Patent Abstract:
A panel connector is disclosed that is used to make a corner in a wall system and a method of installing that component. The panel connector defines two channels into which respective portions of two side panels are inserted, in which the side panels usually serve as forms or walls in forming concrete wall structures. The panel connectors form a corner between the two side panels so that those side panels having a predetermined angle therebetween. It is noted that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to ascertain quickly the subject matter of the technical disclosure. The abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims pursuant to 37 C.F.R. §1.72(b).

Full Description:
[0001]    This patent application claims priority to U.S. Provisional Application Serial No. 60/271,827, which was filed on Feb. 27, 2001, and which is fully incorporated herein by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention encompasses a building component used to form a corner in a wall system and, more particularly, a corner for a system that is used to construct a concrete wall.  
           [0004]    2. Background Art  
           [0005]    Concrete walls in building construction are often produced by first setting up two parallel form walls and pouring concrete into the space between the forms. After the concrete hardens, the builder then removes the forms, leaving the cured concrete wall.  
           [0006]    This prior art technique has drawbacks. Formation of the concrete walls is inefficient because of the time required to erect the forms, wait until the concrete cures, and take down the forms. This prior art technique, therefore, is an expensive, labor-intensive process.  
           [0007]    Accordingly, techniques have developed for forming concrete walls that use a foam insulating material. The modular form walls are set up parallel to each other and connecting components hold the two form walls in place relative to each other while concrete is poured therebetween. The form walls, however, remain in place after the concrete cures. That is, the modular walls, which are constructed of foam insulating material, are a permanent part of the building after the concrete cures. The concrete walls made using this technique can be stacked on top of each other many stories high to form all of a building&#39;s walls. In addition to the efficiency gained by retaining the form walls as part of the permanent structure, the materials of the form walls often provide adequate insulation for the building.  
           [0008]    In prior art systems, however, the corners for form systems have proven to be difficult to manufacture and construct. Often a specific side panel must be manufactured and used, in which the side panels are non-linear to form an angle equal to that required for the building (i.e., 90 degrees). These corner panels necessary to make a corner structure in the prior art concrete form systems are expensive which, in turn, increases the cost of the formed wall.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention comprises a panel connector for making corner structures in building form systems, particularly for systems used to construct concrete walls. The panel connector defines two channels into which respective portions of the side panels are inserted, preferably at the construction site. These panel connectors are designed to form a corner having a predetermined angle to which the inserted side panels are positioned.  
           [0010]    In one exemplary embodiment, the panel connector includes a first base wall, a first pair of side walls, and a second pair of side walls. The first pair of side walls extend from the first base wall and are spaced apart to define a first channel of a size to complementarily receive a portion of one side panel. One of the side walls of the first pair of side walls forms a second base wall, and the second pair of side walls extend from the second base wall to form the second channel. The second channel is also of a size to complementarily receive a portion of another side panel. With this embodiment, the side panels are usually oriented at right angles to each other in plan view.  
           [0011]    In a second exemplary embodiment, the panel connector comprises a pair of connected channels. Each channel includes a first side wall, a second side wall, and a back wall. Both channels have corners formed between the first side wall and the back wall and those corners are connected to each other. The side walls for each channel that do not form the corner of that respective channel (e.g., the second side panel) may extend beyond the connection point of the respective back wall to a distal edge. For structural integrity, it is preferred that the distal edges of the second side walls of both channels are also connected. In fact, the panel connector may be formed so that the connected corners of the channels are coextensive and integral with each other and the distal edges of the connected channels are also coextensive and integral with each other.  
           [0012]    In this second embodiment, the back walls of the respective channels are at an angle with each other in plan view that is less than 180 degrees. In specific preferred embodiments, the back walls are at angles of either 45 or 90 degrees and the side panels accordingly, are at that same angle in plan view.  
           [0013]    The panel connector may also include a fastening means for forming a stronger connection between the panel connector and the respective inserted side panels. The fastening means assists in maintaining the side panels within the respective channels during the construction process and after its completion.  
           [0014]    The present invention also includes a method of constructing a portion of a form wall system having at least one panel connector described herein and at least two side panels.  
