Note: Descriptions are shown in the official language in which they were submitted.
CA 02209251 2000-09-06
r ~ r
2
FORM SYSTEM
Field of the Invent: ion
This in~~ention relates to form systems used to construct
structural components_such as walls.
Background A:rt
Constru~~tion components, such as walls and columns, are
often made from castable materials such as concrete. As is
well known, too make a specifically shaped component from such
materials, a form is built or erected which functions as a
mould for the cast:able 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 (eg. concrete) in a
liquid form. The concrete is then poured or otherwise fed
into the cavity crE:ated 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 rlaterial can not be reused and must be discarded.
Furthermore, the r~amoval of the form requires a significant
amount of labour.
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 =_ndivid.ual form units are not too small, enhanced
CA 02209251 2000-09-06
w r
3
efficiency i:z the construction of a form may be achieved in
such a systE:m. This is particularly the case if the form
units are designed to remain permanently in the situ, 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 side walls 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 metres in length and several metres in
height. Thia wil.1 require many form units that must be held
together. Particularly in forms which are high, the vertical
interconnect__ons between adjacent form units are important as
they resist vertical lift forces that tend to lift and
separate adj,3cent form units.
However, providing interconnections between form units
which are ei=fective, 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 l.ransported to the construction site.
CA 02209251 2000-09-06
4
Summary of the Invention
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 therethrough; at least one tie member, said tie
member comprising a spacer member having first and second
ends, said s.oacer rnember 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 posit_Loned away from said inward facing surface
1$ of said second panel and proximate said outward facing surface
of said second panel, said tie member having a first
attachment me=_ans providing an attachment of said spacer member
to said first un:Lt~ connecting member through said first
opening in said second panel; said first and second unit
connecting nembers 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 i:> 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 spa~~ed apart panels each having an opening
therethrough, said kit comprising, in combination: a plurality
of elongated spacer members, each said spacer members, having
CA 02209251 2000-09-06
first and ~;econd ends, first and second elongated unit
connecting members, each said spacer member having a first
connecting dE=_vice 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,
5 therebetween, through said opening in said first panel; and
said spacer :member having a second connecting member located
proximate sa_Ld second end adapted to co-operated with a second
connecting member to establish a second connection,
therebetween,, though said second opening in said second panel;
said first and sec:c>nd 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 wii;h one of said first and second connecting
members of a second form unit, and said second unit connecting
member of said fir~~t form unit to be connected with the other
said first and second connecting members of said second form
unit, when :>aid panels of said first form unit are placed
above in transverse alignment and abutment with respective
panels of said second form unit.
Accordi:zg 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 therethrough;
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
CA 02209251 2000-09-06
6
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 :aid first connecting member through said
first opening in ~~aid 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 mans of a second form unit to provide to a first
connection between said first form unit and said second form
unit when sa__d panels of said first form unit are placed above
IS 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 pane:Ls of said second form unit.
Brief Description of the Drawings
In drawings which illustrate example embodiments of the
invention:
Figure 1 ins a perspective view of a form unit made in
accordance with one embodiment of the invention;
CA 02209251 2000-09-06
7
Figure 2 is a front, elevation view of part of the form unit
of Figure l;
Figure 3 is a plan view of part of the form unit of Figure i;
Figure 4 is a plan view of the connection between the tie
member and connecting member shown in Figure 1;
Figure 5 is ,~ perspective view showing the connection between
the tie member and connecting member shown in Figure 1;
Figure 6 is a detailed view showing a connection made between
two vertically adja cent connected wall-forming units;
Figure 7 is a plan view from above along the line 7-7 in
Figure E;
Figure 8 is plan view of the detail in Figure 6 along the line
8-8 1T1 Figure 6;
Figure 9 is a similar view to Figure 6 showing a connection
made between two vertically adjacent connected wall-forming
units;
Figure 10 is a schematic side elevational view of part of a
complete form constructed in accordance with an embodiment of
the invention.
