Improvements in a stackable construction panel system

The present invention relates to a wall mold for filling with a liquid material, comprising a pair of foam plates and a set of wall molds.

The present invention generally relates to stacked wall forms having pairs of opposing plates for filling with fluid material such as concrete. More specifically, it relates to improvements in such face forms.

There are now many different systems and methods for making insulating molds for pouring a concrete wall. Often, such systems consist of pairs of opposing foam plates, usually made of polystyrene, which form recesses between them for concrete filling. These pairs of foam plates are placed on top of each other to form a stack of wall forms. After the concrete has set, the assembled wall forms remain in place to insulate the wall. Prior to pouring concrete, the opposing foam boards are usually held parallel to each other by fasteners each having a pair of parallel lateral attachment arms embedded in the respective foam slabs and a web joining the limbs.

The stacking of such boards is carried out at the construction site. It is desirable to use wall forms in this field which allow, on the one hand, easy and very quick stacking without wasting time, and, on the other hand, make it possible to build a stable and durable stack that cannot be accidentally disassembled before pouring concrete. As is easy to understand, once poured with concrete, the chances of the pile collapsing or disassembling are greatly reduced.

For example, wall forms and building foam boards of the type discussed above are disclosed in Canadian Public Patent Applications Nos. 2,292,865 and 2,312,158, both on behalf of the assignee of this application. Other examples of an insulating building board are shown in US Patent Nos. 3,895,469; 4,229,920; 4,704,429; 4,884,382; 4,885,888; 4,894,969 and 5,428,933.

The object of the present invention is to propose an improved stackable foam board that allows a stable and durable stack to be constructed more easily.

The wall form for filling with liquid material comprises a pair of foam plates each having opposite upper and lower surfaces and a connector for binding the foam boards together spaced apart and parallel in the longitudinal direction, the connector comprising a pair of longitudinal anchors each it is embedded longitudinally inside the appropriate one of the foam boards, and each such anchor member has two opposite ends and a head portion extending longitudinally from each of the ends, the head portion having an end surface extending transversely and along a portion of the top or bottom surface of the respective foam board, and the connector further comprises a connecting member for joining. pairs longitudinally anchoring members together.

The essence of the invention is that each of the top and bottom wall surfaces of each of the foam boards has alternating protrusions and depressions, each head portion being seated in one of the protrusions.

Preferably, each head portion is shaped such that its end surface is adapted to extend along the surface of the top or bottom wall.

Preferably, the head portions of each anchoring member are mirror symmetrical to each other.

Preferably, in each foam board, each projection of the top wall surface faces a depression in the bottom wall surface, and each depression of the top wall faces a projection of the bottom wall.

Preferably, each head portion has an L-shaped portion with a transverse arm forming the end surface and a longitudinal arm connecting the transverse arm to the end of the anchoring member from which the head portion protrudes.

Moreover, the invention relates to an assembly of wall forms, characterized in that it comprises a plurality of vertically stacked wall forms.

Preferably, the end surfaces of the adjacent upper and lower wallforms extend along the lower wall surfaces of the foam panels of the upper wallform and rest on the end surfaces extending along the surface surfaces of the upper foam panels of the lower wallform.

Other features and objects of the present invention will be better understood from the following description of a preferred embodiment with reference to the accompanying drawings, which are only examples of how the invention can be put into practice.

The subject of the invention is shown in the drawing, where:

Fig. 1 is a fragmentary perspective view of an assembly of mold walls in accordance with the preferred embodiment of the present invention;

Fig. 2 is a perspective view of the connector according to the preferred embodiment of the invention, shown without its right anchoring member and part of the diaphragm;

Figure 3 is a partially transparent side view of a portion of the connector of Figure 2;

Fig. 4 is a section of the mold wall assembly of Fig. 1;

Fig. 5 is a plan view of a corner mold wall unit having an angle of 90 [deg.] according to a preferred embodiment of the invention, and Fig. 5A is an enlarged side view of the end wall form of Fig. 5;

Figure 6 is an enlarged top view of a portion of the wall unit of the corner mold of Figure 5;

Fig. 7 is a plan view of a corner mold wall unit having an angle of 45 [deg.] according to a preferred embodiment of the invention.

Fig. 1 shows a mold wall assembly 10 which serves to form a mold for a fluid material such as concrete etc. The assembly 10 includes a plurality of stackable, insulating horizontal rows of wall forms 11 each formed of coplanar and substantially rectangular shapes. foamed plastic plates 14A, 14B. The plates 14A, 14B of adjacent wall forms 11 abut against each other along their vertical and horizontal sides.