           [0015]    These and other features and advantages of the present invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings.  
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is a perspective view of one embodiment of the present invention shown being used with an exemplary wall system.  
         [0017]    [0017]FIG. 2 is a perspective side view of a FIG. 1 taken along line  2 - 2 .  
         [0018]    [0018]FIG. 2A is an alternative view of FIG. 2 showing concrete disposed between the two opposed side panels.  
         [0019]    [0019]FIG. 3 is a perspective view of connector shown in FIG. 2.  
         [0020]    [0020]FIG. 4 is a perspective view of a first exemplary embodiment of a panel connector of the present invention.  
         [0021]    [0021]FIG. 5 is a top plan view of the panel connector of FIG. 4 having a portion of a respective side panel disposed within each of the two channels.  
         [0022]    [0022]FIG. 6 is a top plan view of T-wall formed using two panel connectors shown in FIG. 4.  
         [0023]    [0023]FIG. 7 is a perspective view of a second exemplary embodiment of a panel connector of the present invention.  
         [0024]    [0024]FIG. 8 is a top plan view of the panel connector of FIG. 7 having a portion of a respective side panel disposed within each of the two channels, in which the side panels are oriented at an approximately 45 degree angle to each other.  
         [0025]    [0025]FIG. 9 is a top plan view of a panel connector similar to that of FIG. 7, in which the side panels are oriented at an angle of approximately 90 degrees instead of at 45 degrees. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]    The present invention is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. As used in the specification and in the claims, “a,” “an,” and “the” can mean one or more, depending upon the context in which it is used. The preferred embodiment of the present invention is now described with reference to the figures, in which like numbers indicate like parts throughout the figures.  
         [0027]    As shown in FIGS.  1 - 9 , the present invention comprises a corner system  10  used for constructing buildings and the like. Before describing illustrative embodiments of the present invention, however, exemplary components that are used to form the associated concrete form wall are addressed to provide context.  
         [0028]    As best shown in FIG. 2, side panels  20  are used to form the wall, in which each side panel  20  has a top end  24 , a bottom end  26 , a first end  28 , a second end  30 , an exterior surface  32 , and an interior surface  34 . The illustrated side panel  20  has a thickness (separation between the interior surface  34  and exterior surface  32 ) of approximately two and a half (2½) inches, a height (separation between the bottom end  26  and the top end  24 ) of sixteen (16) inches, and a length (separation between the first end  28  and second end  30 ) of forty-eight (48) inches. The dimensions may be altered, if desired, for different building projects, such as increasing the thickness of the side panel  20  for more insulation. Half sections of the side panels  20  can be used for footings.  
         [0029]    Referring now to FIGS. 1 and 2, the interior surface  34  of one side panel  20  faces the interior surface  34  of another side panel  20  and the opposed interior surfaces  34  are laterally spaced apart from each other a desired separation distance so that a cavity  38  is formed therebetween. Concrete—in its fluid state—is poured into the cavity  38  and allowed to substantially cure (i.e., harden) therein to form the wall structure, as shown in FIG. 2A. The opposed interior surfaces  34  are usually parallel to each other. The volume of concrete received within the cavity  38  is defined by the separation distance between the interior surfaces  34 , the height of the side panels  20 , and the length of the side panels  20 .  
         [0030]    The illustrated side panels  20  are constructed of expanded polystyrene (“EPS”), which provides thermal insulation and sufficient strength to hold the poured concrete C until it substantially cures. The formed concrete wall using expanded polystyrene with the poured concrete C has a high insulating value so that no additional insulation is usually required. In addition, the formed walls have a high impedance to sound transmission. However, other materials may be used to form the side panels, including, but not limited to, other polystyrene materials, wood, plywood, combined steel frame and plywood center (commonly known as a steel-ply panel), or any other solid material that can be coupled to either a web member  40  or a connector  50  and can withstand the forces exerted by the fluid concrete when poured into the cavity  38  without substantial bowing, warping, breaking, or other type of failure. The opposed side panels may be formed of the same material or different materials.  
