Note: Descriptions are shown in the official language in which they were submitted.
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STACKABLE CONSTRUCTION PANEL INTERSECTION ASSEMBLY
FIELD OF THE INVENTION
The present invention relates generally to stackable wall forms for receiving
flowable materials such as concrete. More particularly, it concerns assemblies
for
intersection wall forms.
BACKGROUND OF THE INVENTION
Various different systems and methods currently exist for making insulating
forms
for casting a concrete wall. Often, these systems include pairs of opposed
foam
panels generally made of rigid foam such as polystyrene, which define concrete-
receiving cavities therebetween. Those pairs of foam panels are stacked one on
top of the other so as to form the wall form assemblage. Once the concrete is
solidified, the assembled wall forms remain in place to insulate the wall.
Before the
pouring of concrete, the opposed foam panels are typically maintained in
spaced
and parallel relationship by connectors each having a pair of parallel lateral
attachment flanges embedded in the respective foam panels, and a connecting
web interconnecting the flanges.
The stacking of such panels is performed on the construction site. It is
desirable in
this field to provide wall forms that allow, on one hand, an easy and very
rapid
stacking without loosing time and, on the other hand, allow construction of a
stable
and solid stack that is unlikely to accidentally disassemble prior to the
pouring of
concrete. As can be easily understood, as soon as the concrete is poured, the
chances that the stack collapses or disassembles are greatly reduced. However,
it
is desirable to maximize the pre-pouring stability of the non-stacked and
stacked
wall forms, while keeping them manageable.
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Pairs of foam panels are used to construct different kinds of wall forms. On
the
one hand, straight wall forms include two straight parallel foam panels. On
the
other hand, corner wall forms include two parallel foam panels formed to bend
around a corner at various angles. Each foam panel for corner wall forms may
include two or more foam panel sections, which should be longitudinally
contiguous to define the corner and to avoid the flowable concrete leaking
outside
of the wall form. However, it is difficult to use the known stackable panels
to
construct wall forms of certain other types, such as intersection wall forms,
that are
desired in the construction industry.
By way of example, wall forms and construction foam panels of the type
discussed
above are shown in published Canadian patent applications nos. 2,292,865,
2,312,158 and 2,358,195, all in the name of the present assignee. Other
examples
of insulating construction panei are shown in U.S. patents nos. 3,895,469;
4,229,920; 4,704,429; 4,884,382; 4,885,888, 4,894,969; and 5,428,933.
SUMMARY OF THE INVENTION
The present invention presents numerous advantages and overcomes
disadvantages of the prior art, by proposing a stackable construction panel
intersection assembly.
The invention thus provides a wall form intersection assembly for receiving a
flowable material. The wall form intersection assembly includes a pair of
opposed
spaced-apart foam panels having a top surface and a bottom surface. Viewed
from the top surface, each panel includes a first linear section having first
and
second opposed ends, the first linear sections of the pair being in a parallel
relationship to each other. Each panel also includes a second linear section
pointing outwardly from the first end of the first linear section and forming
an angle
therewith. The assembly further includes at least one end foam panel having a
top
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surface and a bottom surface. Each of said at least one end foam panel viewed
from the top surface includes a section facing the second linear sections and
is
tied is spaced relation therewith. The opposed foam panels and the at least
one
end foam panel thereby define therebetween a cavity for receiving the flowable
material and forming an intersection in a wall. The cavity includes a first
portion
between the first linear sections and a second portion between the second
linear
sections and the at least one end foam panel.
Preferably, the second linear sections are integrally formed with the opposed
foam
panels. Also preferably, the second linear sections of the opposed foam panels
extend at right angles relative to the first linear sections and the at least
one end
foam panel consists of a single end foam panel facing the second linear
sections,
thereby making the cavity substantially T-shaped.
Also preferably, the at least one end foam panel consists of a pair of spaced-
apart
end foam panels. Each end foam panel of the pair includes the section,
hereinafter
referred to as the first section, facing a respective one of the second linear
sections. Each end foam panel also includes a second section extending at a
right
angle from an inner end of a respective one of said first sections. Each of
the
second sections is in a collinear relationship with a respective one of the
first linear
sections. The cavity between the at least one end foam panel and the pair of
opposed spaced-apart foam panels is thus cross-shaped.