Each wall mold 10 includes a first foam board 14A and an opposing second foam board 14B spaced apart and connected to each other by a plurality of connectors 16. The foam boards 14A, 14B are movable between the spaced position shown in FIG. 1, wherein the foam boards are 14A, 14B are spaced apart to form a wall form , and in a collapsed position, not shown, in which the foam plates 14A, 14B are positioned close to each other mainly for transportation.

In use, when the wallform assembly to be filled with fluid material is assembled using a plurality of stacked horizontal rows of wallforms, the cavity existing between the plates 14A, 14B is filled with concrete or cement-based mortar. After the filler material has hardened, a composite wall is obtained with the insulating plates rigidly connected by fasteners to the internal concrete wall.

Each foam board 14A, 14B has an upper surface 15 opposite to the lower surface 17, each preferably having a central row 13 of alternating protrusions and depressions 19 of similar complementary shape. This middle row 13 is located between two coplanar edge surfaces 50 delimiting the edges of the plates 14A, 14B. These coplanar edge surfaces 50 preferably have a width sufficiently large to provide increased stability between the joined plates 14A, 14B.

Each protrusion 18 or recess 19 on the top face 15 of one panel 14A is positioned respectively opposite the recess 19 or protrusion 18 of the bottom face 17 of the same panel 14A and faces respectively the recess 19 and protrusion 18 of the top side 15 of the second panel 14B when pairs plates 14A and 14B are in the extended position shown in Fig. 1. It is understood that thereby the pair of plates 14A, 14B can advantageously be coupled to a similar pair of plates with any of its opposing surfaces 15, 17 acting as top or bottom wall surfaces.

Mainly because of the manufacturing process, the projections 18 and recesses are generally rectangular in the preferred embodiment. However, protrusions and depressions of other shapes, such as circular, oblong, square, etc., may also be used. Moreover, in order to avoid damaging the protrusion 18, the present invention preferably uses protrusions 18 with rounded corners. However, projections 18 with angled corners or other shapes would still be effective. Preferably, the projections 18 and recesses 19 each have two opposing substantially convex side surfaces 52, 53 which facilitate the insertion of the protrusions 18 into the recesses 19.

Figures 2, 3 and 4 show in detail parts of a connector 16 according to a preferred embodiment of the present invention. The connector 16 includes a pair of anchoring members 20A, 20B respectively embedded in the first and second foam plates 14A, 14B. Each anchor member 20A, 20B has an extended flange plate 22 extending longitudinally and deeply within the respective foam plate 14A or 14B and an elongated connecting member 24 attached longitudinally to the flange plate 22. The joining element has a projecting end 26 extending from the foam board 14A, 14B. Preferably, the projecting end 26 of each anchor member 20A, 20B includes a stabilizing plate 28 parallel to the flange plate 22 and extending flush with the inner surface 30 of the respective foam plate 14A or 14B when seated therein, as shown in Fig. 4.

PL 210 431 B1

The stabilizing plate 28 of each anchor member 20A, 20B preferably has an upper end 54 and a lower end 56, each having a fastening member 58 for engaging the anchoring member 20A or 20B with a mating anchoring member 20A or 20B of the adjacent wall form 11. More preferably, the fastening member 58 is a hook-type fastening element formed on stabilizing plate 28 with its end extending from the corresponding end of stabilizing plate 28. The upper end fixing member 58 of the stabilizing plate 28 is preferably symmetrically mirrored with the lower end fixing member 58 of the stabilizing plate 28 as best shown in Figs. 2 and 4 and has a side provided with sharp teeth intended to engage the sharp teeth of the mating member. anchoring member 20A, 20B. Advantageously, such an embodiment allows the use of the connector 16 so that each end may be an upper end or a lower end, which greatly facilitates the handling of the wall form on construction sites.

To make the assembly of foam panels lighter, interconnection member 24 preferably has a plurality of openings 25 extending along it. However, interconnection member 24 may also be full-flush.

It should be noted that, saying that the anchoring members 20A, 20B are embedded in the foam plates 14A, 14B, it is understood by those skilled in the art that when manufacturing the foam plates 14A, 14B in a factory, the foam plastic for the plates 14A, 14B is preferably injected to surround the plates 14A, 14B. the anchoring members 20A, 20B, thereby reinforcing the connection between the plates 14A, 14B and the anchoring members 20A, 20B, which therefore act as an anchoring portion of the foam plates 14A, 14B. More specifically, foamed plastic, which preferably is polystyrene or any other material known to those skilled in the art of foamed plastics, is injected to surround the anchoring members 20A, 20B.

