MX2007016304A - Form for casting light weight composite concrete panels. - Google Patents

Abstract

A concrete form for supporting a steel frame above a pouring pad comprises a vertical wall configured to be fastened to the steel frame, a marker on the vertical wall for spacing the frame a predetermined distance above the pouring pad, and a sealing member extending from a lower edge of the wall for sealing the form to the pouring pad. Preferably, the vertical wall has an upper portion, a horizontally offset lower portion, and a shoulder there between which engages an edge of the steel frame. The sealing member is preferably a lip extending from the vertical wall at an obtuse angle and engaging the pouring pad at an obtuse angle.

Description

FORM FOR MOLDING CONCRETE PANELS COMPOSITE OF LIGHT WEIGHT CROSS REFERENCE This application claims priority of the copending United States provisional patent application serial number 60/693/823 filed on June 24, 2005. This application is a continuation of part of the co-pending United States patent application serial number 10 / 565,317 which is the national stage of PCT / US2004 / 023155 filed on July 21, 2004 and which claims priority of the United States provisional patent application serial number 60 / 488,821 filed on July 21, 2003.

FIELD OF THE INVENTION The present application is directed to forms for forming concrete, and in particular forms for molding lightweight composite concrete panels.

BACKGROUND OF THE INVENTION Concrete composite panels and steel frameworks have been used to construct buildings and in particular as exterior cladding panels in industrial, commercial and residential structures. Arming composite panels for construction in one location and transporting the panels to a construction location for use in the fabrication of structures is well known. The use of prefabricated components for construction substantially reduces labor costs in the manufacturing processes and armed.

Composite concrete panels, such as those presented in PCT application PCT serial number PCT / US2004 / 023155 by Smith, which is hereby incorporated by reference, are made of metal frames partially embedded in concrete to provide systems for exterior walls. In many cases, the panels are supported on the building structure and are not designed to support any load other than wind loading, however composite panels can also be used in load-bearing applications. Typically, the panel includes a concrete slab with a finished exterior surface. Structural steel poles, such as C-shaped channels, are assembled in a frame and the frame is partially embedded in the concrete slab. Preferably the earthenware is lightweight concrete, such as for example foam concrete, as presented in Smith's PCT application referred to above. The mechanical systems, insulation and the table for partition or other interior finish are installed inside the panel.

Traditionally, composite concrete panels are formed by assembling an exterior shape composed of wood or metal rails in a cushion for pouring. The inner shapes can be placed with the outer shape to block openings for doors and windows. Optional exterior and interior shapes define a volume in which concrete is poured. Usually a steel frame, and reinforcement posts or mesh are embedded in the concrete. The steel can be assembled and placed inside the form before pouring the concrete, or it can be lowered and pressed into the concrete shortly after pouring the concrete. It is usually necessary to seal the outer and inner members of the shape on the cushion for pouring. This is done conventionally with plastic sheets or by caulking between the shapes and the pouring pad to prevent concrete from seeping under the shapes. After at least partial molding of the concrete panel, the members of the form are separated and removed.

The installation, sealing and removal of the forms in the pouring pad require labor and take time. In addition, the workspace requires excessive cleaning after each panel is set successfully.

According to the above, there is a need for an improved form for molding composite concrete panels.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross section through a first example of a concrete form of the invention fixed in a frame and a retention concrete slurry. Figure 2 is a transverse through two adjacent composite concrete panels formed in the shape of the first copy.

Figure 3 is a perspective view partially cut away from a second example of a concrete form of the invention. Figure 4 is a perspective view partially cut away from a third copy of a concrete form of the invention.

DETAILED DESCRIPTION OF THE INVENTION With reference to Figure 1, a first copy of a concrete form 10 is shown attached to a steel frame 12 with a fastener 14. A layer of reinforcing material 16, such as a groove reinforcement and expanded steel, is fixed to the frame. The reinforcing material and a portion of the steel frame member are partially embedded in lightweight concrete 18, as presented in PCT application serial number PCT / US2004 / 023155. The shape 10 functions to retain the concrete grout 18, separate the steel frame 12 a predetermined distance D on the pouring pad 20 and seal the shape to the pouring pad.

