface of each foam panel are provided with protrusions and recesses alternately, and the head component is embedded in one of the protrusions.   The wall frame according to claim 3, wherein each projection on the top wall faces a recess on the bottom wall, and each recess on the top wall faces a projection on the bottom wall for each foam panel.   A wall frame assembly comprising a plurality of wall frames according to claim 2, wherein the wall frames are stacked vertically.   For adjacent upper and lower wall frames, a terminal surface that extends along the bottom wall surface of the foam panel of the upper wall frame extends along the top wall surface of the foam panel of the lower wall frame. The wall frame assembly according to claim 5, which abuts against the wall frame.

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