The connector 16 further includes a web-shaped connecting member 32 extending between the foam plates 14A, 14B. This connecting member 32, which is preferably made of relatively flexible plastic, has a central portion 44 shaped to fasten and hold the metal bars used to reinforce the concrete. The connecting member 32 further has a first long side end 34A hingedly connected to a projecting end 26 of the first anchoring member 20A and a second long side end 34B opposite the first long side end 34A. The second long side end 34B is hingedly connected to the projecting end 26 of the second anchor member 20B. The foam plates 14A, 14B are thus movable between the extended position shown in Fig. 1, wherein the foam boards 14A, 14B are spaced apart to form a wall-shaped form 11, and a folded position, not shown, in which the foam boards 14A, 14B are brought close together, mainly for transportation.

The connecting member 32 is preferably symmetrical in shape so as to receive and hold the metal bars used to reinforce the concrete in the reversible positions of the wall mold 11. The wall mold 11 can therefore be turned upside down and will still serve to secure and hold the metal rods in the upper grooves. 33, connecting member 32.

A plurality of connecting members 64 are preferably positioned on the stabilizing plate 28 of the projecting end 26 of each anchoring member 20A, 20B to articulate the connecting member 32 to the anchoring members 20A, 20B. Each of these interconnecting members 64 is shaped to form two aligned ridges 66 extending from the stabilizing plate 28 and the space therebetween forms an elongated sleeve 68. A connecting pin 70 may be mounted in the sleeve 68. Preferably for this purpose, pin-receiving holes 71 are provided in the ridges 66, each of which faces the inside of the sleeve 68. The connecting member 32 is preferably made by molding plastic and the connecting pin 70 is permanently seated in the ridges 66.

Each end 34A, 34B of the linking member 32 has a suitable number of legs 72 for interacting with connecting members 64. For example, three arms 72 may be used in a symmetrical connecting member 32. Each arm 72 end 74 connected to a respective connecting pin 70 so as to be pivotable about an axis formed by a connecting pin 70. It can be readily seen that this object can be achieved either by mounting the end 74 of the arm 72 rotatably about the connecting pin 70, or by mounting the connecting pin 70 rotatably in the holes 71 receiving the pin. Preferably, end 74 of each arm 72 has a hole 76 for one of the pins 70.

As will be readily understood by those skilled in the art, connecting members 64 may be made directly by molding during manufacture of the anchoring members 20A, 20B. In the example shown in Figures 2 and 3, the protrusion 78 is produced by a molding process on each side of the ridges 66.

PL 210 431 B1

It will be understood that although the connecting members 64 are formed as aligned ridges 66, the present invention accepts other types of connecting members that would be apparent to those skilled in the art, such as split tube joints. In such an alternative embodiment, the interconnecting member 32 may be preferably removed from the respective anchoring member 20A or 20B. Such a solution is shown, for example, in Fig. 6 for a corner fitting as will be explained below. To articulate connecting member 32 to anchor members 20A or 20B, a connector 16 is provided with a plurality of aligned tube split joints 360 disposed on stabilizing plate 28, each tubular joint 360 defining an inner tube with two longitudinal opposite edge portions. forming a slot 365 aligned with slots in other joints 360. The connecting member 32 has two longitudinal side ends each having an enlarged end portion 370 dimensioned to be slidably inserted into open tubular joints and a band portion 375 connecting the enlarged end portion 370 to a central portion of the connecting member 32.

Still with reference to Figures 2, 3 and 4, each anchor member 20A, 20B has two opposite ends 90, 92 from which a head portion 35 extends longitudinally. Preferably the head portions 35 are attached to the upper and lower ends 90, 92 of the flange plate 22 of the respective anchoring member 20A or 20B. Each head portion 35 has an end face 36 extending transversely. Preferably, each head portion 35 has an L-shaped portion defining a transverse arm defining an end face 36 and a longitudinal arm 38 connecting the transverse arm 36 to an end 90 or 92 of anchoring member 20A or 20B from which the head portion 35 extends.

When the connector 16 is embedded in the foam plates 14A, 14B to form the wall form 11, each head portion 35 is preferably aligned and seated in the plate projection 18, as best shown in Fig. 4, and covers half of the top and bottom. end 90,92 of flange plate 22 as best shown in Fig. 2. The other half of the ends of flange plate 22 correspond to a recess 19. Preferably, the end surface 36 of the head portion 35 extends flush with the respective upper or lower surfaces 15, 17 of the projection 18.

Preferably, the head portion 35 of the upper end 90 of the member is mirror symmetrical to the head portion 35 of the lower end 92 of the respective flange plate 22 and with the head portion 35 at the upper end 90 of the flange plate 22 of the second anchoring member. Thereby, the link 16 can be inverted or pivoted in any direction and still be used properly when positioned correctly between the projection 18 and the recess 19.

