Abstract:
An adjustable connector system for stay-in place formwork has a male adjustable connector end that can be inserted into a corresponding female adjustable connector end at variable positions. Using adjustable connector ends in assembling a formwork system increases accuracy by facilitating on-site adjustability of the length and/or diameter measurements of the system. The stay-in-place formwork can be used to create building surfaces, including ceiling panels, siding and walls, and can be used for forming concrete structures, such as walls and sumps.

Description:
TECHNICAL FIELD 
       [0001]    This invention relates to stay-in-place formwork for creating building surfaces such as ceiling panels, siding and walls, and for forming concrete structures. 
       CROSS REFERENCE TO RELATED APPLICATIONS 
       [0002]    None. 
       GOVERNMENT SUPPORT 
       [0003]    None. 
       BACKGROUND 
       [0004]    Concrete structures are formed by pouring concrete into a particular space, usually in the presence of steel reinforcing bars (re-bars) to add strength to the structure. Wall elements known as concrete forms can be used to keep the concrete contained so that the poured concrete solidifies in the location and shape desired. 
         [0005]    Various designs and uses of concrete forms are known. For example, modular formwork elements and assemblies are described in U.S. Pat. Nos. 5,740,648, 6,219,984 and 6,694,692 to Piccone, which are incorporated herein by reference. 
         [0006]    Formwork elements are prefabricated and then pieced together on-site. Concrete forms typically have discrete inner and outer wall panels to create inner and outer wall surfaces. The inner and outer wall panels can be held in place by cross-panels (or reinforcing panels) that span the inner and outer wall panels, creating a formwork assembly having a series of vertically extending cells into which concrete may be poured and left to harden. The inner and outer wall panels can be further reinforced by the addition of bracing panels, which can be connected to an inner or outer wall and/or a cross-panel at 45 degree angles. The cross-panels and bracing panels are usually formed with apertures so that re-bars and poured concrete can pass through the apertures to connect adjacent cells and form a continuous reinforced concrete structure. 
         [0007]    Known concrete forms of this nature are often made from polyvinyl chloride (PVC). Manufacturing tolerance variations and expansions and/or contractions of PVC and other materials due to temperature changes can give rise to variances between the required length or diameter of a structure and the measured and/or manufactured formwork panels. 
         [0008]    Prefabricated ceiling panels and siding panels can be subject to similar manufacturing tolerance variations and expansion and/or contraction. 
         [0009]    There exists a need for a way to make on-site adjustments to the length of prefabricated formwork panels so that the resulting formwork structure is assembled to its correct dimensions. 
       SUMMARY OF INVENTION 
       [0010]    An apparatus of building components has a first component with a female adjustable connection and a second component with a male adjustable connection, such that the male adjustable connection is lockably insertable into the female adjustable connection in a plurality of positions thereby varying the length of the combination of first and second components. 
         [0011]    A method of installing a building structure involves inserting a first male adjustable connection end of a first building component into a first female adjustable connection end of a second building component. The first male and female adjustable connection ends are adjustable with respect to each other to lockably adjust a distance that the first male adjustable connection end is inserted into the first female adjustable connection end to effectively adjust the length of the combination of the first and second building components. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0012]    In figures which illustrate non-limiting embodiments of the invention: 
           [0013]      FIG. 1  is a plan view of an embodiment of the invention having three separated formwork pieces, namely two female adjustable connectors and one male adjustable connector; 
           [0014]      FIG. 2  is a plan view of the embodiment of  FIG. 1  with the three formwork pieces connected together; 
           [0015]      FIG. 3  is a plan view of an embodiment of the invention with adjustable components connected to form a cell connected to other formwork elements; 
           [0016]      FIG. 4  is a plan view of an embodiment of the invention having single adjustable connections at each of the inner and outer walls of an otherwise fixed length formwork system; 
           [0017]      FIG. 5  is a plan view of the embodiment of  FIG. 4  incorporated into a wall formwork structure; 
           [0018]      FIG. 6  is a plan view of an embodiment of the invention forming a cylindrical formwork structure; 
           [0019]      FIG. 7  is a plan view of a portion of the embodiment of  FIG. 6 ; 
           [0020]      FIG. 8  is a plan view of a portion of the embodiment of  FIG. 7 ; 
           [0021]      FIG. 9  is a plan view of a formwork panel according to an embodiment of the invention having two adjustable female connection ends and one male adjustable connection end; 
           [0022]      FIG. 10  is a plan view of a wall incorporating the formwork panel of  FIG. 9 ; 
           [0023]      FIG. 11  is a plan view of a formwork panel according to an embodiment of the invention having two adjustable female connection ends and one male adjustable connection end; 
           [0024]      FIG. 12  is a plan view of a formwork panel according to an embodiment of the invention having an adjustable female connection end and an male adjustable connection end; 
           [0025]      FIG. 13  is a plan view of an embodiment of the invention having three separated formwork pieces, namely two female adjustable connectors and one male adjustable connector; 
           [0026]      FIG. 14  is a plan view of the embodiment of  FIG. 13  with the three formwork pieces connected together; 
           [0027]      FIG. 15  is a plan view of an embodiment of the invention having two separated formwork pieces, namely an adjustable female connector and an adjustable male connector; 
           [0028]      FIG. 16  is a plan view of the embodiment of  FIG. 15  with the two formwork pieces connected together; and 
           [0029]      FIG. 17  is a plan view of an embodiment of the invention having three formwork pieces connected together along with a spacer. 
