US20030213198A1

US20030213198A1 - Form system

Info

Publication number: US20030213198A1
Application number: US10/321,846
Authority: US
Inventors: Frank Bentley
Original assignee: Individual
Current assignee: Sonoco Development Inc; Sonoco Protective Solutions Inc
Priority date: 2000-06-30
Filing date: 2002-12-18
Publication date: 2003-11-20

Abstract

A form system comprises several form units, each having a pair of panels positioned in spaced relation to each other. A plurality of tie members connects the panels, the tie member comprising a spacer member disposed transversely between the panels. Each tie member further comprises a pair unit connecting members, one positioned on each of an outside surface of a panel. The spacer members are each connected to a first unit and a second unit connecting member through the first opening in the panels. The first and second unit connecting members have first and second connections respectively, to permit the first and second unit connecting members of a first form unit to be connected with corresponding first and second connecting members of a second form unit.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. application Ser. No. 09/462,144, filed Jun. 30, 2000, based on PCT patent WO 99/01626 filed on Jul. 3, 1998, EPO patent EP0996793 filed on Mar. 7, 1998 and Canadian Patent CA 2209251, filed Jul. 4, 1997.[0001]

FIELD OF THE INVENTION

This present technology relates to form systems used to construct structural components such as walls.

BACKGROUND

Construction components, such as walls and columns, are often made from castable materials such as concrete. As is well known, to make a specifically shaped component from such materials, a form is built or erected which functions as a mould for the castable material. In the past, forms were typically made from inexpensive materials such as wood. To make the component, the form is erected to create a cavity capable of holding the castable material (e.g. concrete) in a liquid form. The concrete is then poured or otherwise fed into the cavity created by the form and then allowed to set. Once the material has hardened into a structural component, the form is removed. After use as a form, quite often, much of the form material cannot be reused and must be discarded. Furthermore, the removal of the form requires a significant amount of labor.

Another way a form can be built is to make a form from several form units, each form unit having a pair of spaced panels. The form units are placed adjacent each other, both horizontally and vertically, to build a complete form. So long as the individual form units are not too small, enhanced efficiency in the construction of a form may be achieved in such a system. This is particularly the case if the form units are designed to remain permanently in the site. Once placed, and do not have to be removed once the concrete has been poured and set. One Such system has side panels for each form unit made of an insulative material. These side panels perform the dual purpose of functioning as the sidewalls for the cavity and then after the concrete has set, as an insulative layer on each side of the concrete.

It will be appreciated that it is often necessary to construct a wall many meters in length and several meters in height. This will require many form units that must be held together. Particularly in forms which are high, the vertical interconnections between adjacent form units are important as they resist vertical lift forces that tend to lift and separate adjacent form units.

However, providing interconnections between form units which are effective, but which can quickly be engaged, is problematic.

Another difficulty in such systems is the lack of space efficiency in the transportation of pre-built form units to a construction site.

Accordingly, it is desirable to have a form system that employs form units having both efficient and effective form unit interconnections, and the form unit must be capable of being efficiently transported and assembled to the construction site.

SUMMARY

According to one aspect of the invention there is provided a form system having first and second form units, said first and second panels positioned in spaced relation to each other, each of said first and second panels having an inwardly facing surface and an outwardly facing surface and a first opening there through; at least one tie member, said tie member comprising a spacer member having first and second ends, said spacer member being disposed transversely between said panels, said tie member further comprising first and second unit connecting members being positioned away from said inward facing surface and proximate said outward facing surface of said first panel and said second unit connecting member being positioned away from said inward facing surface of said second panel and proximate said outward facing surface of said second panel, said tie member having a first attachment means providing an attachment of said spacer member to said first unit connecting member through said first opening in said second panel; said first and second unit connecting members of said tie member having a first and second connection means respectively, to permit said first unit connecting member of a first form unit to be connected with one of said first and second connecting members of a second form unit, when said panels of said first form unit is placed above and is in transverse alignment and abutment with respective panels of said second form unit.

According to another aspect of the invention there is provided a kit for building a form unit having first and second spaced apart panels each having an opening there through, said kit comprising, in combination: a plurality of elongated spacer members, each said spacer members, having first and second ends, first and second elongated unit connecting members, each said spacer member having a first connecting device located proximate said first end adapted to co-operate with a first connecting device on said first unit connecting member to establish a first connection, there between, through said opening in said first panel; and said spacer member having a second connecting member located proximate said second end adapted to co-operated with a second connecting member to establish a second connection, there between, though said second opening in said second panel; said first and second unit connecting members of said also having a third and fourth connection means respectively, to permit said first unit connecting member of a first form unit to be connected with one of said first and second connecting members of a second form unit, and said second unit connecting member of said first form unit to be connected with the other said first and second connecting members of said second form unit, when said panels of said first form unit are placed above in transverse alignment and abutment with respective panels of said second form unit.

According to a further aspect of the invention, there is provided a form unit for a form system, said form unit comprising: first and second panels positioned in spaced, generally parallel relation to each other, each of said first and second panels having an inwardly facing surface and an outwardly facing surface and a first opening there through; first and second tie members, each of said first and second tie members comprising an elongated spacer member having first and second ends, said spacer member being disposed transversely between said panels and said first and second tie members being spaced longitudinally from one another, said tie member further comprising first and second elongated unit connecting members, said first unit connecting member being oriented generally vertically and positioned on the outward side of said first panel and said second unit connecting member being oriented generally vertically and positioned on the outward side of said second panel, said tie member having a first attachment means for attaching said spacer member to said first connecting member through said first opening in said first panel, and a second attachment means for permanently attaching said tie member to said second connecting member through said first opening in said second panel; said first unit connecting member having a first unit connection means adapted to cooperate with a second unit connecting means of a second form unit to provide to a first connection between said first form unit and said second form unit when said panels of said first form unit are placed above and in transverse alignment and abutment with respective panels of said second form unit; said second unit connecting member having a third unit connection means adapted to cooperate with a fourth unit connecting means of a second form unit to provide for a second connection between said first form unit and said second form unit when said panels of first form unit are placed above and in transverse alignment and abutment with panels of said second form unit.

According to another embodiment, a spacer member has a rebar clip and a rebar channel for coupling a rebar. The rebar clip may latch and captivate the rebar in order to hold the rebar in place while concrete is poured into the form cavity.