         [0031]    As shown in FIG. 2 and disclosed more completely in U.S. Pat. Nos. 6,170,220 and 6,336,301 and in U.S. patent application Ser. No. 09/848,398 (all of which are incorporated herein in their entireties), each side panel  20  has at least one web member  40  formed into it. Each web member  40  formed within one side panel  20  is usually separated a predetermined longitudinal distance from other web members  40 , which is typically eight (8) inches. Based on the preferred length of the side panel  20  of forty-eight (48) inches, six web members  40  are formed within each side panel  20 . A portion of each web member  40  is shown integrally formed within one side panel  20  and is to be cured within the concrete C so that the web member  40  strengthens the connection between the side panel  20  and the concrete C. That is, since the web member  40  is an integral part of the side panel  20 , it bonds the side panel  20  to the concrete C once the concrete is poured and substantially cures within the cavity  38 . However, other designs are contemplated to be used with the present invention, such as systems in which the web member is not integrally formed into the side panel and, for example, the web member is slid into slots precut into the side panel at the construction site. Still another design with which the present invention may be used includes systems having the web members, side panels, and connectors shipped to the construction site as an integral unit. Such exemplary designs are disclosed in U.S. Pat. Nos. 4,901,494, 5,390,459, and 5,497,592, which are also incorporated herein in by reference.  
         [0032]    Referring still to FIG. 2, portions of each web member  40  that extend through the interior surface  34  of the side panel  20  forms one or more attachment points  44 . The attachment points  44  are disposed within the cavity  38  and are spaced apart from the interior surface  34  of the side panels  20 . However, as one skilled in the art will appreciate, the attachment points  44  may take any of a number of alternate designs formed by or independentl of the web members  40 , including as examples: slots, channels, grooves, projections or recesses formed in the side panels; hooks or eyelets projecting from or formed into the side panels; twist, compression or snap couplings; or other coupling means for engaging cooperating ends of the connectors.  
         [0033]    The illustrated attachment points  44  of the web members  40  extend into the cavity  38  and the attachment points  44  of each web member  40  formed within one side panel  20  are spaced apart from the attachment points  44  of the web members  40  formed within the opposed side panel  20 . Thus, the web members  40  in this illustrative design do not directly contact each other; instead, each attachment point  44  independently engages the connector  50  that interconnects the web members  40  and, accordingly, the side panels  20 .  
         [0034]    Referring now to FIG. 3, the illustrated connector  50  has opposed ends  52  and a length extending therebetween. The ends  52  of the connectors  50  are each of a shape to engage one attachment point  44  of two respective web members  40  within opposed panels. In conjunction, each end  52  of the connector  50  has a track  54  into which the attachment point  44  is complementarily and slidably received. Thus, the illustrated connectors  50  engage two attachment points  44  on opposed web members  40 , which position the interior surfaces  34  of the side panels  20  at a desired separation distance and support the side panels  20  when the fluid concrete is poured into the cavity  38 . The connector  50  thus makes a two-point connection with opposed web members  40  because each connector has two ends  52  that each couple to one attachment point  44 , although it is contemplated making a four-point connection (i.e., each connector  50  engages four attachment points  44  instead of two as illustrated in the figures). As also noted above, however, the web members and connectors can be formed as an integral unit for use with the present invention.  
         [0035]    Referring now to FIGS. 2 and 3, the connectors  50  also define an aperture  56  of a size to complementary receive a re-bar (not shown) therein. The re-bar provides reinforcing strength to the formed wall. The diameter of the re-bar can be one-quarter (¼) inch or other dimension as required for the necessary reinforcement, which depends on the thickness of the concrete wall and the design engineering requirements. The connectors  50  usually have two or more apertures  56  and re-bar can be positioned in any of the apertures  56  before the concrete is poured into the cavity  38 . The apertures  56  can be designed so that the re-bar is securably snapped into place for ease of assembly.  