The head part 35 has two main tasks. First, the head portion 35 helps to support the weight of the entire mold wall set 10 when pouring concrete into the mold wall set 10. In fact, testing has shown that without the head portion 35, the mold wall assembly 10 tends to bend in height after pouring concrete by as much as about 5 cm (2 inches).

Second, the head portion 35 facilitates the stacking of the wall forms 11 on top of each other. In fact, without the head portion 35, it is difficult for a worker to push the first face form 11 onto top of the second face form 11 to properly engage them. When using the head portions 35, the worker may hammer or press against the end face 36 of the head portion 35 to more easily assemble the face molds 11 together.

End-plate assembly 101 is intended to mount the end plate 102 at the side ends of a wall-mold assembly 10. The end plate may for example only be used to close the side ends of the wallform assembly 10 and confine concrete in the structure formed by the wallform when poured. Preferably, the end plate 102 is also used as a wall stud to form, for example, a frame for a window, door, etc.

End plate assembly 101 includes an end plate 102 and a mounting device 103 for attaching the end plate 102 to an end side wall form 11. The end plate 102 is preferably made of wood, e.g. a set of 10 longwall forms. The foam plates 14A, 14B of the wall mold 11 are flush with the side ends 108A, 108B to which the mounting device 103 is attached. Such mounting device includes first and second engagement members 100A, 100B that are releasably engageable with respective portions 108A, 108B of the side end of the plates 14A, 14B.

Preferably, the first and second engaging members 100A, 100B each form an end opening sleeve 108A, 108B of the respective foam plate 14A, 14B and are made of a resilient material such as plastic. The couplers 100A, 100B are shaped in accord

PL 210 431 B1 with the shape of the side end portions 108A, 108B of the foam plates 14A, 14B and are simply mounted thereon by resiliently compressing the foam plates. In the illustrated embodiment, each foam plate 14A or 14B has longitudinal ridges 110 extending along its inner surface 112, i.e. the surface facing the opposing foam plates 14B or 14A, and each engaging member is provided with respective channels 14 engaging each ridge 110.

The mounting device 103 also includes mounting means for longitudinally mounting the end plate 102 between the first and second coupling members 100A, 100B when they engage the end portions 108A, 108B of the pair of foam plates. For example, the mounting elements may be mounted through first and second support portions 104A, 104B, which respectively extend from the first and second engagement members into the pair of foam plates 14A, 14B. As shown in Fig. 5, the two support portions 104A, 104B may define a path for slidably receiving the end plate 102. Screws 106 or any other suitable type of fastening means preferably secure the end plate 102 to the support portions 104A, 104B. The mounting elements according to the present invention are not limited to the above-described embodiment, however. For example, instead of forming a track, the first and second projecting portions may simply form walls on which the end-plate is permanently attached. In another embodiment, in place of the two supporting parts, a single member may be used connecting the two engaging members together to form either a wall or a track.

Figures 5-7 show the present invention relating to wall forms used for corners. The corner is formed by two longitudinally continuous sections 14A, 14A 'of foam board. In the embodiment of Figs. 5 and 6, the plate sections 14A, 14A 'form a right angle, and in the embodiment of Fig. 7, they form an angle of 45 degrees. Of course, any other suitable angular spread between the two plate sections 14A, 14A 'may be contemplated within the scope of the present invention.

A connector 16 is provided inside the corner to strengthen the corner wall. The connector 16 comprises two anchoring members 20A, 20B, each of which is embedded longitudinally in one of the sections 14A, 14A 'of the foam board. The connecting member 32 longitudinally connects the two anchor members 20A, 20B to each other. The anchoring members 20A and 20B and the connecting member 32 may be of the same structure as the connector 16 described above, or alternatively, connectors of a different design may be used.

In a preferred embodiment, the connecting member 32 is preferably hingedly connected to each side of the respective anchoring member 20A or 20B by using slotted tube joints 360 as described above. This arrangement is advantageous as it allows the connection member 32 to be easily removed to bring the wallform to the collapsed position and then reattach it to the construction site. Other types of joints, articulated or otherwise, can also be used. The interconnecting member 32 may be removable from the anchor members 20A, 20B or rigidly attached thereto.

It should be noted at this point that the corner wall form may advantageously have connectors with removable connecting members on only one side of the corner as shown in Figs. 5 and 7, and all the connectors on the other side have, for example, articulated connecting members as shown in Fig. 2 and 3. This particular solution still makes it possible to bring the corner wall form into its folded state for transport while limiting the number of slotted tube joints, which are the most expensive to manufacture.

While preferred embodiments of the invention have been described in detail and illustrated in the accompanying drawings, it should be understood that the invention is not limited to these particular embodiments and that various changes and modifications may be made without departing from the scope or spirit of the invention as set forth in the appended claims.