The present invention also provides a wall form intersection system including
at
least two of the above-mentioned wall form intersection assemblies. The wall
form
intersection assemblies are stackable on top of each other, with the end foam
panel and the opposed foam panels of a first wall form assembly being
respectively mountable on top of the end foam panel and the opposed foam
panels of an underlying wall form assembly.
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Preferably, the system comprises a first set and a second set of the wall form
assemblies. The first and second sets have different lengths of linear
sections, to
enable them to be stackable on each other in a staggered fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments are shown in the drawings, and the elements are
indicated with reference characters. If an element was indicated in one
drawing, it
may not be in another one, in order not to weigh down the drawings.
FIG 1 is a top view of the wall form intersection assembly of the present
invention
according to a"short variant thereof.
FIG 2 is a top view of the wall form intersection assembly of the present
invention
according to a "long" variant thereof.
FIG 3 is a perspective view of the short variant of the intersection assembly
according to the present invention.
FIG 4 is a perspective view of the long variant of the intersection assembly
according to the present invention.
FIG 5 is a perspective view of the wall form intersection system of the
present
invention, where a long assembly and a short assembly are stacked together.
FIG 6 is a top view of the wall form intersection assembly of the present
invention
according to another variant thereof.
FIG 7 is a perspective view of the wall form intersection assembly of the
present
invention according to the variant of FIG 6.
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DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
The present invention is directed to a stackable construction panel assembly
to be
used in a stackable construction system, which uses wall forms arranged to
define
a cavity into which a flowable material may be flowed.
5 First, the wall form intersection assembly of the present invention is
useful for
making intersection walls, an more specifically, T-shaped or cross-shaped
intersection walls.
Referring to FfGs 1 to 7, there are shown a few variants of a wall form
intersection
assembly (10) which are suitable to make a form for receiving flowable
material
such as concrete or the like into a cavity (11). The assembly (10) includes a
pair
of opposed spaced-apart foam panels (12A, 12B), which are also called
"longitudinal" panels. The opposed panels (12) are preferably parallel and
substantially rectangular foamed plastic panels.
Referring briefly to FIG 3, each of the pair of foam panels (12A, 126) has a
top
surface (13A) and a bottom surface (13B).
Referring back to FIG 1, viewing the assembly from the top surface, each of
the
pair of foam panels (12A, 12B) has a first linear section (14A, 14B). The
first linear
sections (14) are preferably tied together in a spaced and parallel
relationship
along a first axis (15) with at least one connector (16). The first linear
sections (14)
are in a parallel relation relative to each other since most walls to be
formed
therein are designed to have a uniform width, among other reasons that would
be
known to a person skilled in the art. Furthermore, the first linear sections
(14A,
14B) delimit therebetween a first portion (18) of the cavity (also called the
"first" or
"longitudinal" cavity (18)). Preferably, a plurality of connectors (16) is
used,
depending on the length of the pair of foam panels (12). The connectors (16)
may
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be, for exemple, spaced at about eight inch intervals. However, depending on
the
width of the first cavity (18) and other parameters of the assembly (10), a
person
skilled in the art could arrange the connectors at functional intervals that
are
regularly spaced or not. The width of the first cavity is for example about
six
inches, but the assembly may be easily adapted depending on the desired width.
Still referring to FIG 1, it is preferable that the connector (16) include a
pair of
anchor members (20A, 20B) respectively embedded in the first and second
opposed foam panels (12A, 12B), and a web-shaped connecting member (22)
extending between the foam panels (12A, 12B) and being connected to the anchor
members (20A, 20B).
Furthermore, the opposed foam panels (12A, 12B) are preferably movable
between an extended position (as shown in FIG 1) where the foam panels (12A,
12B) are spaced apart to make the wall form, and a collapsed position (not
illustrated) where the foam panels (12A, 12B) are brought close to each other,
mainly for transport and shipping purposes. This may be achieved by mounting
the web-shaped member (22) to the anchor members (20A, 20B) in a pivotal or
otherwise movable relationship.