In another embodiment, the wall form unit may comprise a wall-forming reversible panel having projections and recesses for interconnecting panels together. The recess on the top end of the panel is opposed to the projections on the bottom end of the panel. As a result, the top end of the panel is interconnectable with either the top end or the bottom end of a like panel. Likewise, the bottom end of the panel is interconnectable with either the top end or the bottom end of a like panel.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate various exemplary embodiments: [0014]
FIG. 1 is a perspective view of a form unit made in accordance with one embodiment; [0015]
FIG. 2 is a front, elevation view of part of the form unit of FIG. 1 according to one exemplary embodiment; [0016]
FIG. 3 is a plan view of part of the form unit of FIG. 1 according to one exemplary embodiment; [0017]
FIG. 4 is a plan view of the connection between the tie member and connecting member shown in FIG. 1 according to one exemplary embodiment; [0018]
FIG. 5 is a perspective view showing the connection between the tie member and connecting member shown in FIG. 1 according to one exemplary embodiment; [0019]
FIG. 6 is a detailed view showing a connection made between two vertically adjacent connected wall-forming units according to one exemplary embodiment; [0020]
FIG. 7 is a plan view from above along the line [0021] 7-7 in FIG. 6 according to one exemplary embodiment;
FIG. 8 is plan view of the detail in FIG. 6 along the line [0022] 8-8 in FIG. 6 according to one exemplary embodiment;
FIG. 9 is a similar view to FIG. 6 showing a connection made between two vertically adjacent connected wall-forming units according to one exemplary embodiment; [0023]
FIG. 10 is a schematic side elevation view of part of a complete form constructed in accordance with an embodiment of the invention according to one exemplary embodiment; [0024]
FIG. 11 is a schematic elevation view of part of a form constructed in accordance with an embodiment of the invention; [0025]
FIG. 12 is a perspective view of the form unit and the connection between the spacer member and connecting member shown in FIGS. 1 and 2 according to one exemplary embodiment; [0026]
FIG. 13[0027] a shows a ridged structure for interlocking panels according to the embodiment of FIG. 12;
FIG. 13[0028] b shows a complementary grooved structure for cooperation with the structure of FIG. 13a;
FIG. 14 is a front view of the interior of a form cavity with multiple spacer members according to one exemplary embodiment; [0029]
FIG. 15 is a view of a spacer member having an inwardly pointing protrusion according to one exemplary embodiment; [0030]
FIG. 16 is a view of a spacer member having a curved rebar clips according to one exemplary embodiment; [0031]
FIG. 17 is a view of a spacer member shown with rebar clips having double angled ridges according to one exemplary embodiment; [0032]
FIG. 18 is a view of a spacer member shown with rebar clips having inwardly pointing v-shaped hooks according to one exemplary embodiment; [0033]
FIG. 18A is a view of a spacer member shown with rebar clips having inwardly pointing v-shaped hooks according to one exemplary embodiment; [0034]
FIG. 19 is a view of a spacer member shown with rebar clips having a biasing spring according to one exemplary embodiment; [0035]
FIG. 20 is a view of a spacer member shown with rebar clips having a track of teeth according to one exemplary embodiment; [0036]
FIG. 21 is a view of a spacer member shown with rebar clips having paddle latches according to one exemplary embodiment; [0037]
FIG. 22 is a view of a spacer member of FIG. 21 with the addition of a snap ball on the paddles; [0038]
FIG. 23 is a view of a spacer member of FIG. 21 with the addition of a toothed track coupled with the paddles; [0039]
FIG. 24 is a view of a spacer member shown with rebar clips having barbs on an interior surface of the rebar clips according to one exemplary embodiment; [0040]
FIG. 25 is a view of a spacer member shown with rebar clips having L shaped hooks according to one exemplary embodiment; [0041]
FIG. 26 is a view of a spacer member shown with rebar clips having outwardly pointing u-shaped hooks according to one exemplary embodiment; [0042]
FIG. 27 illustrates a latch mechanism similar to the latch mechanism described with reference to FIG. 15 where the flanges have a rounded tip according to one exemplary embodiment; [0043]
FIG. 28 illustrates a latch mechanism similar to the latch described with reference to FIG. 16, however, the entrance to barb channel has angled pinching [0044] clips 170 according to one exemplary embodiment;
FIG. 29 illustrates an embodiment of the latch with curved hooks for latching a [0045] rebar 151 when inserted according to one exemplary embodiment;
FIG. 30 illustrates a rebar latch mechanism similar to the latch mechanism described with reference to FIG. 29 with the addition of barbs at the end of the curved hooks according to one exemplary embodiment; [0046]
FIG. 31 illustrates a rebar latch mechanism having prongs that extend from posts to beyond the center of the rebar channel according to another exemplary embodiment; [0047]
FIG. 32 is a perspective view of a wall form unit having a pair of panels in accordance with one exemplary embodiment; [0048]
FIG. 33 illustrates a single panel according to another embodiment; [0049]
FIG. 34 illustrates a cross-sectional view of two like panel members in accordance with one exemplary embodiment; [0050]
FIG. 35 is a top plan view of a portion of a reversible corner block [0051] 10 in accordance with one exemplary embodiment;
FIG. 36 shows a panel where the projections and recesses are triangular in accordance with one exemplary embodiment; [0052]
FIG. 37 shows a top view of a panel where the projections and recesses are triangular in accordance with one exemplary embodiment; [0053]
FIG. 38 shows a top view of a panel where the projections and recesses have a star shape in accordance with one exemplary embodiment; [0054]
FIG. 39 shows a top view of a panel where the projections and recesses have six sides in accordance with one exemplary embodiment; [0055]
FIG. 40 illustrates a perspective view of a panel where the projections and recesses are pyramids in accordance with one exemplary embodiment; [0056]
FIG. 41 shows a side view of one end of a panel where the projections and recesses form the shape of an arrow head in accordance with one exemplary embodiment; [0057]
FIG. 42 shows a perspective view of one end of a panel with a combination of shapes in accordance with one exemplary embodiment; [0058]
FIG. 43 shows a perspective view of one end of a panel with a combination of shapes with rows having reverse symmetry in accordance with one exemplary embodiment; and [0059]
FIG. 44 shows a perspective view of one end of a panel with a combination of shapes with symmetric rows in accordance with one exemplary embodiment.[0060]

DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1, a [0061] single form unit 20 a is illustrated. In the construction of a structural component, for example a wall, several such form units 20 a are utilized. Wall form units 20 a are placed adjacent to, and in lateral alignment with, other form units to make a complete form structure, as illustrated in FIG. 10.
A [0062] single form unit 20 a has a pair of spaced, generally planar and transversely aligned panel members 22 a and 24 a. In one embodiment, panel members 22 a and 24 a are made from a lightweight, temperature insulating material such as polystyrene or an extruded form. The panels may however, be made of materials other than those which are particularly adapted to provide for temperature insulation, but which will retain the liquid material.
In FIG. 1, [0063] panel unit 20 a is shown with a single tie member 26 a in detail. However, to provide greater stability for a form unit, a pair of tie members 26 a and 28 a may be employed.
As shown in FIGS. 2 and 3, each [0064] tie member 26 a comprises three components: a transversely oriented spacer member 30 a and a pair of vertically oriented unit connecting members 34 a and 36 a. In FIGS. 2 and 3, the form unit 20 a, including the tie member 26 a, is shown in its disassembled state. However, spacer member 30 a may be easily attached to vertical unit connecting members 34 a and 36 a in the manner thereafter described. In one embodiment of the invention, spacer member 30 a has a recess 38 a, 40 a extending substantially the full vertical length of the spacer member, as is clearly illustrated by a top view in FIG. 4. Spacer member 30 a, and elements 34 a and 36 a, are made from a material Such as polypropylene, nylon 6/6, PVC or A.B.S.
As shown in FIG. 3, [0065] spacer member 30 a also has an indentation 62 a on the upper transverse arm 63 a of the spacer member 30 a and an indentation 64 a on the lower transverse arm 65 a of the spacer member 30 a, although other embodiments of this invention may have a plurality of such indentations. Each indentation 62 a and 64 a is adapted to be able to receive, and support at that location, a concrete strengthening material such as steel rebar 61. It will be appreciated that when several form units are arranged laterally adjacent to each other, lengths of rebar may be supported laterally on the indentations 62 a and 64 a of successive laterally positioned form units. To assist in the insertion and retention of the lengths rebar 61, the indentations 62 a and 64 a may be made from a resilient material.
Each of the vertical form [0066] unit connecting members 34 a and 36 a has a fin 58 a and 60 a extending substantially the full vertical length of the inside end of the connecting member 34 a and 36 a. Recesses 38 a and 40 a are so arranged to cooperate with the fins 58 a and 60 a such that each of the said fins can be received into one of said recesses 38 a, 40 a though one of two apertures in panels 22 a and 24 a. It will be appreciated if panels 22 a and 24 a are constructed of a material such as polystyrene, it will be easy for a person assembling form unit 20 a to create the apertures required for the interconnection between the spacer member 30 a and the vertical unit connecting members 34 a and 36 a. However, greater efficiency may be achieved if the apertures are at least pre-marked, if not pre-formed.
The attachment between [0067] recesses 38 a and 40 a and fins 58 a and 60 a is illustrated in FIG. 4. In this figure, a positive attachment is created when the fin 60 a slides into the recess 40 a in a vertical direction. The recess 40 a narrows at its outer margin 41 a in order to grasp the correspondingly narrowed portion 61 a of the fin 60 a and provide a snug fit between spacer member 30 a and connecting elements 34 a and 36 a. The recess does not reach all the way to the upper end of the spacer element 30 a, thus preventing further sliding of the connecting elements 34 a and 36 a, as is illustrated in FIG. 5.
This connection, between the [0068] fins 58 a and 60 a and the recesses 38 a and 40 a, is not permanent, and the form units can be reshaped if it is discovered that a mistake was made.
Once the [0069] spacer member 26 a is attached to the vertical unit connecting members, such as 36 a, the vertical unit connecting members are oriented vertically and have a surface which lies against the outward facing surface of a panel.
A may be seen in FIG. 1, connecting [0070] elements 34 a and 36 a have a laterally (in direction of axis X) extending channel or groove 76 a in their upper lateral surfaces 75 a and lower lateral surfaces 77 a. A linking element 71 a has a laterally extending tongue or protrusion 72 a which extends upwards from an upper, lateral surface 74 a and downwards from a lower, lateral surface 79 a.
A pair of form units may be positioned one on top of the other wherein the channel of a lower form unit will be received in corresponding and respective protrusion of a linking element, which is then received in a corresponding and respective channel of an upper form unit (not shown). The result is that displacement of a first upper form unit relative to a second lower form unit is resisted. [0071]
The mechanism for providing a positive connection between adjacent vertically positioned form units is illustrated in further detail in FIGS. 6, 7, [0072] 8, and 9.
In FIG. 6, the lower portion of a typical [0073] unit connecting member 34 a and the upper portion of a typical linking element 71 a are shown disconnected from each other. The unit connecting member and the linking element both lie against the outer surfaces of their respective panels. Formed in the lower portion of member 34 a is a recess 76 a defined by an opening and vertically oriented side walls 82 a, 84 a and a base 80 a. The side walls 82 a, 84 a are each saw-toothed.
[0074] Connection member 54 a has at its upper end an arrow formation 86 a with an arrowhead 88 a. The saw-tooth pattern of the walls 82 a, 84 a is such that the sloped sides of arrowhead 88 a are guided and carried past the individual teeth during axial insertion of the arrow formation 86 a into the recess 76 a in the direction of axis z of FIG. 1.
The lower portion of the connecting member is deformable and permits side walls to be displaced allowing insertion of the [0075] arrowhead 88 a into the recess. But the side walls are resilient. Thus, once arrowhead 88 a has passed a pair of oppositely positioned saw teeth on the sidewalls 82 a and 84 a, axial removal of the arrowhead 88 a is prevented as the side portions of the arrowhead engage the rear sides of the saw-teeth.
However, even when two [0076] form units 20 a and 20 d have been interconnected through use of linking element 71 a and connection members 34 a and 36 a as shown in FIG. 9, the recess 76 a is still accessible. Thus, if it is desired to disconnect the connection between arrowhead 86 a and the side walls 82 a and 84 a of the recess, a transverse application of force in a manner generally depicted in FIG. 9 (generally in the direction along of axis Y in FIG. 1), permits arrowhead 88 a to become dislodged from the side walls.
The dimensions of the [0077] arrowhead formation 86 a and the materials from which it is made, are such that it would be quite stiff and a have a relatively high degree of resistance to bending. Typically it would require a lever device to be employed to bend the arrowhead out of the recess to release the connection. Such a lever device might be a crow bar or a hammer claw.
When building a form from many form units, it is possible to provide a lateral interconnection between form units. This can be accomplished by erecting a form with form units such as those of FIG. 1 placed in a pattern as shown in FIG. 10. In this embodiment, each form unit has a pair of vertical form unit connecting members. Each form unit is off-set in its lateral position relative to form unit above and below. Taking one [0078] such form unit 20 e, one of the pair of connecting members 26 e is connected to a connecting member 28 g of a form unit 20 g, and also to a connecting member 28 k of a form unit 20 k. The other of the pair of connecting members 28 e is connected to connecting member 26 f of a form unit 20 f and also to a connecting member 26 h of a form unit 26 a.
In use, individual panels and the components of the tie members may be shipped to a construction site. The components of the tie members can be conveniently packaged as kits. Unassembled, the components of the form system can be efficiently carried by conventional transport devices. Once at the site, the wall forming units can be easily assembled by using a pair of panels and the components of at least one tie member, but preferably using as least two tie members. For each tie member, a spacer portion is positioned in between the two panels, with its connecting members each passing through an aperture in a panel. A pair of vertical connecting members will be secured in a vertical orientation, against the outer surface of each panel and then will be attached to the spacer member by the attachment of the connecting members to the spacer members as described above. [0079]
As many form units are built as required to construct a complete form for the desired structure. If the form is not continuous, the ends of the form may blocked in a conventional means, so as to provide a complete cavity which will hold the liquid concrete. [0080]
In a construction project, the lower most form units may be secured to a base in lateral alignment (for example, a previously poured footing) providing an interconnection between a concrete footing made with a length of 2×4 secured to the concrete (e.g. by concrete nails) and then providing interconnections between the lengths of 2×4 and the vertical unit connecting members. [0081]
Thereafter, form units may be placed on top of the base form units and interconnected such as in the manner described above. Preferably, each form unit will comprise at least a pair of laterally spaced tie members. This will provide for greater vertical stability of the form and assist in the construction process. [0082]
Once the concrete has set, the panels will remain in situ. The vertical unit connecting members will provide a base to which other finishing components may be attached (for example, dry wall for interior walls, siding on exterior walls). [0083]
A further embodiment of the present invention is illustrated in FIG. 12. FIG. 12 shows a cutaway view of a [0084] wall form unit 100, including a tie assembly 104, previously referred to as a tie member, connecting two opposing panels 108.
[0085] Tie assembly 104 is an interconnected assembly of a spacer member 112 and two connecting members 116. Spacer member 112 consists of edges 120 spaced apart by a plurality of arm members 124. As illustrated, arm members 124 can be provided with indentations 126 for supporting reinforcing members, such as conventional rebar, as described above. Edges 120 have a generally
T-shaped profile for engaging complementary T-shaped [0086] channel 130 provided on connecting members 116. An end 132 of each edge 120 is also provided with an abutment 134 which limits the sliding engagement between edges 120 and channel 130.
As described above, connecting [0087] members 116 consist of a support portion 136 supporting a projecting coupling 138, previously designated a connection means. Coupling 138 is formed by two opposing rows 140 and 142 of staggered teeth 144 defining channel 130. The substantially L shaped teeth 144 give channel 130 its T-shaped profile complementary to edge 120.
In this further embodiment of the present invention, the support portion [0088] 136 of connecting member 116 is embedded in its respective panel 108. Typically, connecting member 116 is an extruded, or otherwise molded, plastic component and panel 108 is a blown polystyrene panel.
Connecting [0089] members 116 can be prefabricated and then provided to insulating panel manufacturers.
The polystyrene panels can then be manufactured in known conventional manners to incorporate the connecting [0090] members 116 in a predetermined arrangement suitable for their interconnection to form wall form unit 100. In a preferred embodiment, the connecting members 116 are embedded in the panel such that coupling 138 is disposed within a groove 146, but still accessible for interconnection with the edges 120 of spacer member 112.
A further feature of this embodiment, as shown in FIGS. 13[0091] a and 13 b, is the provision of an integral means for interlocking the panels 108 to form a wall form system. A ridged, interlocking structure 150 is provided on the at one edge 152 of the panel 108, and a complementary grooved structure 154 is provided on the opposite edge 156. The ridged interlock 150 and grooved interlock 156 permit the wall form units 100 to be stacked and retain the units 100 in place. As will be apparent to those skilled in the art, a wall form system constructed of stacked wall form units 100 will not require separate interconnecting means as described in the previous embodiment.
Various modifications and changes are also possible within the scope of the invention. The outer facing surfaces of the panels may be recessed to provide a recess into which the vertical unit connecting members may be received such that when the form unit is assembled, the vertical connecting members have outward facing surfaces which sit flush with the remaining parts of the outer surfaces of the panels. [0092]
Form units may be arranged as shown in FIG. 12. wherein each form unit may be secured both above and below to a pair of form units. For example, form unit is connected by three vertical connecting elements associated with each of the two panels (only one of the panels and one set of vertical connecting elements being visible in FIG. 12) to corresponding sets of connecting elements associated with [0093] form units 220 b and 220 c.
In one embodiment, the side panels are not parallel to each other, but are angled to form a concrete wall having a trapezoidal cross-section. In another embodiment, only one side panel is used to create a wall section horizontally, that is later raised vertically. [0094]
Rebar Channel [0095]
FIG. 14 is a front view of the interior of a form cavity with multiple spacer members according to one exemplary embodiment. [0096] Rebar 151, may be clipped or latched into multiple spacer members 150 to hold the rebar 151 in place within the form cavity 200 while concrete is poured into the form cavity 200 and while the concrete is curing. The term concrete reinforcement is used interchangeably with the term rebar 151 or strengthening material 161. The rebar 151 may be any material such as steel, iron, metal or plastic. Additionally, the rebar 151 may be any shape or size suitable for reinforcing the concrete. For example, the shape of the rebar 151 may be round, oval, rectangular, or square. The diameter of the rebar 151, for example, may be one quarter of an inch (¼), to one inch or more. However, the diameter of the rebar 151 may be any size including (⅜), (½), (⅝), (¾) of an inch. In one embodiment, the outer surface of rebar 151 is ribbed.