       
    
    
     DESCRIPTION 
       [0030]    Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense. 
         [0031]    With reference to  FIGS. 1 and 2 , embodiment  10  has a female adjustable connector  20  and a female adjustable connector  22 , each of which have a female adjustable connector  26  and  28 , and a fixed female connection end  30  and  32 . Each of the female adjustable connection ends  26  and  28  are comprised of a series of ribs  34  and gaps  36  formed between ribs  34 . Double-ended male adjustable connector  24  at male adjustable connection ends  40  and  42  is configured to be inserted in female adjustable connection ends  26  and  28  respectively. Double-ended male adjustable connector  24  is similarly comprised of a series of ribs  34  interspaced by gaps  36 , which correspond to the ribs  34  and gaps  36  of the female connection ends  26  and  28 . The combination of the female adjustable connection ends  26  and  28  on connectors  20  and  22  when combined with double-ended male adjustable connector  24 , is such that the spacing between female connector  20  and female connector  22  is adjustable depending upon how much of male connection ends  40  and  42  are inserted into female adjustable connection ends  26  and  28 . 
         [0032]    In  FIG. 2 , double-ended male adjustable connector  24  is inserted at male adjustable connection end  14  into female connection end  26  with two ribs of female connection end  26  not utilized, and with three ribs of female connection end  28  not utilized by the male connector  24 . As shown in  FIG. 2 , in this particular arrangement, there is a gap of distance  44  between female connector  20  and female connector  22  of the space equaling the distance from the beginning of one rib to the end of the fourth rib  34  on double-ended male connector  24 . If double-ended male connector  24  were inserted at a different length into one or both sides of the female connection ends  26  and  28 , the distance  44  separating female connectors  20  and  22  would change accordingly. 
         [0033]    Embodiment  10 , through fixed female connection ends  30  and  32 , can be connected to known fixed-length modular formwork panels, such as those described in U.S. Pat. No. 5,740,648 to Piccone, to add an adjustable length variation segment. 
         [0034]    With reference to  FIG. 3 , embodiment  50  is a segment of formwork elements for forming a segment of wall. Cross-panel or reinforcing panel element  52  has adjustable female connection ends  54  and  56 . Reinforcing panel  58  has adjustable female connection ends  60  and  62 . Reinforcing panels  52  and  58  are separated by male double-ended connection ends  64  and  66  respectively at a separation distance  68 . 
         [0035]    Reinforcing formwork members  70  and  72  are shown with truncated portions representing indeterminate length at points  74 . Reinforcing panel member  70  has a female fixed connection end  80  which snaps into male connection fixed end  76  of reinforcing panel  52 . Similarly, reinforcing panel  58  has a female fixed connection end  78  which is snapped into by male connection end  82  of reinforcing panel  72 . Male connection end  84  of reinforcing panel  52  is snapped into female can fixed connection end  88  of reinforcing panel  70 . Male fixed connection end  90  of reinforcing panel  72  is snapped into female connection end  86  of reinforcing panel  58 . The resulting wall structure creates an inside wall surface  92  and an outside wall surface  94 . The space between the inside wall surface  92  and the outside wall  94  forms a cavity  96 , which is suitable for receiving concrete/cement and/or insulation, as required. 
         [0036]    With reference to  FIG. 4 , embodiment  100  is an interconnected closed-loop chain of formwork elements  102 ,  104 ,  106 ,  108 ,  118 ,  124 ,  136  and  142 , which together create cell cavity  164 . 
         [0037]    Connector  102  has an adjustably interconnectable male end  110  for slideably and lockably engaging an adjustably interconnectable female end  112  of connector  106 . Connector  102  has a fixed interconnectable female end  116  for slideably and lockably engaging a male connection end  162  of connector  118 . 