Each foam panel (12A, 12B) of the pair also has a first end (21A) and a second
end (21 B); and a second linear section (24A, 24B) pointing outwardly from its
first
end (21A). Preferably, the second linear sections (24A, 24B) are integrally
formed
with their respective first linear sections (14A, 14B). Alternatively, the
second
linear sections (24A, 24B) may be integrated with the assembly using a variety
of
fixing means, or made to abut on the fist end (21A) of the first linear
section (14).
In such a case (not illustrated), the first linear sections (14) would have
butt-ends
at their first ends (21A) to which the second linear sections (24) are
operatively
connected or abutted. The second linear sections (24A, 24B) extend laterally
outward away from the first portion (18) of the cavity (11). Preferably, they
extend
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at right angles relative to the first linear sections (14) to provide for a
right-angled
intersection. However, as was previously mentioned, the second linear sections
(24A, 24B) may also extend at other angles, be they obtuse or acute, different
from each other or the same, depending on the desired wall intersection to be
formed.
Still referring to FIG 1, the intersection assembly (10) further includes at
least one
end foam panel (26). In the preferred embodiment of FIGs 1 to 5, the at least
one
end foam panel is a single end foam panel (26). In this case, the end foam
panel
(26) is the third foam panel in the inventive assembly (10), the others being
the
pair of opposed foam panels (12A, 12B). The end foam panel (26) has section
(27) that may also be referred to as the first section. The end foam panel is
tied in
spaced relation to the second linear sections (24A, 24B) of the opposed
iongitudinal panels (12A, 12B) using end connectors (28A, 28B), which are
preferably similar to those used to tie together the longitudinal panels (12A,
12B).
The end connectors (26) are thus arranged so that the end foam panel (26) and
the second linear sections (24A, 24B) define there-between a second portion
(30)
of the cavity (11) (also called the usecond" cavity or the "end" cavity).
Preferably,
the second cavity (30) extends along a second axis (31). This second axis is
preferably at a right angle relative to the first axis (15), but may also be
arranged at
other angles. Alternatively, when the second linear sections (24A, 24B) point
outwardly at different angles, the second axis would be nonlinear, but would
have
a V-shape or another shape.
In any case, the three foam panels (12A, 12B, 26) are interconnected so that
the
end cavity (30) and the longitudinal cavity (18) make up a cavity (11) into
which the
flowable material may be flowed.
Again referring to FIG 1, the end foam panel (26) is preferably tied to the
second
linear sections (24A, 24B) so as to be in a parallel relationship therewith.
Thus,
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when the second linear sections (24A, 24B) extend in opposite directions and
at
right angles relative to the first axis (15) direction, the end foam panel
(26) is
straight. However, as may be appreciated by a person skilled in the art, if
the
second linear sections (24A, 24B) extend at forward angles, the end foam panel
(26) may be V-shaped in order the remain parallel therewith, thus enabling the
assembly to define more of an overall Y-shaped cavity.
Now referring to the embodiment of FIG 6, the at least one end foam panel (26)
consists of a pair of spaced-apart end foam panels (26A, 26B). Thus, for this
embodiment, there are four foam panels that make up the wall form intersection
assembly. Each end foam panel of the pair includes a section (27A, 27B),
hereinafter referred to as the first sections. The first sections (27A, 27B)
face a
respective one of the second linear sections (24A, 24B). Each end foam panel
(26)
aiso includes a second section (29A, 29B) extending at a right angle from an
inner
end (33A, 33B) of a respective one of said first sections (27A, 27B).
Preferably,
each of the second sections (29A, 29B) is in a collinear relationship with a
respective one of the first linear sections (14A, 14B). The cavity (11)
between the
at least one end foam panel (26) and the pair of opposed spaced-apart foam
panels (12A, 12B) is, for this embodiment, cross-shaped. There is thus a third
portion of the cavity (35), which enables another type of intersection wall to
be
formed.