[0097] Spacer member 150 may be configured with a rebar clip or latch 163 fastener to latch the rebar 151, upon insertion into the rebar channel 162 ( indentation 62 a, 64 a). Since the clip 163 latches or otherwise fastens the rebar 151 to spacer members 150, there is no need to manually tie the rebar 151 into the spacer member 150. However, the rebar 151 may be tied to spacer member 150 with wire, tie-wrap or any suitable fastener. The integration of channel 162 and rebar clip or latch 163 into spacer member 150 provides a convenient attachment of rebar 151 to spacer member 150. Less time is required for attaching rebar 151 to spacer member 150 through the use of rebar clip 63 than manually tying rebar 151 to spacer member 150. As a result, labor costs for the assembly of the forms is reduced because less time is required to attach the rebar 151 to the spacer members 150. Further, material costs are lowered as well because no separate wires, tie-wraps, or clips are required to secure the rebar 151 to spacer member, 150.
FIG. 15 is a view of a [0098] spacer member 150 having multiple rebar channels 162 in order to permit the rebar 151 to latch onto spacer member 150 in different locations within the form cavity 200 depending on where the rebar 151 is required. In one embodiment, the upper transverse arm 152, and the lower transverse arm 154, of the spacer member 150 may have multiple rebar clips 162 in order to allow the placement of the concrete reinforcement 151 in multiple locations within cavity 200.
A variety of clip or latch mechanisms are described below where each mechanism provides features appropriate for a specific condition. For example, the rebar [0099] clip latch mechanism 163 may be required to adapt to different sizes of rebar, be easily removed, or restrict movement or play of the rebar 151 in rebar channel 162.
The latching mechanism and the function of the [0100] rebar clip 160 may be any appropriate design suitable for latching the rebar 151 to the spacer member 150. The latching mechanism on the top side 152 and the bottom side 154 may be the same or may be different. Therefore, the spacer member 150 may use any combination of latching mechanisms described below or developed in the future. In one embodiment, the spacer member 150 is reversible such that either side of the spacer member 150 may be receive rebar 151.
In one embodiment as shown in FIG. 15, [0101] spacer member 150 latches the rebar 151 with protrusions 160 attached to posts 164 located on both sides of the channel 162. In one embodiment the end of protrusions 160 have barbs to resist extraction of rebar 151 from rebar channel 162. According to one exemplary embodiment, the protrusions 160 are flexible and are angled downward toward the rebar channel 162 in order to spread apart and permit the rebar 151 to pass by the protrusions 160 and into the interior of the channel 162. Once the rebar 151 has passed by the spread open protrusions 160, the protrusions 160 flex back into their extended position. The protrusions 160 are spring biased in such a way so that in their normal position, the barbs extend across the opening of the rebar channel 162 sufficiently to keep the rebar 151 captive inside of the rebar channel 162. The rebar 151 becomes captive inside the channel 162 as a result of the protrusions 160 flexing back to their extended position. The rebar 151 may be removed from the channel by pushing the protrusions 160 on both sides of the rebar channel 162 to their spread open position such that the spacing between the protrusions 160 is large enough to permit the rebar 151 to pass between the protrusions 160. In one embodiment, the protrusions 160 are integrally molded into posts 164 or alternatively, protrusions 150 may be attached to post 164 with a fastener such as a screw, pin or similar device.
FIG. 16 illustrates in another embodiment, a [0102] rebar channel 162 having two smooth sliding curved clips 172 for permitting the rebar 151 to slide between clips 172 and into channel 162. The clips 172 have ends that are spread apart from each other for receiving the rebar 151 and for guiding the rebar 151 into the channel 162. As the rebar 151 passes through the clips 172, the clips 172 spread apart into a spread open position. Once the rebar 151 is inside the rebar channel 162, the clips 172 spring back to reduce the width of the opening to less than the diameter of the rebar 151 in order to latch or captivate the rebar 151 inside the rebar channel 162. The rebar 151 may be removed from the rebar channel 162 by spreading the clips 172 to a width greater than the diameter of the rebar 151 so that the rebar 151 may be removed from the rebar channel 162. In another embodiment, a roller may be attached to clips 172 in order to permit rebar 151 to slide past clips 172 and into rebar channel 162.
FIG. 17 illustrates another embodiment where the interior of [0103] channel 162 has double angled ridges 174 for latching the rebar 151 in multiple locations or positions when inserted. In this embodiment, the one, two, or more angled ridges 174 function to seat the rebar 151 into one of the notches formed by the double angled ridges 174 causing the rebar 151 to remain captive inside of the channel 162 in multiple positions. The notches further reduce movement of the rebar 151 while in the rebar channel 162. In another embodiment, the angled ridges 174 break away partially to adaptively fit rebar 151 so that when the angled ridges 174 retract back into their normal position, the ridges have a gap between them that is approximately the same as the diameter of the rebar 151.
FIG. 8 illustrates an embodiment where the ends of [0104] posts 164 have U-shaped compression hooks 176 for latching the rebar 151 when inserted. Insertion of rebar 151 into rebar channel 162 results in a force on the compression hook 176 that is mostly perpendicular to the ends of the U-shaped compression hook 176. As the rebar 151 is inserted, the U-shaped compression hooks 176 also push against posts 164 causing the posts to 164 spread apart. As a result, the U-shaped compression hooks 176 spread apart from each other in order to permit the rebar 151 to enter into the channel 162. However, once the rebar 151 is inside the rebar channel 162, the U-shaped compression hooks 176 spring back to their extended position to form a narrowed gap between the U-shaped compression hooks 176 that is less than the diameter of the rebar 151. The rebar 151 is captive inside the channel 162 because if an attempt is made to remove rebar 151, the tips of the U-shaped hooks 176 engage rebar 151. Once the rebar 151 pass through hooks 176, the U-shaped compression hooks 176 flex outward toward each other compressing rebar 151. Therefore, upon removal, as the rebar 151 pushes against the tips of the U-shaped compression hooks 176, the gap between the compression hooks 176 decreases. As a result, as the removal force increases, the U-shaped compression hooks 176 function together to apply a compression force on rebar 151 to impede removal (unless the compression hooks 176 break). However, the rebar 151 may be easily removed by spreading the U-shaped compression hooks 176 apart and lifting the rebar 151 from the channel 162. FIG. 18A illustrates a latch mechanism similar to the latch mechanism of FIG. 15 except that compression hooks 176 are V-shaped rather than U-shaped.
FIG. 19 illustrates a biasing [0105] spring 180 at the bottom of the indention 162 for reducing movement of the rebar 151 inside the channel 162. The biasing spring 180 reduces movement of the rebar 151 inside the channel 162 by applying a force from the bottom of the channel 162 to push the rebar 151 to the barbs 178. The biasing spring 180 may be flexible enough to accommodate different sizes of rebar 151 and may deflect fully, partially, or not at all when rebar 151 is inside channel 162. Accordingly, the biasing spring 180 may adapt to the rebar to provide a fit appropriate for different sizes and shape of rebar. The biasing spring 180 may be applied to any of the latch mechanisms described in FIGS. 14-31, or to any other latch mechanism already developed or later developed. In another embodiment, biasing spring 180 may be part of the sides of rebar channel 162 or in combination with the bottom or any side of rebar channel 162. The biasing spring 180 may be integrally molded with the bottom or any side of rebar channel 162.
FIG. 20 illustrates an embodiment for a rebar clip latch mechanism having a track of [0106] teeth 190 along the interior of the rebar channel 162. In one embodiment, the track of teeth 190 are on each side of the rebar channel 162. The top portion of posts 164 have a curved opening for guiding rebar 151 into the rebar channel 162. The posts 164 on each side of channel 162 are flexible so that as the rebar 151 is inserted into the channel 162, the track teeth 190 adaptively engage the rebar 151 in multiple locations. As the rebar 151 engages the track teeth 190, the flexible posts 164 spread apart to allow the rebar 151 to click past the track teeth 190. The posts 164 flex from side to side so that the track teeth 190 frictionally engage the rebar 151. As a result, the rebar 151 has less of a tendency to move around in the channel 162 because the track teeth 190 frictionally engage the rebar 151. In an alternative embodiment, the track teeth may break away a sufficient amount to conform to the rebar 151 in order to more closely engage rebar 151 and therefore further reduce movement of rebar in channel 162.
FIG. 21 illustrates an embodiment having paddle latches [0107] 200 mounted on posts 164 of channel 162 at pivot points 201. The top portion of paddle latches 200 are initially spread open in the receiving position in order to accept rebar 151. As the rebar 151 is inserted past the pivot points 201 and into the rebar channel 162, the paddles latches 200 rotate inward. The posts 164 may spread apart in order to provide a gap between paddles 200 at pivot points 201 that is wide enough to allow rebar 151 to pass into rebar channel 162. Once the rebar 151 slides pasts the pivot points 201, the paddle latches 200 rotate inward. While the rebar 151 is inside the rebar channel 162, or when an attempt is made to remove the rebar from rebar channel 162, the rebar 151 makes contact with the paddle latches 200 below the pivot point 201. As a result, the rebar 151 is latched inside the cavity 200 until a force is applied on the rebar 151 to cause the paddles 200 to spread apart posts 164 and rotate paddle latches outward from channel 162 to remove rebar 151 from the rebar channel 162. In another embodiment, the paddle latches 200 have a biasing spring (not shown) for biasing the paddle latch 200 in a receiving position. In this position, the bottom portion of the paddle latch 200, or the portions of the paddle latch 200 within the rebar channel 162 are close together to prevent removal. In this configuration, the rebar 151 slides easily into the channel, however, the end portions of paddle latch 200 engage rebar 151 if an attempt is made to remove rebar channel 162.
FIG. 22 illustrates a latch mechanism similar to the latch described with reference to FIG. 21 with the addition of a [0108] snap ball 202 on paddles 204. In one embodiment, snap ball 202 is located near pivot points 201 to engage rebar 151 when rebar 151 is inserted into rebar channel 162. However, snap ball 202 may be located anywhere on paddle 204. The snap balls 202 assist in keeping the rebar 151 captive inside channel 162 by forcing the rebar 151 to frictionally engage the snap balls 202 as the rebar 151 slides past pivot points 201. The snap balls 202 may also function to apply an additional pinching force by spreading flexible posts 164 during insertion or removal of rebar 151 from rebar channel 162.
FIG. 23 illustrates a latch [0109] mechanism having paddles 206 and a toothed track 208 at the bottom end of the paddles 206 for engaging a detent 207. As the rebar 151 is inserted and engages the paddles 206, the paddles 206 begin to spread the flexible posts 164 apart as previously described with reference to the mechanism described in FIGS. 21 and 22. Once the rebar 51 is inserted past the pivot point 201, the paddles rotate inward causing the toothed track 208 to engage detent 207 so that each tooth clicks passed the detent 207 to latch toothed track 207. As the rebar 151 is inserted into channel 162 and the paddles 206 rotate inward, the top portion of the paddles rotate together in order to create a narrowed gap between the top portion of the paddles 206. The rebar 151 is captive inside the rebar channel 162 by the narrowed gap between the top portion of the paddles 206 and by the latching effect of the toothed track 208 being held by the detent 207. In one embodiment, the paddle is angled relative to the attached toothed tract 208 so that when the rebar 151 is inserted into the rebar channel 162 the top portion of paddles 206 creates a substantially closed gap. In another embodiment, the toothed track 208 may be integrated into the sides of the rebar channel 162 to form a right angle with paddles 206.
FIG. 24 illustrates a latch mechanism with [0110] angled barbs 210 formed along the interior of channel 162, clips 212 and inside posts 164. The angled barbs 210 are flexible in order to accommodate rebar 151 of different diameters and to assist the clips 212 to further reduce movement of the rebar 151 within the channel 162. In the embodiment shown in FIG. 24, the barbs 210 point into the barb channel 162 in order to permit insertion of rebar 151 into the channel. If an attempt is made to remove rebar 151 from the rebar channel 162, the barbs 210 frictionally engage the rebar 151 causing barbs 219 to bend thereby impeding removal of rebar 151 from rebar channel 162. Although FIG. 24 illustrates a latch mechanism similar to that as described with reference to FIG. 16 with the addition of angled barbs 210 formed along the interior of channel 162, the barbs 210 may be formed on any rebar clip shape or type.
FIG. 25 illustrates a latch mechanism similar to that described with reference to FIG. 19 but with the addition of an “L” shaped [0111] tip 214 at the bottom of paddle 216. Once the rebar 151 is inserted into channel 162, the “L” shaped tip 214 further reduces movement of rebar 151 inside channel 162. If an attempt is made to remove rebar 151, “L” shaped tips 214 will tend to rotate toward each other and move closer together. As tips 214 rotate together, the gap between “L” shaped tips 214 narrows to impede removal of rebar 151 from rebar channel 162. The length of the “L” shaped flange 214 is such that the “L” shaped tip 214 contacts rebar 151 when an attempt is made to remove rebar 151 from channel 162. Rebar 151 may be removed from channel 162 by spreading “L” shaped tips 214 and paddles 217 apart.
FIG. 26 illustrates a latch mechanism similar to the latch mechanism described with reference to FIG. 19 except the [0112] posts 164 have attached upwardly pointing U-shaped clips 220. The tips 218 of the upwardly pointing clips 220 as well as posts 164 spread open when the rebar 151 is inserted in order to allow the rebar 151 to pass into channel 162. Once the rebar 151 is inserted into the channel 162 and the clips 218 flex back, the gap between U-shaped clips 218 is reduced to a width less than the diameter of rebar 151. As a result, the rebar 151 remains captive in channel 162 after rebar 152 is inserted into channel 162. Posts 164 may be any size or shape in order to permit U-shaped clips 218 to flex sufficiently for permitting rebar 151 to slide into and out of rebar channel 162.
FIG. 27 illustrates a latch mechanism similar to the latch mechanism described with reference to FIG. 15 where the [0113] protrusions 224 have a rounded tip 222. The rounded tip 222 provides an additional detent as the rebar 151 is inserted or removed from the channel 162. The rounded tip 222 allows the rebar 151 to be inserted by snapping rebar 151 into channel 162. Once the rebar 151 has been inserted, the rebar 151 is held captive by the ends of flanges 224. Rebar 151 may be released by spreading flanges 224. A rounded tip may be located along an axis perpendicular to the axis of the protrusion. Alternatively, the rounded tip may be located on an axis that is parallel to the protrusion.