         [0038]    Connector  106  has a fixed interconnectable female end  120  for engaging a male end  126  of formwork member  124 . Connector  106  has a fixed interconnectable male end  122  for engaging with a formwork element not shown in  FIG. 4 , but shown in  FIG. 5 . 
         [0039]      FIG. 5  illustrates embodiment  170  which incorporates embodiment  100  into a larger wall formwork structure, including the formation of cell cavity  188 . Wall connector panel  172  is connected to connector  106 , cross-panel  180  and wall panel  176  via fixed connections. Wall panel  174  is connected to connector  108 , cross-panel  180  and wall panel  178  via fixed connections. Cross-panel  180  is shown with fixed female connectors ends  182  which could be connected to other panels as desired, such as connecting to a bracing panel that could be added at a 45 degree angle and connected to wall panel  172 , etc. 
         [0040]    Wall panel  184  is connected to connector  118  and wall panel  186  is connected to connector  142  via fixed connection. Wall panels  176 ,  178 ,  184  and  186  are shown to be of indeterminate length at points  74 . 
         [0041]    With reference to  FIG. 6 , embodiment  190  shows formwork elements arranged to create a cylindrical formwork column. The connection of formwork elements results in an outer wall  192  of circular cross-section, and inner wall  194  of circular cross-section, having reinforcing framework elements  196 . In embodiment  190 , there is a fixed female connection end  200 . Cement can be poured into the cavities  202  created by the combination of formwork elements. Portion  210  of embodiment  190  is shown in  FIG. 7  in further detail. 
         [0042]    With reference to  FIG. 7 , column portion  210  comprises a connector system  214  shown in even further detail in  FIG. 8 . The formwork elements in  FIG. 7  together create outer wall  192  and inner wall  194 . Reinforcing element members  196  help the structure retain rigidity and shape. Connector  198  adjustably connects formwork elements to enable more exact shape than if the adjustable nature of the connection were not present. 
         [0043]    As shown in  FIG. 8 , connector  198  comprises female adjustable connection ends  218  and  220  and a fixed female connection end  222 . It is understood that in other embodiments, one or all of the connection ends could be adjustable. 
         [0044]    With reference to  FIG. 9 , embodiment  224  is a formwork element having a female connection end  226  which is seamlessly integrated at point  228  such that an outer wall surface  234  can be created smoothly from the flat section through to the connection section. Adjustable female connection end  230  is provided to allow adjustable connection to reinforcing members. Adjustable male connection end  232  is disposed inwardly from outer wall surface  234  to be offset at elbow  236  by a distance which corresponds to the distance to insert into a female adjustable connection end to create a flat outer wall surface when the male end is fully inserted into the female end, for example as shown at connection  252  in  FIG. 10 . 
         [0045]    With reference to  FIG. 10 , embodiment  240  shows formwork element  224  incorporated into a wall structure having outer wall surface  234  and inner wall surface  248 . 
         [0046]    Prefabricated seam-filling segments can correspond to the shape and distance of a male adjustable connector sticking out of a female adjustable connector, whether that distance relates to 1, 2, 3, 4 or more ribs, such that the outer wall surface can be easily and immediately filled into to a flat surface even when the male and female adjustable connection ends  232  and  226  are not completely inserted into one another in a manner that might otherwise leave an indented gap in the outer wall surface  234 . Seam filling segment  238  is an example of such a segment, in this case relating to an indentation gap  242  created when two ribs of the male adjustable connection end  232  stick out of the corresponding female adjustable connection end  226 . 
         [0047]    Adjustable female connection ends  230  are connected to reinforcing members  244  and  246  respectively, forming cell cavity  250 . In one instance, a male adjustable connection end of reinforcing member  246  is not inserted completely into the corresponding female adjustable connection end such that a gap  248  appears within the female adjustable connection end. As the male and female adjustable connection ends have a multiplicity of ribs, reinforcing panel  246  is firmly held in position by the adjustable connection irrespective of the gap  248  due to the rib(s) that remain in contact. 
         [0048]    Embodiment  260  in  FIG. 11  is a panel element having a smooth male connection end  262  and a smooth female connection end  264 , and having a ribbed adjustable connection end  266  for connection to a cross-panel member. 
         [0049]    Embodiment  268  in  FIG. 12  is a panel element having a smooth male connection end  262  and a smooth female connection end  264 , but does not have a connection end for connection to a cross-panel member. 
         [0050]    Connections between a smooth male connection end  262  and a smooth female connection end  264  are adjustable to allow very precise adjustments that do not require choosing one rib distance or another. The connections can be further locked in position, where desired, by glue, or screws, nails, or the like. In suitable applications, the connection can be left without glue, screws or nails or the like to allow for expansion or contraction. 
