Note: Descriptions are shown in the official language in which they were submitted.
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CONCRETE WALL FORMWORK MODULE
Background of the invention
1 ) Field of the invention
The present invention relates to concrete forms. More particularly, the
invention relates to a prefabricated concrete formwork module that can be
assembled with other identical modules like a brick wall to form a mold into
which
concrete is poured. Once assembled and filled with concrete, the modules are
left
in place thereby providing a concrete wall with panels on both of its sides.
2) Description of the prior art
US patent No. 4,888,931 in the name of the present inventor discloses an
insulating formwork for casting a concrete wall, which is made of foam panels
connectable to each other in parallel relationship by means of tie-rods. Once
assembled, the panels define a concrete framework into which concrete can be
poured. US Patent No. 4,604,843 also discloses a formwork for casting a
concrete
wall, which is made of insulating slabs of foam material reinforced by a metal
core.
The slabs are connectable to each other in parallel relationship by means of
horizontal elements having a ladder like configuration.
In both cases, the formworks must be assembled on the premises, thereby
requiring time and manual dexterity.
US patent No. 4,516,372 discloses a concrete formwork made of modules
each comprising two parallel spaced apart panels preferably made of insulating
foam. Each module also comprises backing plates extending on the external
surfaces of the panels. These plates are connected to each other by means of
tie-
rods extending through the panels. This patent does not disclose or suggest
that
reinforcing cores or grids be embodied into the panels. It does not disclose
or
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suggest either that a concrete reinforcing structure such as rods or grids be
part of
each module and be permanently positioned between the panel of the module to
be embodied with the concrete and thus to reinforce the same when it is cast.
In view of the above, it is clear that there is a need for a one-piece
prefabricated formwork module that can be easily and rapidly assembled with
other similar modules in order to form a reinforced concrete wall formwork.
The
purpose of this invention is to fulfil this need along with other needs that
will be
apparent to those skilled in the art upon reading the following specification.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a one piece prefabricated formwork
module that may easily be assembled with similar modules for forming a
reinforced concrete wall formwork.
The module of the invention comprises a reinforcing structure, a pair of
opposite panels forming spaced apart longitudinal side-walls and bridging
means
for providing stability between the module and other similar modules adjacent
to it
when assembled to form a wall.
The reinforcing structure comprises at least three and preferably four metal
grids extending in parallel vertical relationship. The grids are spaced apart
from
each other with two of the grids extending externally, every other grid
extending
inwardly between the externally extending grids. A plurality of tie-rods
extending
transversely to the grids rigidly connect to each other and altogether the
grids so
as to form a unitary structure
The panels extend in parallel vertical planes. Each panel embodies one of
the two externally extending grids and forms therewith a longitudinal side-
wall. The
panels are thus spaced apart and facing each other in parallel relationship.
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The bridging means are rigidly connected to the reinforcing structure and
they project upwardly above the panels in order to co-operate with the
reinforcing
structure of a similar module stacked upon the module.
In a preferred embodiment, the bridging means comprises arms rigidly
connected to at least one of the inwardly extending grids for providing
horizontal
and vertical stability between the modules when assembled to form a wall. The
arms defines a U-shaped trough sized and positioned to engage in a tight-fit
manner with at least one of the inwardly extending grids of the similar
vertically
stacked module.
As aforesaid, the formwork module preferably comprises two inwardly
extending grids and the bridging means comprises a junction grid rigidly
connected to each of the two inwardly extending grids. The junction grids
incorporate the arms and project upwardly above the panels so as to define the
U-
shaped though which is thus sized and positioned to engage in a tight-fit
manner
the inwardly extending grids of the similar vertically stacked module.
In another embodiment of the invention, the concrete wall formwork module
further comprises joining means rigidly connected to the reinforcing structure
and
projecting horizontally away from the panels. The joining means co-operate
with
the reinforcing structure of a similar adjacent module and provide an
additional
stability between the modules when assembled to form a wall.
It is another object of the invention to provide a formwork module having a
high insulating ability. In accordance with the invention, this object is
achieved by
using a module as described hereinabove wherein at least one, and preferably
both of the panels are made of a low density plastic foam having a high
insulating
ability, such as polyurethane or polystyrene.