         [0036]    To alter the width of the cavity  38  (i.e., the separation between the interior surfaces  34  of the opposed side panels  20 ), different connectors  50  can have varying lengths. The width of the cavity  38  can be two (2), four (4), six (6), eight (8) inches or other separation. Different connectors  50  are sized accordingly to obtain the desired width of the cavity  38 . Also, as one skilled in the art will appreciate, the fire rating, sound insulation, and thermal insulation increase as the width of the cavity  38 , which is filled with concrete, increases. One skilled in the art will appreciate that the cavity  38  may only be partially filled with concrete, but such an embodiment is usually not desired.  
         [0037]    The web members  40  and connectors  50  are usually constructed of a thermoplastic, but other materials may be used. Factors used in choosing the material include the desired strength of the web member  40  and connector  50 , the compatibility with the material used to form side panels  20  and with the concrete, and cost. Another consideration is that the end plates of the web members (positioned adjacent the exterior surface of the side panel  20 ) should be adapted to receive and frictionally hold a metal fastener, such as a nail or screw, therein, thus providing the “strapping” for a wall system that provides an attachment point for gypsum board (not shown), interior or exterior wall cladding (not shown), or other interior or exterior siding (not shown).  
         [0038]    Referring back to FIGS. 1 and 2, one skilled in the art will appreciate that a plurality of side panels  20  can be longitudinally aligned to form a predetermined length and be vertically stacked to form a predetermined height. For example, the first end  28  of one side panel  20  abuts the second end  30  of another side panel  20  and the bottom end  26  of one side panel  20  is disposed on the top end  24  of another side panel  20 . Thus, a series of side panels  20  can be aligned and stacked to form the concrete system into which concrete C is poured to complete the construction of the wall. One consideration, however, is that the side panels  20  are not vertically stacked too high and filled at once so that the pressure on the bottom side panel  20  is greater than the yield strength of the web members  40  or side panels  20 . Instead, the stacked wall of panels  20  can be filled and cured in stages so that the static and dynamic pressures are not excessive on the lower side panels  20 .  
         [0039]    Still referring to FIGS. 1 and 2, the side panels  20  are optionally provided with a series of projections  35  and indentations  37  that complementarily receive offset projections  35  and indentations  37  from another side panel  20  (i.e., a tongue-and-groove-type system) to facilitate the stacking of the components. The projections  35  and indentations  37  in the adjacent side panels  20  mate with each other to form a tight seal that prevents leakage of concrete C during wall formation and prevents loss of energy through the formed wall.  
         [0040]    In the context of these exemplary components, the present invention is disclosed, which comprises a panel connector  60  that is used to form a corner of the wall structure. The panel connector  60 , which is shown in FIGS. 1 and 4- 9 , joins or interconnects two or more side panels  20  in a fixed or stationary relationship relative to each other. As noted above, the interconnected side panels  20  can employ any design used in the art, ranging from plywood panels to the illustrative EPS panels illustrated in the Figures.  
         [0041]    In a preferred embodiment, the panel connector  60  comprises first and second channels  70 ,  80 , both of which have a back wall  72 ,  82  and two side walls  74 ,  84 . For each of the first and second channels  70 ,  80 , the back wall  72 ,  82  has two opposed ends  73 ,  83  and each side wall  74 ,  84  has two opposed edges  75 ,  85 , in which one edge  75 ,  85  of each side wall  74 ,  84  connects to one respective end  73 ,  83  of the back wall  72 ,  82 . Together the two spaced apart side walls  74 ,  84  and interconnected back wall  72 ,  82  form one respective channel  70 ,  80 . The first and second channels  70 ,  80  are preferably of a size to receive a portion of a side panel  20  therein. As discussed below, the channels  70 ,  80  may also include a fastening means to assist inkeeping the side panel  20  retained within to the respective channel once interconnected.  
         [0042]    It is also preferred that the back and side walls  72 ,  74 ,  82 ,  84  are substantially planar and it is further preferred that the side walls  74 ,  84  are both oriented substantially perpendicular to the back wall  72 ,  74  in plan view (i.e., top or bottom view). Thus, the channel  70 ,  80  is substantially a squared U-shape in plan view, which matches the profile of the portion of the illustrated side panels  20  inserted into that channel. Of course, the shape and orientation of the channels  70 ,  80  may be varied as desired; for example, the two opposed side walls  74 ,  84  could be oriented inwardly (not shown) to form an acute angle relative to the back wall  72 ,  82  and such an alternative channel design could still receive a portion of the respective side panel therein.  