FIG. 28 illustrates a latch mechanism similar to the latch described with reference to FIG. 19, however, the entrance to [0114] barb channel 162 has angled pinching clips 170. As the rebar 151 is inserted and engages the pinching clips 170, the pinching clips 170 begin to spread. The angled pinching clips 170 may be flexible enough to spread open an amount sufficient enough to permit the rebar 151 to be inserted into the channel 162. As the rebar 151 is inserted into the channel 162, the upper ends of the barbs 170 help to guide the rebar 151 into the channel 162. The angled pinching clips 170 frictionally contact the rebar 151 when inserted. The angled pinching clips 170 then spread outward. Once the rebar 151 has passed through the angled pinchinig clips 170, the angled pinching clips 170 spring back to their normal position so that the opening created by the angled pinching barbs 170 is smaller than the diameter of the rebar 151. As a result, the rebar 151 is captivated inside the rebar channel 162. In one embodiment, if the rebar 151 is textured with, for example, a longitudinal, ribbed or cross-hatched pattern, the angled pinching clips 170 catch the rib on the rebar 151 in order to more securely captivate the rebar 151. The rebar 151 may be removed by spreading the flexible angled pinching clips 170 to a sufficient width for permitting the rebar 151 to be removed from barb channel 162.
FIG. 29 illustrates an embodiment of the latch with [0115] curved hooks 164 for latching the rebar 151 when inserted. The curved hooks 226 and posts 164 bend in order to permit the rebar 151 of different sizes to enter into the channel 162. However, once the rebar 151 is inside the channel 162, the curved hooks apply constant biasing pressure on rebar 151 to captivate rebar 151. In another embodiment, when rebar 151 is inside channel 162, the curved hooks 226 spring back to form a gap between the curved hooks 226 that is less than the diameter of the rebar 151. The rebar 151 remains captive inside the channel 162 because the gap between the curved hooks 226 is less than the diameter of rebar 151. As the removal force increases, the curved hooks 226 function together to apply a force to resist removal until curved hooks 226 bend and spread apart. As a result, the rebar 151 may be removed by spreading the curved hooks 226.
FIG. 30 illustrates a rebar clip latch mechanism similar to the latch mechanism described with reference to FIG. 29 with the addition of [0116] barbs 230 at the end of the curved hooks 228. The barbs 230 permit the rebar 151 to pass into channel 162, but the barbs 230 catch rebar 151 upon removal and further force curved hooks 228 toward each thus impeding removal of rebar 151.
FIG. 31 illustrates a rebar latch [0117] mechanism having prongs 252 that extend from post 164 to beyond the center of the rebar channel 162. The prongs 252 in another embodiment may also cross over each other where one prong 252 extends in front of the other prong 252, or alternatively, one prong may extend above or below the other prong 252. In yet another embodiment, prongs 252 are horizontal. In another embodiment the latch mechanism is similar to the latch mechanism described with reference to FIG. 29 except the crossing curved hooks 226 overlap when in the unlatched position. The crossing curved hooks 226 are flexible enough to permit the rebar 151 to pass into channel 162 by bending inward. Once inserted, the crossing curved hooks 226 spring back outwardly to keep the rebar 151 inside the rebar channel 162 by reducing the opening of the channel 162. In another embodiment, each spacer member 150 may be molded with one curved hook 226 on one side post 164 rather than both side posts 164 so that adjacent spacer members 150 have curved hooks on alternate posts.
The rebar clip and rebar channel may be formed on a [0118] spacer member 150 having 1, 3, 4, 5, 6 or more cross members. Spacer member 150 may have cross members other than upper 152 and lower 154 cross members described. For example, the cross members may be angled, or may cross over each other at one or more locations. In one embodiment, the spacer member has a single cross member with a rebar channel on one side of the cross bar. In another embodiment, the spacer member 150 may have a recess at the ends of the spacer member for sliding engagement with a fin on opposing connecting members.
Numerous modifications and variations of the latch form unit and mechanisms as described by the examples above may be made. For example, the latch mechanism may employ any combination of the barbs, clips, hooks, and paddles and the like. Therefore, other latch configurations not described above are contemplated. [0119]
Reversible Panel [0120]
According to another embodiment as shown in FIG. 32, a wall form unit comprises a pair of panels or [0121] side walls 20 a, 24 a, with an interconnecting member design (tread) 16 that is the same on both the top and bottom ends of the panel 20 a, 24 a. As a result, the panels 20 a, 24 a are reversible so that either end of the panel will interconnect with either end of a like panel.
The [0122] panels 20 a, 24 a may be generally parallel to each other, but may also be non-parallel depending on the wall structure required. Panels 20 a, 24 a are coupled together by tie assembly 104. Interconnection members 16 permit stacking and interconnection of compatible blocks for the construction of a wall.
The [0123] interconnection members 16 permit the stacking and interconnection of a plurality of like panels 20 a, 24 a or blocks for the construction of a wall or similar arrangement. The panels 20 a, 24 a may, in one embodiment, be assembled above and below each other in the same plane to construct a wall. The interconnection members 16 comprise a plurality of projections 18 and recesses (channels) 14 arranged in an alternating pattern. The projections 18 and recesses 14 may be substantially the same shape and of the same dimensions. The projections 18 and recesses 14 may be any shape or size such as a polygon. For example, the projections 18 and recesses 14 may have an octagonal shape as shown in FIG. 32. Examples of the various shapes for projections 18 and 14 are shown in FIGS. 36-42.
The [0124] interconnection members 16 on the top and bottom ends of the side walls 20 a, 24 a are substantially symmetrical, thereby permitting the interconnection of like blocks in a bi-directional and/or reversible member. In one embodiment, as shown in FIG. 32, the interconnection members 16 may be formed by two rows of alternating projections 18 and recesses 14. However, the number of rows may be greater than two, such as three, four, five, six, seven, eight, nine, ten or more. For example, the reversible corner block shown in FIG. 35 is shown with four rows of alternating projections 18 and recesses 14 although a different number of rows, and a different design for the projections 18 and recesses 14 may be used.
In one embodiment, if the end of a [0125] panel 20 a, 24 a has two or more rows, each projection 18 is adjacent to a recess 14, and each recess 14 is adjacent to a projection 18. Additionally, the interconnection member 16 of the top end of the panel 10, 12 is symmetrical with the interconnection member 16 of the bottom end of panel 10, 12. Such an arrangement permits the interconnection of like panel blocks in any orientation such as bottom to top, top to top, bottom to bottom, and top to bottom. As a result, the panel blocks 10, 12 are bi-directional as well as reversible. As a result, no special construction tools are needed to assemble a wall form unit using panels 20 a, 24 a. Additionally, because less time is required for assembly, the panels 20 a, 24 a are easier, cleaner and safer to assemble resulting in lower labor costs. In one embodiment, the panel 34 is made from an insulating material such as polystyrene or Styrofoam and provides insulation to the wall upon construction.
In another embodiment, the [0126] interconnection members 16 may also include a sealing member 22 in order to assist in preventing liquid concrete from leaking through the seams formed between adjacent panels 20 a, 24 a. In one embodiment, the sealing member 22 has a height less than the height of projections 18 although sealing member 22 may have a height equal to or greater than projections 18. The sealing member 22 is shown positioned between the two rows of projections 18 and recesses 14, however, the sealing member may be position on either or both sides of panels 20 a, 24 a.
FIG. 33 illustrates a [0127] single panel 34 according to another embodiment. The panel 34 comprises an interconnecting member 16 without a sealing member as shown in FIG. 32. As in FIG. 1, the interconnection members 16 comprise a plurality of projections 18 and recesses 14 arranged similarly to the interconnection member design 16 as shown in FIG. 1.
FIG. 34 illustrates a cross-sectional view of two like panel members A and B interconnected together to show an alternate embodiment of [0128] interconnection members 16. As shown in FIG. 34, a row comprising projection 18 and corresponding recess 14 has dimensions greater than the other three rows of projections 18 and recesses 14. However, the dimensions for two, or three rows of projections 18 and recesses 14 may have all have dimensions greater than one of the rows.
The arrangement of FIG. 34 does not show a sealing means although a sealing means may be provided, for example, between any row of [0129] projections 18 and recesses 14, or at either side of panel 20 a, 24 a. Although four rows of alternating projections 18 and recesses 14 are shown without a sealing means, any number of rows and any appropriate number of sealing members may be provided as previously stated.
FIG. 35 is a top plan view of a portion of a reversible corner block [0130] 10. In one embodiment, corner block 10 is a pre-molded corner form for use as either a left or right corner block. In order to reduce shipping costs, reversible corner blocks may be shipped nested. Additionally, the corner blocks are more quickly assembled since they are already in position for insertion of the tie assembly 104.
In another embodiment, corner block [0131] 10 includes projections 20 and channels 32 on the inside surface of side wall 10 to permit the mounting of blocks in a perpendicular fashion in addition to the co-planar bidirectional and reversible mounting. In yet another embodiment, corner block 10, and panels 20 a, 24 a also include linking elements 71 a as previously describe with reference to FIG. 1.
FIG. 36 shows a [0132] panel 20 a, 24 a where the projections 18 and recesses 14 are triangular. In another embodiment, the triangular projections are pointed at the end of projections 18 and recesses 14 to form a pyramid shape. In this embodiment, the pyramid shape allows easy attachment between panels 20 a, 24 a because exact alignment between panels 20 a, 24 a is not required when the panels 20 a, 24 a are initially inserted during assembly.
FIG. 37 shows a top view of [0133] panel 20 a, 24 a where the projections 18 and recesses 14 are triangular and where adjacent triangles are oriented 180 degrees apart from each other. As described with reference to FIG. 36, projections 18 and recesses 14 may have pointed ends in order to form pyramid shapes.
FIG. 38 shows a top view of [0134] panel 20 a, 24 a where the projections 18 and recesses 14 have a star shape. Although the star shape shown in FIG. 38 has five points, the star shape may have any number of points. As described with reference to FIG. 36, projections 18 and recesses 14 may have pointed ends in order to form pyramid shapes. Although the star shape in FIG. 38 has 10 sides, other configurations for a 10-sided polygon may be similarly used. Additionally, the shape of projections 18 and recesses 14 may be, but is not limited to a hemi-sphere, a pyramid, an arrow, a wave, a sinusoidal wave, a triangular wave, a square wave, a conical slice, and a cone.
FIG. 39 shows a top view of [0135] panel 20 a, 24 a where the projections 18 and recesses 14 have six sides (a hexagon). Although the polygon shown in FIG. 38 has six sides and points, the polygon may have any number of points. For example, projections 18 and recesses 14 may be a polygon that may be, but is not limited to being triangular, pentagonal, 7-sided, 9-sided, 10-sided, 11-sided, 12-sided, 13-sided, 14-sided, 15-sided, 16-sided, 17-sided, 18-sided, 19-sided, 20-sided, 21-sided, 22-sided, 23-sided, 24-sided.
FIG. 40 illustrates a perspective view of [0136] panel 20 a, 24 a where the projections 18 and recesses 14 are pyramids. As previously stated, the pyramid may have any appropriate number of sides, and may take on any appropriate shapes.
FIG. 41 shows a side view of one end of [0137] panel 20 a, 24 a where the projections 18 and recesses 14 form the shape of an arrowhead. In the exemplary embodiment shown, the projection 18 has five teeth, however, any number of teeth may be used. For example, the arrow head configuration may be as shown in FIG. 9 where the projection 18 has one tooth. In another embodiment, the teeth may be barbs, or the top portion of the projection 18 may have a barb. Alternatively, the top of the projection 18 may have a curved top, or a cornered top.
Numerous modifications and variations of [0138] projections 18 and recesses 14 as described by the examples above may be made. For example, FIG. 42 shows a perspective view of one end of panel 20 a, 24 a where the projections 18 and recesses 14 have a combination of shapes. In one embodiment the row of alternating projections 18 on one end of the panel 20 a, 24 a has a corresponding row of alternating recesses 14 on the opposite end of the panel. In the same embodiment, the alternating row of recesses 14 on one end of the panel 20 a, 24 a has a corresponding row of alternating projections 18 on the opposite end of the panel. Using this convention, the panel may be used with the top end either in the upright or up-side down position. Although eight different shapes are shown, any different number of shapes may be used. Further, all shapes do not necessarily have to be different, but may some shapes may be repeated. In one embodiment, certain shapes, such as the pyramids may be places on the corners of the top of end panel 20 a, 24 a in order to assist in aligning the panels during assembly.
In another embodiment as shown in FIG. 43, the two adjacent rows have a row of [0139] projections 18 and recesses 14 are symmetrical in reverse order so that the panel 20 a, 24 a may be reversed. The bottom of panel 20 a, 24 a would have the same shapes as shown on the top of panel 20 a, 24 a, but the projections 18 on the top side would have corresponding shaped recesses 14.
FIG. 44 illustrates one end of a [0140] panel 20 a, 24 a that is similar to the one shown in FIG. 43 except that the projection 18 shown in one row has a recess that is the same shape in the adjacent row. This configuration allows panel 20 a, 24 a to be reversible both from top to bottom. Additionally, panel 20 a, 24 a may be reversed so that either side of the panel 20 a, 24 a may form either the inside or outside of the panel. The bottom of panel 20 a, 24 a would have the same shapes as shown on the top of panel 20 a, 24 a, but the projections 18 on the top side would have corresponding shaped recesses 14 on the bottom side.