Referring to FIG 7, this embodiment of the pair of spaced-apart end foam
panels
(26A, 26B) is also shown. It should be noted that the second sections (29A,
29B)
and/or the first sections (27A, 27B) may be oriented in a fashion to obtain a
desired cavity shape, depending on the shape of the intersection wall to be
formed. It is nevertheless preferable that the wall form intersection assembly
be
symmetrical along axes (15) and (31), as shown in FIGs 6 and 7. Also, the
possibilities discussed in relation to variants of FIGs 1 to 5 are also
pertinent in
relation to the variant of FIGs 6 and 7.
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As can be appreciated in FIG 1, it is also preferable that the two opposite
ends of
the end foam panel (26) respectively extend to a same distance as the ends of
the
second linear sections (24A, 24B) of the pair of opposed foam panels (12A,
12B).
However, depending on other wall forms to be abutted, connected and/or stacked
on the wall form intersection assembly (10), the ends of the end foam panel
(26)
and the second linear sections (24A, 24B) may be designed to be of different
lengths, dimensions, etc.
Preferably, the first cavity (18) and the second cavity (30) each have a width
of "n",
which is preferably six inches. Also preferably, the assembly (10) may be
modified
by bringing the longitudinal opposed panels (12A, 12B) closer together (i.e.
by
changing connectors (16)) so that the width of the first cavity (18) is for
example
four inches. In such a case, a different end foam panel (26), one which has a
length of two less inches, may be used in order that the two ends of the end
foam
panel (26) respectively extend to a same distance as the second linear
sections
(24A, 24B) of the pair of opposed foam panels (12A, 12B). As would be readily
appreciated by a person skilled in the art, the assembly (10) may be modified
to
give many different combinations of widths and lengths of the first and second
cavities (18, 30).
It is also preferred that the end foam panel (26) further include a ridge
(32).
Viewed from the top surface of the end foam panel (26), the ridge (32)
preferably
projects from an inner face (33) thereof towards the first portion (18) of the
cavity
(11) to guide the flowable material into the second portion (30) of the
cavity. The
ridge (32) preferably extends from the top surface (13A) to the bottom surface
(13B) of the end foam panel (26), as shown in FIG 3. Preferably, this ridge
(32)
helps the flowable material flowing into the second cavity (30), distributing
the
material into both sides thereof. Alternatively, the ridge (32) may be used to
direct
the flowable material in another desired location depending on the cavities
(shape,
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size, orientation, etc.), the flowable material (fluidity, viscosity,
composition, etc.)
and the flowing conditions (laminar, turbulent, etc.). Preferably still, the
ridge (32),
viewed from the top surface (1 3A), has a tapered shape with a curved apex,
and is
integrally formed with the end foam panel (26).
5 Furthermore, similarly to what is possible with the longitudinal opposed
panels
(12A, 12B), the end foam panel (26) is movable between an extended position,
as
shown in FIG 1, where the end foam panel (12A, 12B) is spaced apart from the
second linear sections (24A, 24B) to define the second cavity (30) of the wall
form,
and a collapsed position (not illustrated) where the end foam panel (26) is
brought
10 closer to the second linear sections (24A, 24B).
Referring now to FIG 3, another advantageous aspect of the three
interconnected
pane!s (12A, 12B, 26) is that each of the top (13A) and bottom (13B) wall
surfaces
of each of the foam panels are provided with a median row (38) of alternating
recesses (40) and projections (42) having a similar complementary shape. The
projections (42) are shown with the reference character "M" in FIGs 1 and 2.
This
median row (38) is disposed between two coplanar edge surfaces (44) bordering
the edges of the panels (12A, 12B, 26). These coplanar edge surfaces (44)
preferably have a width sufficiently large so as to offer an increased
stability
between interlocked panels (12A, 12B, 26).
Each projection (42) or recess (40) of the top wall surface (1 3A) of one
longitudinal
panel (12A) is opposed respectively to a recess (40) or a projection (42) of
the
bottom wall surface (13B) of the same panel (12A), and is facing respectively
a
recess (40) and a projection (42) of the top surface (34) of the other
longitudinal
panel (12B), when the pair of panels (12A and 12B) are in the extended
position.
It will be understood that in this manner, the pair of longitudinal panels
(12A, 12B)
may advantageously be interconnected with a!ike pair of panels with either of
its
opposed wall surfaces (13A, 13B) acting as the top or bottom wall surface.