Figure 11 is a schematic elevational view of part of a form
constructed ~_n accordance with an embodiment of the invention.
CA 02209251 2000-09-06
8
Description of the Preferred Embodiments
- With reference to Figure 1, a single form unit 20a is
illustrated. In the construction of a structural component,
for example a wall, several such form units 20a are utilized.
Wall form units 20a are placed adjacent to, and in lateral
alignment with, other form units to make a complete form
structure, as illustrated in Figure 10.
A single form unit 20a has a pair of spaced, generally
planar and transversely aligned panel members 22a and 24a. In
one embodiment, panel members 22a and 24a 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 rnaterial.
In Figure l, panel unit 20a is shown with a single tie
member 26a in detail. However, to provide greater stability
for a form unit, a pair of tie members 26a and 28a may be
employed.
As shown in Figures 2 and 3, each tie member 26a
comprises three components: a transversely oriented spacer
member 30a and a pair of vertically oriented unit connecting
members 34a and 36a. In Figures 2 and 3, the form unit 20a,
including the tie member 26a, is shown in its disassembled
state. However, spacer member 30a may be easily attached to
vertical unit connecting members 34a and 36a in the manner
hereafter described. In one embodiment of the invention,
spacer member 30a has a recess extending substantial ly the
full vertical length of the spacer member, as is clearly
' CA 02209251 2000-09-06
9
illustrated :by a top view in Figure 4. Spacer member 30a,
and elements 34a and 36a, are made from a material such as
polypropylene, nylon 6/6, PVC or A.B.S.
Spacer member 30a also has an indentation 62a on the
upper transverse arm 63a of the spacer member 30a and an
indentation G4a on the lower transverse arm 65a of the spacer
member 30a, ~slthoudh other embodiments of this invention may
have a plurality of such indentations. Each indentation 62a
and 64a is adapted to be able to receive, and support at that
location, a concrete strengthening material such as steel
rebar 61. It: will ;oe appreciated that when several form units
are arranges: laterally adjacent to each other, lengths of
rebar may be supported laterally on the indentations 62a and
64a of successive laterally positioned form units. To assist
in the insertion a:nd retention of the lengths rebar 61, the
indentations 62a and 64a may be made from a resilient
material.
Each of the vertical form unit connecting members 34a and
36a has a fin 58a and 60a extending substantially the full
vertical length of the inside end of the connecting member.
Recesses 38a and 4Ca are so arranged to cooperate with the
fins 58a and 60a such that each of the said fins can be
received into one of said recesses though one or two apertures
in panels 22a and :?4a. It will be appreciated if panels 22a
and 24a are constructed of a material such as polystyrene, it
will be easy for a person assembling form unit 20a to create
the apertures required for the interconnection between the
spacer member 30a and the vertical unit connecting members 34a
and 3&a. However, greater efficiency may be achieved if the
apertures are at least pre-marked, if not pre-formed.
CA 02209251 2000-09-06
The attachment between recesses 38a and 40a and fins 58a
and 60a is illustrated in Figure 4. In this figure, a
positive attachment is created when the fin 60a slides into
the recess 40a in a vertical direction. The recess 40a
narrows at its outer margin 41a in order to grasp the
5 correspondingly narrowed portion 61a of the fin 60a and
provide a snug fit between spacer member 30a and connecting
elements 34a and 3F>a. The recess does not reach all the way
to the upper end of the spacer element 30a, thus preventing
further slid_~ng of the connecting elements 34a and 36a, as is
10 illustrated .in Figure 5.
This connection, between the fins 58a and 60a and the
recesses 38a and 40a, is not permanent, and the form units can
be reshaped if it is discovered that a mistake was made.
Once the spacer member 26a is attached to the vertical
unit connecting members, such as 36a, the vertical unit
connecting members are oriented vertically and have a surface
which lies a~~ainst t:he outward facing surface of a panel.