Claims

We claim:

1. A spacer member for maintaining first and second panels of a wall form unit in a predetermined relationship, each panel having a connecting member which has a row of teeth defining a T-shaped profile, said spacer member comprising:

opposing edges that are spaced apart by at least one arm member, each edge having a generally T-shaped profile configured for sliding engagement with a corresponding connecting member T-shaped profile, wherein the at least one arm member has at least one rebar channel on an upper surface thereof, wherein each rebar channel has an opening; and

at least one rebar clip formed on the opening of each rebar channel of the at least one arm member.

2. The spacer member of claim 1 wherein the at least one rebar clip comprises at least one protrusion pointing toward the rebar channel.

3. The spacer member of claim 2 wherein the at least one protrusion comprises a flexible barb.

4. The spacer member of claim 1 wherein the rebar channel comprises a biasing spring integrated into the rebar channel.

5. The spacer member of claim 2 comprising a tip on the protrusion wherein the tip is rounded.

6. The spacer member of claim 5 wherein the rounded tip is located along a same axis as the protrusion.

7. The spacer member of claim 5 wherein the rounded tip is located along an axis perpendicular to the axis of the protrusion.

8. The spacer member of claim 1 wherein the rebar clip comprises a flexible smooth sliding curved clip having hooked tips pointing away from the opening.

9. The spacer member of claim 8 wherein the at least one rebar channel comprises a plurality of barbs generally pointing into the rebar channel.

10. The spacer member of claim 1 wherein the at least one rebar clip comprises at least one angled barb, wherein the angled barb points into the rebar channel.