         [0043]    For purposes of discussing the present invention, the first channel  70  will be disclosed as receiving a first side panel  20 A and the second channel  80  as receiving a second side panel  20 B. The illustrated first and second side panels  20  are of the same design, but one skilled in the art will appreciate that the first side panel  20 A may be an EPS panel and the second side panel  20 B formed of a different material. Similarly, the first and second side panels  20 A,  20 B may have different widths between their respective interior and exterior surfaces  32 ,  34 .  
         [0044]    The present invention also preferably includes a means for positioning the first and second channels  70 ,  80  adjacent to each other. It is preferred that the positioning means comprises integrally connecting a portion of the first channel  70  to a portion of the second channel  80 . More specifically, it is preferred that the panel connector  60  be formed or extruded so that the first and second channels  70 ,  80  are fixedly attached to each other (i.e., coextensive and integrally formed together) along a potion or their entire heights, which extends between the top and bottom of the channel. However, the two channels may be interconnected using other means, such as fusing, welding, chemically bonding such as with glue, mechanically attaching such as with nails, screws, or rivets, or other techniques known in the art.  
         [0045]    Similar to the exemplary web members and connectors described above, the panel connectors  60  may be formed of plastic, more preferably high-density plastic such as high-density polyethylene or high-density polypropylene, although other suitable polymers may be used. Other contemplated plastics include acrylonitrile butadiene styrene (“ABS”) and glass-filled polyethylene or polypropylene. Likewise, other materials that may be used are other plastics and thermoplastics (including polyvinyl chloride (P.V.C.), polytetrafluoethylene (P.T.F.E.), polyamides such as nylon), metal, and natural and other synthetic materials. Factors used in choosing the material include the desired strength of the panel connector  60 , the compatibility with the material used to form side panels  20  and with the concrete C, and cost.  
         [0046]    In the first exemplary embodiment of the present invention shown in FIGS.  4 - 6 , the positioning means comprises one side wall  74  of the first channel  70  also forming the back wall  82  of the second channel  80  so that the first and second channels  70 ,  80  are oriented substantially perpendicular in plan view. Stated differently, this illustrated embodiment comprises a first back wall  72  and a first pair of side walls  74  extending from the first base wall  72  to define the first channel  70 . One of those two side walls  74  of the first channel  70  forms a second back wall  88 . The second pair of side walls  84  extend substantially perpendicular from the second back wall  88 . Similar to the first set of side walls, the second pair of side walls  84  are also spaced apart from each other to define the second channel  80 . The first and second channels  70 ,  80  receive respective first and second side panels  20 A,  20 B, as shown in FIGS. 5 and 6, so that the side panels interconnected by this embodiment are oriented substantially perpendicular to each other in plan view.  
         [0047]    Referring now to FIGS. 1 and 7- 9 , a second exemplary embodiment of the present invention is shown, in which the two channels are interconnected at one of their respective corners. Specifically, for the first channel  70 , the intersection of one end  73  of the back wall  72  and one edge  85  of one respective side wall  84  forms a first channel corner  76 , and, similarly for the second channel  80 , the intersection of one end  83  of that back wall  82  and an edge  85  of one respective side wall  84  forms a second channel corner  86 . The positioning means in this embodiment comprises a portion of the first channel corner  76  being attached to a portion of the second channel corner  86 . As noted above, the first and second channel corners  76 ,  86  preferably are fixedly attached to each other along the entire height of the panel connector  60 , but other designs of the positioning means are contemplated as mentioned above.  
         [0048]    It is preferred that that the back walls  72 ,  82  of the first and second channels  70 ,  80  form an angle θ in plan view between approximately 0 and 179 degrees, more preferably between 1 and 170 degrees, still more preferably between 30 and 135 degrees, and most preferably between and including 45 and 90 degrees. The 45 degree embodiment is illustrated in FIGS. 1, 7, and  8  and the 90 degree embodiment is illustrated in FIG. 9. As one skilled in the art will appreciated, the angle θ between the first and second side panels  20 A,  20 B interconnected by a panel connector  60  form the same sized angle in plan view as the angle formed by the back walls in the illustrated embodiments.  