The shape 10 comprises a vertical wall 22 having an upper portion 24 and a lower portion 26. The upper portion of the vertical wall is configured to be secured to the frame member 12 with a fastener 14. A shoulder 28 is formed between the upper portion and bottom of the wall. The lower portion of the vertical wall is horizontally spaced from said upper portion of the wall. A sealing member, namely, lip 30 extends at an obtuse angle from said lower vertical wall and is configured to form an obtuse angle with the cushion for pouring. The lip of preference is flexible and elastic, but has sufficient strength to support the frame.

The shoulder 28 functions as a marker to locate the frame at a predetermined distance D on the cushion for pouring 20. This distance D may vary as determined by the architect or engineer. Usually, the distance D is about one inch.

The lip 30 functions as a lip seal to seal the shape in the cushion for pouring. Because the flexible lip is at an obtuse angle, as illustrated in Figure 1, the weight of the concrete slurry 18 will press the lip down into a seal coupling with the pour pad 20.

The composite concrete panel is preferably manufactured by first assembling the steel frame and placing the frame upside down on the pouring pad. The reinforcing steel is then fixed to the top of the frame in reverse. The members of form 10 are then fixed to the perimeter of the steel frame and said interior openings as desired. Because the frame is upside down, the shapes are set upside down, ie with the lip 30 extending in an upward and downward direction. The shoulder 26 is nested with the edge of the frame, which facilitates a quick and easy assembly without the need to measure distances. The shape members are fixed to the frame with fasteners 14, such as screws. After the forms are in place, the assembly is turned over, so that the lips 30 mesh with the cushion for pouring. After the concrete is poured into the interior of the form. The concrete is preferably a lightweight concrete, such as a foam concrete. Because the concrete is lightweight, the plastic shapes 10 have sufficient strength to retain the concrete without the need for wood or steel rails or other important structural elements. When the concrete has at least partially cured, the shapes can optionally be peeled off and removed by removing the fasteners. However, it is desirable to leave the forms in place during storage and transportation to protect the edges of the composite concrete panels.

Figure 2 shows two concrete panels 32a and 32b fabricated using the shapes 10. The adjacent panels 32a and 32b are joined together with a plurality of fasteners, for example, screw 34, extending between the frame members 12a and 12b. The lip 30 of the shape 10 functions to form chamfers 36a and 36b at the edge of each concrete panel. The horizontal separation between the lower 26 and upper portions 24 of the wall creates a desirable loom 38 between the panels 32a and 32b. The loom of preference is filled with a sealing material 40, such as macula or slurry.

Figure 3 illustrates a second exemplary 110 of the concrete form of the invention. The characteristics of the second copy corresponding to the similar characteristics of the first copy have the same reference numerals, but in the series 100. The shape 110 comprises an "L" shaped member for supporting a frame member 112 of a concrete panel. composed on a cushion for pouring 120. The shape member 110 is fixed to the frame member 112 with fasteners 114. During assembly of the panel, the shape members 110 are preferably arranged on the perimeter of the frame assembly 18 to allow the Concrete grout flow (not shown) to partially embed the frame assembly in a concrete slab.

The shape member 110 comprises a vertical wall 122 and a sealing member comprising a horizontal leg 129 and a seal 130. The seal 130 engages to form a seal with the pouring pad 120. The seal 130 prevents the concrete grout it is filtered under the shape member 110 to avoid the need to wrap the shapes in plastic or the need to seal the perimeter of the shapes. The seal 130 is deformed in contact with the cushion to pour 120 to retain the concrete grout within the confines of the shape.

The vertical wall 122 has at least one, but preferably several markers to establish the height of the frame 112 above the pour pad 120. The markers comprise grooves 127 arranged in a inner surface 121 for indexing the relative position of the frame member 112 with the shape member 110 and the pouring pad 120. Although the raised grooves 127 are disposed on the inner surface 121, it is contemplated that other indicators may be used, such as example a shoulder, hidden grooves, lines or separate markers. Preferably, a plurality of grooves are arranged at vertically spaced intervals to facilitate the selection of different heights to separate the frame above the cushion for pouring and hence the concrete cover on the frame and reinforcement materials.