11. The spacer member of claim 1 wherein the at least one rebar clip comprises at least one double angled ridge pointing into the rebar channel.

12. The spacer member of claim 11 wherein the at least one double angled ridge breaks away partially when a rebar is inserted into the rebar channel.

13. The spacer member of claim 1 wherein the rebar clip comprises at least one inwardly pointing flexible u-shaped compression hook.

14. The spacer member of claim 1 wherein the rebar clip comprises at least one outwardly pointing flexible u-shaped hook.

15. The spacer member of claim 1 wherein the rebar clip comprises at least one tooth on a track attached to an interior surface of the rebar channel.

16. The spacer member of claim 1 wherein the at least one rebar clip comprises:

at least one post coupled to the at least one arm member to form the opening of the rebar channel; and

at least one paddle latch coupled to the at least one arm member mounted to each post at a pivot point.

17. The spacer member of claim 16 comprising a snap ball coupled to the paddle latch to engage a rebar upon insertion into the rebar channel.

18. The spacer member of claim 1 wherein the at least one rebar clip comprises:

at least one post coupled to the at least one arm member to form the opening of the rebar channel;

at least one paddle having a toothed track mounted to each post at a pivot point; and

at least one detent coupled to an interior surface of the rebar channel for engaging the toothed track.

19. The spacer member of claim 1 wherein the rebar clip comprises at least one flexible L hook having a tip wherein the tip of the L hook points toward the rebar channel.

20. The spacer member of claim 1 wherein the rebar clip comprises at least one flexible inwardly curved hook.

21. The spacer member of claim 20 wherein the at least one curved hook comprises at least one barb pointing into the rebar channel.

22. The spacer member of claim 20 wherein the at least one curved hook extends beyond a middle of the opening of the barb channel.

23. The spacer member of claim 20 wherein the flexible inwardly curved hook has a curled tip.

24. The spacer member of claim 1 wherein the rebar clip has at least one overlapping protrusion extending beyond a middle of the opening of the barb channel.

25. The spacer member of claim 1 comprising:

an abutment disposed at one edge of the spacer member and configured to prevent the spacer member from sliding out of the end of the connecting member-coupling,

wherein each edge has a generally T-shaped profile configured for attaching to the connecting member-coupling having a corresponding T-shaped profile.

26. A method for latching a rebar to a spacer member comprising:

inserting the rebar into a rebar clip formed on the spacer member, wherein the spacer member has at least one rebar channel with an opening, and wherein the rebar clip is formed on the opening of the rebar channel;

inserting the rebar into the rebar clip;

spreading apart at least one protrusion coupled to the rebar clip;

inserting the rebar into the rebar channel; and

retracting the protrusions back to an initial position.

27. The method of claim 26 comprising biasing the rebar inside the rebar channel with an integrated biasing spring.

28. The method of claim 26 wherein the protrusions point into the rebar channel forming a gap between the protrusions, the method comprising receiving the rebar upon insertion into the rebar channel.

29. The method of claim 26 comprising:

impeding removal of the rebar from the rebar channel by frictionally engaging the rebar with a tip of the protrusions.

30. The method of claim 29 comprising snapping the rebar into the rebar clip wherein the rebar tip has a rounded shape.

31. The method of claim 26 comprising sliding the rebar into the rebar clip wherein the rebar clip comprises outwardly curved clips.

32. The method of claim 26 comprising frictionally engaging the rebar with a plurality of barbs coupled to the rebar channel.

33. The method of claim 26 comprising frictionally engaging the rebar into a double angled ridge coupled to the rebar channel.

34. The method of claim 33 wherein the double angled ridges break away partially.

35. The method of claim 26 wherein the at least one protrusion comprises an inwardly pointing flexible u-shaped compression hook.

36. The method of claim 26 wherein the at least one protrusion comprises an outwardly pointing flexible u-shaped hook.

37. The method of claim 26 wherein the rebar clip comprises a track of teeth attached to an interior surface of the rebar channel and coupled to the at least one protrusion.

38. The method of claim 26 wherein the rebar clip comprises:

at least one post forming the opening of the rebar channel; and

at least one paddle latch mounted to each post at a pivot point.

39. The method of claim 38 comprising snapping the rebar into the paddle latch wherein a snap ball is coupled to the paddle latch.

40. The method of claim 26 wherein the rebar clip comprises:

at least one post forming the opening of the rebar channel;

at least one detent coupled to the rebar channel for engaging the toothed track.

41. The method of claim 26 wherein the rebar clip comprises at least one flexible L hook wherein a tip of the at least one flexible L hook points toward the rebar channel.

42. The method of claim 26 wherein the rebar clip comprises flexible inwardly curved hooks.

43. The method of claim 42 wherein the curved hooks comprise at least one barb pointing into the rebar channel.

44. The method of claim 42 wherein the curved hooks cross over each other substantially at a middle of the opening of the rebar channel.

45. The method of claim 42 wherein the flexible inwardly curved hooks have a curled tip.

46. A spacer member for maintaining first and second panels of a wall form unit in a predetermined relationship, each panel having a connecting member, said spacer member comprising:

opposing edges that are spaced apart by at least one arm member, each edge configured for engagement with a corresponding connecting member; and

at least one rebar clip formed on the arm member.

47. The spacer member of claim 46 wherein the at least one rebar clip comprises at least one protrusion.

48. The spacer member of claim 47 wherein the at least one protrusion comprises a flexible barb.

49. The spacer member of claim 47 wherein the at least one rebar clip comprises a biasing spring.

50. The spacer member of claim 47 comprising a tip on the at least one protrusion wherein the tip is rounded.

51. The spacer member of claim 46 wherein the at least one rebar clip is a flexible smooth sliding curved clip having hooked tips pointing away from each other.

52. The spacer member of claim 46 wherein the rebar clip comprises a plurality of barbs.

53. The spacer member of claim 46 wherein the rebar clip comprises at least one double angled ridge having inwardly pointing angles.

54. The spacer member of claim 46 wherein the rebar clip comprises at least one inwardly pointing flexible u-shaped compression hook.

55. The spacer member of claim 46 wherein the rebar clip comprises at least one outwardly pointing flexible u-shaped hook.

56. The spacer member of claim 46 wherein the rebar clip comprises at least one track of teeth.

57. The spacer member of claim 46 wherein the rebar clip comprises:

at least one post; and

at least one paddle latch mounted to each post at a pivot point.

58. The spacer member of claim 46 wherein the rebar clip comprises:

at least one post formed on the connecting member;

at least one detent coupled to the post for engaging the toothed track.

59. The spacer member of claim 46 wherein the rebar clip comprises at least one flexible inwardly pointing L hook having a tip wherein the tip of the at least one L hook points toward the rebar channel.

60. The spacer member of claim 46 wherein the rebar clip comprises at least one flexible inwardly curved hook.

61. The spacer member of claim 60 wherein the at least one curved hook comprises at least one barb.

62. The spacer member of claim 60 wherein the at least one curved hook crosses over substantially at a middle of the opening of the barb clip.

63. The spacer member of claim 60 wherein the flexible inwardly curved hook has a curled tip.

64. A tie assembly for a wall form unit, the tie assembly configured to connect first and second panels in spaced relation for containing a pourable, curable construction material to form a wall section, the tie assembly comprising:

first and second connecting members configured to be coupled to the first and second panels, respectively, each connecting member comprising at least one row of teeth defining a T-shaped profile;

a spacer member maintaining said first and second connecting members in the spaced relation, said spacer member having spaced apart, opposing ends, each opposing end having a T-shaped profile complementary to, and for sliding engagement with the corresponding connecting member row of teeth T-shaped profile, the spacer member comprising at least one rebar channel and rebar clip for latching a rebar; and

an abutment disposed on at least one of the opposing ends of said spacer member, to prevent said spacer member from sliding out of engagement with the corresponding connecting member.

65. The tie assembly of claim 64 wherein the rebar clip comprises at least one protrusion pointing toward the rebar channel.

66. The tie assembly of claim 65 wherein the at least one protrusion comprises a flexible barb.

67. The tie assembly of claim 64 wherein the rebar channel comprises a biasing spring integrated into the rebar channel.

68. The tie assembly of claim 65 comprising a tip on the protrusion wherein the tip is rounded.

69. The tie assembly of claim 68 wherein the rounded tip is located along a same axis as the protrusion.

70. The tie assembly of claim 68 wherein the rounded tip is located along an axis perpendicular to the axis of the protrusion

71. The tie assembly of claim 68 wherein the rebar clip comprises a smooth sliding curved protrusion having hooked tips pointing away from the opening.

72. The tie assembly of claim 71 wherein the rebar channel comprises a plurality of barbs generally pointing into the rebar channel.

73. The tie assembly of claim 64 wherein the rebar clip comprises at least one double angled ridge having inwardly pointing angles.

74. The tie assembly of claim 73 wherein the at least one double angled ridge breaks away partially when a rebar is inserted into the rebar channel.

75. The tie assembly of claim 64 wherein the rebar clip comprises an inwardly pointing flexible u-shaped compression hook.