         [0049]    Although not required, it is preferred for structural strength of the panel connector  60  of this second exemplary embodiment that the channels interconnect at another point besides the first and second channel corners  76 ,  86 . One contemplated embodiment includes one or more extension members (not shown) extending between the back walls of the first and second channels  70 ,  80  to stationarily position the back walls relative to each other. Such an extension may, for example, interconnect the opposed corners of the channels so that the two ends of one back wall are either directly or indirectly connected to corresponding ends of the other back wall. This extension may be substantially planar, arcuate, or other shape that is preferably aesthetically pleasing.  
         [0050]    In another embodiment illustrated in FIGS.  7 - 9 , the channels include respective first and second side extensions  90 ,  94 . The first side extension  90  is connected to the side wall  74  that is opposed to the side wall that forms the first channel corner  76  (i.e., the corner not connected to the second channel  80 ) and, likewise, the second side extension  94  is connected to the side wall  84  that is opposed to the side wall that forms the second channel corner  86 . Both the first and second side extensions  90 ,  94  have extending portions that extend away from the first channel  70  toward the second channel  80  and terminate at a respective distal edge  92 ,  96 . As illustrated, the distal edge  92  of the first side extension  90  contacts the distal edge  96  of the second side extension  94  and, more preferably, the two distal edges  92 ,  96  are fixedly attached together.  
         [0051]    Referring still to FIGS.  7 - 9 , the first side extension  90  is substantially linear in plan view and oriented substantially perpendicular to the back wall  72  of the first channel  70 . Likewise, the second side extension  94  is substantially linear in plan view and is also oriented substantially perpendicular to the back wall  82  of the second channel  80 . The extending portion of the first side extension  90  and the extending portion of the second side extension  94  form a non-linear angle Φ therebetween. That angle Φ between the first and second side extensions  90 ,  94  is preferably supplementary to the angle θ formed between the back walls  72 ,  82  of the first and second channels  70 ,  80  (i.e., collectively the angles (θ+Φ) total 180 degrees). This embodiment is presently preferred because the exterior surface of the formed wall is aesthetically pleasing and provides a contiguous mounting surface when covered, such as with stucco or the like. As noted above, however, other embodiments are contemplated, such as arcuate shapes, to address all architectural designs.  
         [0052]    As noted above, the present invention may optionally further comprise a fastening means associated with at least one of the first and second channels  70 ,  80  for detachably holding a portion of the respective side panel  20  within that respective channel. The embodiment of the fastening means shown in FIGS. 4, 5, and  7 - 9  comprises at least one protrusion  100  that engages the side panel  20  inserted into the channel. As illustrated, each of the side walls  74 ,  84  of the two channels has an engaging surface that faces the opposed side wall  74 ,  84  of that channel and the protrusions  100  are formed on the engaging surfaces of the side walls  74 ,  84 . The illustrated protrusion  100  is saw-tooth shaped in plan view, in which the saw-tooth shape has opposite steep and gradual sides. The gradual side generally faces the front of the side wall  74 ,  84  and the steep side generally faces the respective back wall  72 ,  82  of that channel  70 ,  80 .  
         [0053]    It is also contemplated that the side panels  20  include an indentation  39  or detent in their respective exterior surfaces  32  of a size to receive one respective protrusion  100  therein when the side panel  20  is fully inserted into the channel. In use, when the side panel  20  is inserted into the respective channel, at least one indentation  39  within the interior and/or exterior surface of the side panel  20  engages the steep side of the protrusion  100  to secure the received side panel  20  to the respective channel. There may be a plurality of spaced-apart protrusions  100  on the mating surface of each side wall  74 ,  84  and corresponding indentations  39  to engage each protrusion  100 .  