Form members 110 are optionally removed from the panel before the concrete is cured. The horizontal leg 129 will cause the perimeter edges of the concrete panel to be slightly hidden from an outer face of the concrete panel. If desired, putty or grout may be added around the perimeter 25 of the concrete panel to provide a level finish to the rest of the concrete panel. One or more ribs 137 are preferably arranged on the inner surface of the leg 129 which will form corresponding grooves at the edges of the concrete panel to improve the bonding of the putty or grout with the panel. As indicated above, the shape member 110 may optionally be permanently or provisionally retained in the concrete panel. It is desirable to retain the shape on the panel during storage and transportation to protect the edges of the panel against damage. With reference now to Figure 4, a third is shown exemplary concrete form 210 of the invention. The characteristics of the third specimen corresponding to the similar characteristics of the first and second specimens have the same reference numerals, but in the series 200. The third specimen is similar to the second specimen, except that the horizontal leg 229 is directed outwards in instead of inward. As in the second example, the frame 212 is mounted on the inner surface 221 of the vertical wall 222. Concrete is poured onto the cushion for pouring 220 to a desired height, preferably embedding a portion of the frame assembly 212. A seal 230 on the bottom surface of leg 229 retains the concrete within the confines of the shape. However, unlike the second copy, when the shapes 210 are removed from the concrete panel, the resulting peripheral edges of the panel are flush with the rest of the outer surface of the panel. In the third copy, unlike the second copy, it is not practical to leave the shape on the panel during storage or transport due to the projecting leg 229.

A single form can be used in any of the orientations illustrated in the second and third copies. Markers can be placed on both sides of vertical wall 122, 222. Thus, the shape is reversible and can be used in any orientation.

The members of form 10, 110, 210 can be manufactured inexpensively with extruded plastic or other material having sufficient strength to hold the frame member on the cushion for pouring and retaining the concrete grout. In the first copy, the lip seal 30 is preferably formed integrally with the vertical wall 22. In the second and third copies, the stamp 130, 230 may be separate and coupled to the shape member 110, 210. The stamp 130, 230 preferably has a high elasticity, that is, it is softer than the shape member 110, 210.

While specific specimens of the present concrete form have been shown and described herein, those skilled in the art will appreciate that changes and modifications can be made thereto without departing from the invention in its broader aspects and as established in the following claims.

Claims (10)

1. A form of concrete for supporting a steel frame on a cushion for pouring, said form comprises: a vertical wall configured to be fastened to the frame; a marker on said vertical wall for separating the frame at a predetermined distance above the cushion for pouring; and a sealing member extending from a lower edge of said vertical wall to seal the shape to the cushion for pouring.

2. A concrete form as in Claim 1, said vertical wall comprises an upper portion and a lower portion, and said marker comprises a shoulder between said upper and lower portions of the wall.

3. A concrete form as in Claim 2, wherein said upper and lower portions of the wall are horizontally spaced from each other on the shoulder.

4. A concrete form as in Claim 1, wherein said sealing member comprises a lip extending from said vertical wall at an obtuse angle, and engaging with the cushion for pouring at an obtuse angle.

5. A concrete form as in Claim 1, wherein said sealing member comprises a leg extending horizontally from said vertical wall and a seal on said leg configured to mate with the cushion for pouring.

6. A concrete form as in Claim 5, further comprising one or more ribs on an interior surface of said horizontal leg.

7. A concrete shape for supporting a frame member on a pouring pad, said shape comprising: a vertical wall having an upper portion and a lower portion, a shoulder between said upper and lower portions of the wall for supporting the frame member at a predetermined distance above the cushion for pouring, and a sealing member in said lower wall configured to mate with the cushion for pouring.

8. A concrete form as in Claim 7, wherein said sealing member comprises a lip extending from said lower wall at an obtuse angle.

9. A concrete form as in Claim 7, wherein said bottom wall is horizontally spaced from said top wall to form a loom at an edge of a concrete panel molded with the shape.

10. A form of concrete for supporting a steel frame member on a cushion for pouring, said form comprising: an upper vertical wall configured to be fixed on the frame member, a lower vertical wall, said bottom wall being horizontally separated from said top wall , a shoulder between said upper and lower walls configured to engage an edge of the frame member, and a lip extending at an obtuse angle from said lower vertical wall and configured to engage with the cushion for pouring at an obtuse angle, said Top wall, bottom wall, shoulder and lip are a unitary extrusion.