The prefabricated formwork module of the invention may thus rapidly and
easily be assembled with other similar modules to form a reinforced concrete
wall
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formwork. Once assembled and filled with concrete, the modules are left in
place
thereby providing a concrete wall with panels on both of its sides. Since the
panels
are preferably made of insulating material, the resulting concrete wall is
insulated
both on the inside and the outside.
Other objects and features of the invention will become apparent upon
reading the following, non restrictive description of several preferred
embodiments
thereof, made with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1A is a top perspective view of a formwork module according to a
first preferred embodiment of the invention, the module having a reinforcing
structure with two inwardly extending parallel grids.
Figure 1 B is a front elevation view of the module shown in Figure 1A.
Figure 1C is a top plan view of the module shown in Figure 1A.
Figure 1 D is a side elevation cross-section view of the module shown in
Figure 1A, taken along line 1 D-1 D of Figure 1 B.
Figure 2 is a front elevation view of a formwork wall made of assembled
modules as shown in Figures 1A to 1 D.
Figure 3 is a side elevation view of a module according to another
embodiment of the present invention, wherein one of the two panels forming
the module is made of insulating material and the other panel is made of a
composite material.
Figures 4A and 4B are side elevation views of two different embodiments of
the reinforcing structure used in the module according to the invention.
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Figure 4C is a view showing tie-rods of different sizes that may be used in
the manufacture of the reinforcing structure shown in Figure 4B.
5 Figure 5 is a side elevation view of a. module according to a further
embodiment of the invention comprising a reinforcing structure having only
one inwardly extending grid.
Figures 6A, 6B and 6C are side elevation cross-section views of three
different embodiments of an optional fixation plate that can be used with the
module of the invention.
DESCRIPTION OF SEVERAL PREFERRED EMBODIMENTS OF THE
INVENTION
Figs. 1A, 1 B, 1 C and 1 D illustrate a module 1 according to a first
preferred
embodiment of the present invention. As can be seen, the module 1 is
prefabricated and comprises:
a) a reinforcing structure 11;
b) a pair of opposite panels 13, 13' forming spaced apart longitudinal side-
walls; and
c) bridging means 21 for providing stability between the module 1 and
adjacent similar or identical modules when assembled to form a wall.
The expression "similar or identical module" is used herein to make it clear
that the adjacent modules may be entirely but not necessarily identical in
shape
and size. In all cases, their width should be identical but their length and
height
could be varied as needed.
The reinforcing structure 11 comprises four rows of metal grids 17, 1T
which extend in parallel vertical relationship. The grids 17, 1T are spaced
apart
from each others. Two of the grids, viz. those numbered 17, extend externally,
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whereas the two other grids numbered 1T extend inwardly between the externally
extending grids 17. A plurality of tie-rods 19 extend transversely to the
grids 17,
17' and rigidly connect to each other and altogether the grids 17, 1 T thereby
forming a unitary structure. As is illustrated, the grids 17, 17' preferably
are
identical in length and horizontally offset in pairs.
The panels 13, 13' extend in parallel vertical planes, with each of the panels
13, 13' embodying one of the two externally extending grids 17. Each of the
panels
13, 13' form a longitudinal side-wall. The so-formed side walls are spaced
apart
and face each other in parallel relationship. During the manufacture of the
module
1, the panels 13, 13' are cast onto the two externally extending grids 17 that
are
parts of the reinforcing structure 11. The inwardly extending grids 17', which
have
as a function to reinforce the concrete wall, are preferably at a distance of
from 5/8
to 3/ inch of the closest panel.
Preferably, each panel has a length varying from about 4 feet to about 10
feet, and a height length varying from about 1 foot to about 10 feet. More
preferably the panels are 8 feet long and 2 feet high. Preferably also the
panels
13, 13' are horizontally offset with respect to each other. Therefore, when
two
similar module are assembled in line end to end, there is no facing joint.
Furthermore, modules having offset panels may be aligned perpendicularly with
respect to each other to form a corner.
In order to provide a formwork module having a high insulating ability, the
panels 13, 13' are preferably made of a low density plastic foam having a high
insulating ability such as polyurethane or polystyrene. The thickness of such
foam
panels may vary from about 1 inch to about 4 inches. More preferably, each
panel
is about 1 1/2 inch thick.