         [0054]    Additionally, each side wall  74 ,  84  has a lateral height extending between the top surface and the bottom surface of the respective side wall. Each protrusion  100  may extend substantially the lateral height of the side wall, which is greater than half the lateral height, more preferably greater than three-quarters of the lateral height, and most preferably substantially the entire lateral height. Further, each protrusion  100  may extend substantially parallel to the back edge  75 ,  85  of the side wall.  
         [0055]    Other fastening means are also contemplated. One example of an alternative fastening means may comprise at least one orifice (not shown) in each of the side walls of the first and the second pairs of side walls and a plurality of fasteners (not shown). After the first and second side panels  20 A,  20 B are inserted into the respective first and second channels  70 ,  80 , a fastener may be inserted through the orifice into the received side panel  20 . In another design, the fastening means may comprise at least one starter indentation (not shown) in each of the side walls of the first and the second pairs of side walls and a plurality of fasteners (not shown) so that one fastener may be driven through the starter indentation and into the received side panel. It is also contemplated that the fastening means may include chemical adhesives as well as other types of mechanical fasteners such as rivets, nails, screws, bolts and the like if the materials allow (i.e., when using plywood side panels).  
         [0056]    Referring back to FIGS. 4 and 5, one of the side walls  74  of the first pair of side walls and one of the side walls  84  of the second pair of side walls each may define a laterally extending lip  78  formed at the front edge of the respective side wall. As one skilled in the art will appreciate, when the first side panel  20 A is received into the first channel  70  and when the second side panel  20 B is received into the second channel  80 , the defined lips  78  extend outwardly away from the interior surface  34  of the respective received side panels  20  so that a portion of the panel connector  60  extends into the cavity  38  to be substantially cured within the concrete C. Since the lips  78  are an integral part of the panel connector  60 , the lip, assists in “locking” the panel connector  60  to the concrete C once the concrete is poured and substantially cures within the cavity  38  around the exposed portions of the panel connector  60 .  
         [0057]    As illustrated in FIG. 1, multiple panel connectors  60  can be used in conjunction with each other to form the wall structure. Another example is the formation of a T-wall, which is illustrated in FIG. 6. There are two panel connectors shown: a right panel connector  60 R and a left panel connector  60 L. The embodiment of the panel connector  60  illustrated in FIGS. 4 and 5 is shown, but one skilled in the art will appreciate that other panel connector designs may similarly be used, including the embodiment shown in FIG. 9. This T-wall system also uses four side panels, including a first, a second, a third, and a fourth side panel, in which the first and second side panels  20 A,  20 B are inserted into the left panel connector  60 L and the third and fourth side panels  20 C,  20 D are inserted into the right side panel connector  60 R. To form the T-wall, the right and left panel connectors  60 L,  60 R are spaced apart from each other. Also, the first side panel  20 A is oriented substantially linearly with the third panel  20 C and the second and fourth side panels  20 B,  20 D are oriented substantially parallel to each other. The second and fourth side panels  20 B,  20 D are spaced apart a predetermined distance, in which the predetermined distance preferably corresponds to the width of the cavity  38 . As further disclosed in U.S. patent application Ser. No. 09/848,398 (which is incorporated by reference herein in its entirety), flexible linking members  62  and extenders  64  can be used to interconnect the side panels  20  and to assist in preventing bowing when fluid concrete fills the cavity  38 .  
         [0058]    Although the present invention has been described with reference to specific details of certain embodiments thereof, it is not intended that such details should be regarded as limitations upon the scope of the invention except as and to the extent that they are included in the accompanying claims. For example, as noted above, the present invention is described with reference to a system incorporating the depicted concrete form system, it will be understood by those skilled in the art that the present invention is applicable to other types of concrete form systems utilizing one or more form panels or other concrete retaining and/or molding elements retained in position by one or more connectors or other relative position-fixing elements. Also, although the present invention is described with reference to a system, method and components thereof for use in the forming of concrete building components, the present invention may also find application in the formation of various other types of products of concrete and/or other moldable and curable materials such as, for example, structural and nonstructural building components and consumer products of concrete, plastics, and other synthetic and natural materials.

Technology Classification (CPC): 4