76. The tie assembly of claim 64 wherein the rebar clip comprises an outwardly pointing, flexible u-shaped hook.

77. The tie assembly of claim 64 wherein the rebar clip comprises at least one track of teeth attached to an interior surface of the rebar channel.

78. The tie assembly of claim 64 wherein the rebar clip comprises:

at least one post to form the opening of the rebar channel; and

at least one paddle latch mounted to each post at a pivot point.

79. The tie assembly of claim 78 comprising a snap ball coupled to the paddle latch to engage a rebar upon insertion into the rebar channel.

80. The tie assembly of claim 64 wherein the rebar clip comprises:

at least one post to form the opening of the rebar channel;

81. The tie assembly of claim 64 wherein the rebar clip comprises at least one flexible L hook having a tip wherein the tip of the L hook points toward the rebar channel.

82. The tie assembly of claim 64 wherein the rebar clip comprises at least one flexible inwardly curved hook.

83. The tie assembly of claim 82 wherein the at least one curved hook comprises at least one barb pointing into the rebar channel.

84. The tie assembly of claim 82 wherein the at least one curved hook crosses over substantially at a middle of the opening of the barb channel.

85. The tie assembly of claim 82 wherein the flexible inwardly curved hook comprises a curled tip.

86. A form unit for containing concrete comprising:

a first and second panel each having a top and a bottom end;

at least two rows of alternating octagonal projections and channels, wherein said projection of one row is adjacent said channel of another row, and wherein said channel on said top end is opposed to said projection on said bottom end, wherein the top end of the first and second panel is interconnectable with either the top end or the bottom end of a like panel, and the bottom end of the first and second panel is interconnectable with either the top end or the bottom end of a like panel; and

at least one connecting member configured to be coupled to the first and second panels in a spaced relation.

87. The form unit of claim 86 wherein said projections and channels being substantially the same dimension.

88. The form unit of claim 86 wherein said projections and channels for one row have substantially different dimensions than said projections and channels for another row on the panels.

89. The form unit of claim 86 wherein the panels are stackable insulating foam panels to form a wall section.

90. The form unit of claim 86 wherein said at least one row being disposed between two coplanar edge surfaces.

91. The form unit of claim 86 wherein a first row corresponds to a projection having a height and a channel having a depth that is substantially different than a height for a projection and a depth for a channel corresponding to a second row.

92. The form unit of claim 91 comprising at least one middle row and two opposite end rows, wherein said height for said projection and said depth for said channel at said at least one middle row is greater than said height for said projection and said depth for said channel at the end rows.

93. The form unit of claim 86 wherein the alternating octagonal projections and channels have a top portion shape selected from the group consisting of a wedge, an arrow head, at least one tooth, a cornered top, a curved top, and a barbed top.

94. The wall-forming panel of claim 86 wherein the panel is a reversible corner block.

95. A wall-forming panel having a top and a bottom end comprising:

at least two rows of alternating octagonal projections and recesses, wherein said projection of one row is adjacent said recesses of another row, and wherein said recess on said top end is opposed to said projection on said bottom end, wherein the top end of the panel is interconnectable with either the top end or the bottom end of a like panel, and the bottom end of the panel is interconnectable with either the top end or the bottom end of a like panel.

96. The wall-forming panel of claim 95 comprising a second wall-forming panel in spaced relation to the first panel to form a wall unit.

97. The wall-forming panel of claim 95 wherein the wall-forming panel is coupled to adjacent substantially coplanar like panels.

98. The wall-forming panel of claim 95 wherein said projections and recesses for all rows being substantially the same dimension.

99. The wall-forming panel of claim 95 wherein said projections and recesses for one row have substantially different dimensions than said projections and recesses for another row on a panel.

100. The wall-forming panel of claim 95 wherein at least one row being disposed between two coplanar edge surfaces.

101. The wall-forming panel of claim 95 wherein the panel is a reversible corner block.

102. The wall-forming panel of claim 95 comprising at least one middle row and two opposite end rows, wherein said height for said projection, and said depth for said recess at said at least one middle row, is greater than said height for said projection, and said depth for said recess at said end rows.

103. The wall-forming panel of claim 102 wherein said projections and said recesses for the middle row have substantially greater dimensions than said projections and said recesses for said end rows.

104. The wall-forming panel of claim 95 wherein the alternating octagonal projections and channels have a top portion shape selected rim the group consisting of a wedge, an arrow head, at least one tooth, a cornered top, a curved top, and a barbed top.

105. A wall-forming panel having a top and a bottom end comprising:

at least one row of alternating octagonal projections and recesses, wherein said recess on said top end is opposed to said projection on said bottom end, wherein the top side of the panel is interconnectable with either the top end or the bottom end of a like panel and the bottom side of the panel is interconnectable with either the top end or the bottom end of a like panel.

106. The wall-forming panel of claim 105 further comprising another wall-forming panel in spaced relation to the other panel to form a wall unit.

107. The wall-forming panel of claim 105 wherein the wall-forming panel is coupled to adjacent substantially coplanar like panels.

108. The wall-forming panel of claim 105 wherein said projections and recesses being substantially the same dimension.

109. The wall-forming panel of claim 105 wherein said projections and recesses for one row have substantially different dimensions than said projections and recesses for another row on said panel.

110. The wall-forming panel of claim 105 wherein said at least one row being disposed between two coplanar edge surfaces.

111. The wall-forming panel of claim 105 wherein the alternating octagonal projections and channels have a top portion shape selected from the group consisting of a wedge, an arrow head, at least one tooth, a cornered top, a curved top, and a barbed top.

112. The wall-forming panel of claim 105 wherein the panel is a reversible corner block.

113. A wall-forming panel having a top and a bottom end comprising:

at least one row of an interconnecting design comprising projections and recesses, wherein said recess on said top end is opposed to said projection on said bottom end, wherein the top end of the panel is interconnectable with either the top end or the bottom end of a like panel, and the bottom end of the panel is interconnectable with either the top end or the bottom end of a like panel;

wherein the interconnecting design is selected from the group consisting of a; triangular, pentagonal, hexagonal, 7-sided, 9-sided, 10-sided, 11-sided, 12-sided, 13-sided, 14-sided, 15-sided, 16-sided, 17-sided, 18-sided, 19-sided, 20-sided, 21-sided, 22-sided, 23-sided, 24-sided, a hemi-sphere, a pyramid, an arrow, a wave, a sinusoidal wave, a triangular wave, a square wave, a conical slice, and a cone.

114. The wall-forming panel of claim 113 wherein the interconnecting design of all projections and recesses on the panel is the same.

115. The wall-forming panel of claim 113 wherein each recess and opposing projection has a complementary shape pairing, wherein the interconnecting design comprises two or more different interconnecting design pairings on said at least one row.

116. The wall-forming panel of claim 113 wherein the wall-forming panel is coupled to adjacent substantially coplanar like panels.

117. The wall-forming panel of claim 113 wherein said projections and channels being substantially the same dimension.

118. The wall-forming panel of claim 113 wherein said projections and recesses for one row have substantially different dimensions than said projections and recesses for another row on said panel.

119. The wall-forming panel of claim 113 wherein at least one row being disposed between two coplanar edge surfaces.

120. The wall-forming panel of claim 113 wherein the alternating octagonal projections and channels have a top portion shape selected from the group consisting of a wedge, an arrow head, at least one tooth, a cornered top, a curved top, and a barbed top.

121. The wall-forming panel of claim 113 wherein the panel is a reversible corner block.

122. A method for constructing a concrete structure, comprising:

disposing at least two panels having a top and a bottom end to create a form cavity;

interconnecting the top end or the bottom end of one panel with either the top end or the bottom end of another panel, said panels comprising at least one row of alternating octagonal projections and recesses, wherein said recess on said top end is opposed to said projection on said bottom end; and

pouring concrete into the form cavity.

123. The method of claim 122 wherein said projections and recesses being substantially the same dimension.

124. The method of claim 122 wherein said projections and recesses for one row have substantially different dimensions than said projections and recesses for another row on a panel.

125. The method of claim 122 comprising stacking two or more panels to form a wall section.

126. The method of claim 122 wherein said at least one row being disposed between two coplanar edge surfaces.

127. The method of claim 122 wherein the alternating octagonal projections and channels have a top portion shape selected from the group consisting of a wedge, an arrow head, at least one tooth, a cornered top, a curved top, and a barbed top.

128. The method of claim 122 wherein the wall-forming panel is coupled to adjacent substantially coplanar like panels.

129. The method of claim 122 wherein said projections and recesses for one row have substantially different dimensions than said projections and recesses for another row on said panel.

130. The method of claim 122 comprising at least one middle row and two opposite end rows, wherein said height for said projection and said depth for said recess at said at least one middle row is greater than said height for said projection and said depth for said recess at said end rows.

131. The method of claim 122 comprising inserting at least one tie assembly configured to be coupled between two panels in a spaced relation.

132. The method of claim 122 comprising interconnecting said panel with a like panel in a bidirectional or reversible manner.

133. The method of claim 122 comprising delivering the panels in flat bundles.

134. The method of claim 122 wherein the panel is a reversible corner block.

135. The method of claim 134 comprising shipping said reversible corner block nested.