In the illustrated embodiment of Figures. 1A to 1 D, the externally extending
grids 17 are fully embodied into the panels 13,13', thereby forming cores
within the
panels 13, 13'. Such an isolated core reduces to a minimum extent the thermal
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conduction from the external side of the module to the opposite internal side
through the metal reinforcing structure. However, the panels 13, 13' may also
be
cast such that one or both of the externally extending grids 17 are protruding
partially or entirely to the external surface of the corresponding panel(s),
thereby
providing an external rough surface to the panels)
Referring more particularly to Figure 1D, each panel 13,13' comprises an
upper edge 31 and a lower edge 33. Preferably, one of these edges comprise a
longitudinal tongue 35 while the other opposite edge comprises a longitudinal
groove 37. In the illustrated embodiment of Figure 1 C, the longitudinal
tongue 35
is on the upper edge 31 and the longitudinal groove 37 is in the lower edge
33.
The tongue 35 and the groove 37 are sized to respectively co-operate with the
groove and tongue of the identical or similar module stacked upon the said
module
to form a joint.
The bridging means 21 which is an essential part of the module 1, is best
shown in Figures 1A and 1 D. The bridging means 21 is connected to the
reinforcing structure 11 and projects upwardly above the panels 13,13'. In the
illustrated preferred embodiment, the bridging means 21 comprises arms 23
rigidly
connected to the inwardly extending grids 17'. The arms 23 may simply consist
of
rods extending vertically. As shown in Figure 1 D, the arms 23 define a U-
shaped
trough sized and positioned to engage in a tight-fit manner a portion of at
least one
of the inwardly extending grids of the similar vertically stacked module (not
shown). The bridging means 21 thus provides horizontal and vertical stability
between the modules when assembled to form a wall.
When, as shown in Figures 1A and 1 D, the formwork module 1 comprise
two inwardly extending grids 17', the bridging means preferably comprises a
junction grid rigidly connected to each of the two inwardly extending grids.
The
junction grids are made of parallel horizontal 25 and vertical 27 rows of wire
or
rods, all welded together. The junction grids incorporate the arms 23 and
project
upwardly above the panels 13,13' so as to define the U-shaped though which is
CA 02258985 1999-O1-28
thus sized and positioned to engage in a tight-fit manner the inwardly
extending
grids of the similar vertically stacked module (not shown).
Although not illustrated, the bridging means could also consist of a H-
shaped metal structure devised to engage in a tight-fit manner a portion of at
least
one of the inwardly extending grids 17' of the module and a portion of at
least one
of the inwardly extending grids of a vertically stacked module. This H-shaped
structure would be inserted to the top of the module before stacking the
similar
module.
Although neither illustrated, a person skilled in the art may easily visualise
a
module further comprising joining means rigidly connected to the reinforcing
structure and projecting horizontally away from the panels. The joining means
could be similar to the bridging means and would co-operate with the
reinforcing
structure of a similar adjacent module thereby providing an additional
stability
between the modules when assembled to form a wall.
As shown in Figure 2 a plurality of modules 1 according to the invention
may be assembled together to form a wall 2. The illustrated wall 2 comprises
four
rows of horizontally aligned and vertically stacked modules 1. In use, a wall
comprising modules of the invention stacked upon each other to a high
equivalent
to four floor building could be built without any problem. Obviously, the
person
skilled in the art will easily understand that buildings having more than four
floors
may be built by modifying accordingly the strenght of the reinforcing
structure of
the modules (increasing the diameter and number of grids and rods for
example).
In order to provide a stronger wall 2, the stacked modules 1 are preferably
offset
with respect with each other such that there is no vertically aligned joint 3.
Figure 3 shows a module 1 according to another embodiment of the
invention wherein one of the panel 13 is made of a composite material, while
the
other panel 13' is made of a foam insulating material. The composite material
includes PVC, concrete or polymers. In fact, any moldable material could be
used.
Modules wherein only one or both of the panels 13, 13' are made of a composite
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material will be heavier and more resistant than modules with panels made of
foam. Such modules, with parts made of a composite material could be useful,
by
way of example, for manufacturing interior walls of a building. The thickness
of the
composite panels may vary from about 1/2 inch to about 2 inches, depending on
the kind of composite material that is used.