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Similarly, each projection (42) or recess (40) provided on the top surface (1
3A) of
the end foam panel (26) is opposed respectively to a recess (40) or a
projection
(42) of the bottom wall surface (13B) of the same panel (26). Advantageously,
a
projection (42) or recess (40) provided on the top surface (13A) of the second
linear sections (24A, 24B) of the longitudinal panels (12A, 12B) are facing
respectively a recess (40) and a projection (42) of the top surface (13A) of
the end
foam panel (26), when the end foam panel (26) is in the extended position.
Referring to FIG 5, the present invention provides a wall form intersection
system (46) including at least two of the above-mentioned wall form
intersection
assemblies (10). The wall form intersection assemblies are stackable on top of
each other, with the end foam panel and the opposed foam panels of a first
wall
form assembly (10A) being respectively mountabie on top of the end foam panel
and the opposed foam panels of an underlying waii form assembly (10B).
Preferably, two variants (so called "short" (10A) and "long" (10B)) of the
assembly
are used together to construct the wall form intersection system (46). When
assembling a wall form with stackable assemblies (10), they are placed one on
top
of each other. The two variants of assemblies are preferably stacked
alternatively
on top of each other in order in a staggered fashion to increase the stability
of the
wall form and improve the insulation and other features thereof. The so-called
"short" assembly variant is shown in FIGs 1 and 3, and prescribes, as may be
appreciated, that the end foam panel (26) has substantially the same (or
shorter)
length as the longitudinal panels (12A, 12B). The so-called "long" assembly
variant is shown in FIGs 2 and 4, and prescribes, as may be appreciated, that
the
end foam panel (26) has a longer length than the longitudinal panels (12A,
12B).
It should be understood also that the cross-shaped variant of FIGs 6 and 7 is
a
"short" type assembly, and may be used in combination with a corresponding
"long" type assembly that is cross-shaped (not shown).
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Referring to FIG 5, the short variant (10A) has been stacked on top of the
long
variant (10B), thereby making up a two-assembly wall form setup (46) and
extending the cavity vertically. The two variants may be alternatively placed
one
on top of the other, thereby overlapping while fitting together via the
projections
(42) and recesses (40) and extending the cavity vertically until a desired
height.
Furthermore, as can be readily appreciated by a person skilled in the art,
there
may be more than two different assembly variants used to construct a
construction
panel wall forms, albeit that the variants should be sufficiently compatible
with one
another.
Also, the panels of neighbouring wall forms are preferably arranged to abut
one
another along their horizontal and vertical sides, thereby enabling a variety
of
arrangements of wall forms to be constructed. Thus, a wall form system may be
constructed, which combines one or more intersection assemblies (10) with one
or
more assemblies known in the art (described in "BACKGROUND" section
hereabove).
Preferably, the wall form intersection assembly (10) according to the present
invention defines a T-shaped cavity, as shown in the preferred embodiments of
FIGs 1 to 5. The T-shape is preferable since right angles and T-junctions are
commonly used in the construction industry. However, as may be envisioned by a
person skilled in the art, the wall form assembly may more generally define a
cavity for forming an intersection wall, that is, a wall combination that
includes at
least three wall segments. As shown in FIGs 6 and 7, the intersection wall may
have four wall segments that intersect to form a cross-shaped wall. Various
different wall shapes may be desirable for different construction and
architectural
needs and constraints. The assembly is thus not restricted to the embodiment
of
strictly right-angled or symmetrical T-shapes or cross-shapes. For example,
the
end part of the "T" or cross may be angled or non-symmetrical with respect to
the
longitudinal part; also, the end part may be longer, shorter or the same
length as
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the longitudinal part. The shape of the assembly may, alternatively,
substantially
resemble a"Y", an "-Y", or another shape (curved, irregular, etc.) useful in
forming
an intersection wall. These embodiments are not shown in the appended FIGs,
but would be evident to a person skilled in the art.
Although preferred embodiments and variants of the invention have been
described in detail herein and illustrated in the accompanying drawings, it is
to be
understood that the invention is not limited to these precise embodiments
and/or
variants and that various changes and modifications may be effected therein
without departing from the scope of the invention as defined in the appended
claims.
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