A may be seen in Figure 1, connecting elements 34a and
36a have a laterally (in direction of axis X) extending
channel or groove 76a in their upper lateral surfaces 75a and
lower lateral surfaces 77a. A linking element 71a has a
2:~ laterally extending tongue or protrusion 72a which extends
upwards from an upper, lateral surface 74a and downwards from
a lower, lateral surface 79a.
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
CA 02209251 2000-09-06
11
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.
The mechanism for providing a positive connection between
adjacent vertically positioned form units is illustrated in
further detail in figures 6,7,8, and 9.
Tn Figure 6, the lower portion of a typical unit
connecting rr.ember 34a and the upper portion of a typical
linking element 71a are shown disconnected from each other.
The unit connecting member and the linking element both lie
against the cuter surfaces of their respective panels. Formed
in the lower portion of member 34a .is a recess 76a defined by
an opening and ver'~ically oriented side walls 82a,84a and a
l~ base 80a. The side: walls 82a,84a are each saw-toothed.
Connection member 54a has at its upper end an arrow
formation 86~. with an arrowhead 88a. The saw-tooth pattern of
the walls 82a,84a is such that the sloped sides of arrowhead
2G 88a are guided and carried past the individual teeth during
axial insertion of the arrow formation 86a into the recess 76a
in the direci:ion of axis z of Figure 1.
The lower portion of the connecting member is def ormable
2~ and permits side walls to be displaced allowing insertion of
the arrowhead 88a into the recess. But the side walls are
resilient. Thus, once arrowhead 88a has passed a p air of
oppositely positioned sawteeth on the sidewalls 82a and 89a,
axial remova:L of the arrowhead 88a is prevented as the side
3U portions of 'the arrowhead engage the rear sides of the saw-
teeth.
CA 02209251 2000-09-06
12
However,, even when two form units 20a and 20d have been
interconnected through use of linking element 71a and
connection members 34a and 36a as shown in Figure 9, the
recess 76aa is sti:Ll accessible. Thus, if it is desired to
disconnect the connection between arrowhead 86a and the side
walls 82a and 84a c>f the recess, a transverse application of
force in a manner gc=nerally depicted in Figure 9 (generally in
the direction along of axis Y in Figure 1), permits arrowhead
88a to become dislc>dged from the side walls.
The dimensions of the arrowhead formation 86a 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 :oend the arrowhead out of the recess to release
1~ 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
necessary that there also be a lateral interconnection between
form units. This can be accomplished by erecting a form with
form units such as those of Figure 1 placed in a pattern as
shown in Figure 10. In this embodiment, each form unit has a
pair of vertical foam unit connecting members. Each form unit
is off-set in its lateral position relative to form unit above
2'~ and below. 7.'aking one such fo-~~m unit 20e, one of the pair of
connecting members 26e is connected to a connecting member 28g
of a form unit 20g, and also to a connecting member 28k of a
form unit 20k. The other of the pair of connecting members 28e
is connected to connecting member 26f of a form unit 20f and
3(1 also to a connecting member 26h of a form unit 26a.
CA 02209251 2000-09-06
13
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 it.s connecting members each passing through
1f 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 membez~s as described above.
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.
In a construction project, the lower most form units may
be secured t~~ a base in lateral alignment (for example, a
previously poured footing) providing an interconnection
between a concrete footing made with a length of 2 X 4
secured to the concrete (eg. by concrete nails) and then
providing interconnections between the lengths of 2 X 4 and
the vertical unit connecting members.
Thereafter, foam units may be placed on top of the base
form units an~~ interconnected such as in the manner described
above. Preferably, each form unit will comprise at least a
CA 02209251 2000-09-06
,. ,
14
pair,of laterally spaced tie members. This will provide for
greater vertical ~;tability of the form and assist in the
construction process.
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).
1C~ 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
1'~ 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.
20 Form unuts may be arranged as shown in Figure 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
2:i connecting elements being visible in Figure 12) to
corresponding sets of connecting elements associated with form
units 220b and 220c.