Figures 4A to 4C give more details relating the reinforcing structure 11. As
shown on Figure 4A, the grids 17, 17' are built according to normal procedures
by
welding together a plurality of parallel horizontal rows 41 and vertical rows
43 of
metal wires. Although not illustrated, the grids 17, 17' could be wrinkled or
undulated. As stated herein before, a plurality of tie-rods 19-extend
transversely
between the grids 17, 17' and are welded to the same in order to form a rigid
unitary structure.
Figure 4B shows another embodiment of reinforcing structure 11 comprising
preshaped tie-rods 19'. As show in Figure 4C, these preshaped tie-rods 19'
comprises a central region W whose length depends on the requested width of
the
module. As shown in Figure 4B, the length of the central region W is slightly
inferior to the free space F existing between the inwardly extending grids
17'. The
use of tie-rods 19' as shown in Figure 4C may be advantageous for easily and
rapidly manufacture the reinforcing structure of modules of different width.
Although in the previously illustrated embodiments, the reinforcing structure
11 comprises four parallel extending grids 17,17', the module 1 may be
provided
with more than four grids or with only three grids as shown in Figure 5. In
this
illustrated embodiment, only one grid 17' extend inwardly between the panels
13,13'. In this Figure, the externally extending grids 17 are not shown since
they
are embodied into the panels 13,13'.
Like in the previous embodiment, the embodiment illustrated in Figure 5
comprises bridging means 21 which is rigidly connected to the reinforcing
structure
11 and projects upwardly above the panels 13,13'. In this preferred
embodiment,
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the bridging means 21 comprises arms 23 rigidly connected to the inwardly
extending grid 17'. The arms 23 may be rods extending vertically. However,
they
are preferably parts of a junction grid made of a plurality of parallel
horizontal 25
and vertical 27 rows of metal wires welded all together. The arms 23 define
with
5 the upper tie-rod 19 a U-shaped trough sized and positioned to engage in a
tight-fit
manner a portion of the inwardly extending grid of a similar module (not
shown)
vertically stacked upon the illustrated module. The bridging means 21 thus
provide
horizontal and vertical stability between the modules when assembled to form a
wall.
Since external elements may not be solidly fastened to foam panels and
neither can they easily be fastened to the concrete once it is poured between
the
panels and it has hardened, it may be advantageous to provide formwork module
according with at least one fixation plate integral to the module. Such a
fixation
plate would provide a support onto which external elements could be easily and
rigidly fastened.
Figure 6A shows a first embodiment of fixation plate. The plate 61 consists
of a piece of wood or of a composite material (such as plastic) inserted
between
one of the inwardly extending grids 17' and one of the two panels 13,13'. Of
course, the plate must be inserted within the module 1 adjacent to the side
wall
when elements are to be fixed before concrete is poured in the module.
Figure 6B shows a second embodiment of fixation plate. In this
embodiment, the plate consists of a L-shaped metal sheet 71. As shown, the
metal
sheet 71 has an horizontal longitudinal portion 73 and a perpendicular
vertical
portion 75 providing the support onto which external elements may be fastened.
The sheet 71 is fixed to the module 1 by pushing its horizontal portion 73
into one
of the panels 13,13' before concrete is poured into the module 1. As shown on
the
perspective view, the horizontal portion 73 of the sheet 71 is preferably
triangular
in shape and provided with a plurality of retaining teeth.
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Figure 6C shows a third embodiment of fixation plate. As best shown in the
enlargement, the plate consists of a L-shaped sheet 81 having an horizontal
longitudinal portion 83 mounted over an upper edge 31 of one of the panels
13,13'
and shaped to fit onto this upper edge 31. The sheet 81 also has a
perpendicular
vertical portion 85 providing the support onto which external elements may be
fastened. The sheet 81 may be mounted over the upper edge 31 such that the
perpendicular vertical portion 85 is located on the outside or the inside of
the panel
13'.
Preferably, the sheet 81 is mounted on the outside the panel 13' and the
horizontal portion 83 the sheet 81 further comprises a U-shaped edge 87
located
within the module 1. As shown in Figure 6C, the edge 87 has a first vertical
section
co-operating in a tight fit manner with an internal portion of the panel 13'.
The edge
87 also has an horizontal section and a second vertical section providing
anchor
means that will become integral to the module 1 once the concrete will be
poured
into the module.
Of course, numerous modifications and improvements could be made to the
embodiments that have been disclosed hereinabove. These modifications and
improvements should, therefore, be considered a part of the invention, the
scope
of which is to be determined by the following claims.