         [0051]    With reference to  FIGS. 13 and 14 , embodiment  270  has a female adjustable connector  272  and a female adjustable connector  274 , each of which have a female adjustable connector  278  and  280 , and a fixed female connection end  30  and  32 . Each of the female adjustable connection ends  278  and  280  are have relatively smooth surfaces to allow for micro adjustment and/or expansion and contraction of the joint. Double-ended male adjustable connector  276  at male adjustable connection ends  284  and  286  is configured to be inserted in female adjustable connection ends  278  and  280  respectively. Double-ended male adjustable connector  276  is similarly smooth, or relatively smooth, to allow for micro adjustments and/or expansion or contraction of the resulting joint formed with adjustable female connection ends. 
         [0052]    The combination of the female adjustable connection ends  272  and  274  on connectors  278  and  280 , when combined with double-ended male adjustable connector  276 , is such that the spacing between female connector  278  and female connector  280  is adjustable depending upon how much of male connection ends  284  and  286  are inserted into female adjustable connection ends  278  and  280 . 
         [0053]    In  FIG. 14 , double-ended male adjustable connector  276  is inserted into female connection end  26  with two ribs of female connection ends  278  and  280  respectively. The lengths of the male adjustable connector  276  and the female adjustable connector ends  278  and  280  can be cut off on site, such as by using a knife and/or saw, to match the dimensions required so that a single seam with no gap can be achieved, while providing the correct spacing. 
         [0054]    Embodiment  270 , through fixed female connection ends  30  and  32 , can be connected to known fixed-length modular formwork panels to add an adjustable length variation segment. 
         [0055]    With reference to  FIGS. 15 and 16 , embodiment  290  has connector  292  with a fixed female end  30  and a click-in adjustable female connection end  296 . Embodiment  290  further has a building element  294  having a click-in adjustable male connection end  298 . Ash shown in  FIG. 16 , the click-in adjustable male connection end  298  can be pushed in direction  300  to click into adjustable female connection end  296  in a variety of positions, such as with one position not used, which can leave a gap  302 . In other cases, gap  302  may be predetermined and may be filled with an insert, for example spacer insert  314  shown in  FIG. 17 . 
         [0056]    Click-in adjustable male connection end  298  and click-in adjustable female connection end  296  are designed to push together in one direction and be locked from expanding apart. It may be possible to separate the two during construction by lifting one piece out of the other in a direction into or out of the plane of the paper in  FIG. 16 , a direction perpendicular to direction  300 . 
         [0057]    Embodiment  310  in  FIG. 17  has double-ended click-in male adjustable connector  312  clicked into female adjustable connection end  296  of connector  292 . Connector  312  is not fully inserted into connection end  296  due to the presence of spacer  314 . The other end of connector  312  is fully inserted into adjustable female connection end  318  of connector  316 , which also features fixed female connection end  320 . In embodiment  310  there is a gap  322  between connectors  292  and  316  which in this case generally corresponds to the length of the spacer  314  to effectively lengthen the combination of connectors  292 ,  312  and  316 . The gap  322  may be filled in by putty or plaster or a strip of PVC or metal or other suitable material, if desired, to create a uniform outward appearance for one or both surfaces. 
         [0058]    Embodiments of this invention can be made from polyvinyl chloride (PVC), or from other suitable plastics, which depending upon the application may include ethylene propylene diene monomer (EPDM), thermoplastic elastomer polyolefin (TPO), cross-linked polyethylene (XLPE, marketed as PEX), polyethylene (PE), high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), nylon, ethylene vinyl acetate (EVA), poly(methyl methacrylate) (Plexiglass™), polypropylene (PP), polyolefins, and fiberglass. However, it is understood that it could be used with panels and connection systems using other suitable materials, such as cast aluminum, sheet metal, carbon fiber, or other suitable metals, synthetic or natural materials, including fiber cement, rubber, or wood. The invention has application for systems of mixed concrete forming and other materials, such as the use of Styrofoam™ or other forms of insulation replacing some or all of the concrete. 
         [0059]    Some embodiments of the invention may have modular construction applications completely separate from concrete forming. For example, embodiments  224  and  260  could be used as a ceiling with connection ends  230  and  266 , or suitable alternatives, used to secure the ceiling surface beams or other structure. Embodiments  224 ,  260  and  268 , and similar, can be used as siding for buildings and/or for wall or flooring coverings and/or surfaces. 
         [0060]    As will be apparent to those skilled in the art in the light of the foregoing disclosure the present invention is not limited by what has been particularly shown and described herein. Rather the scope of the present invention includes both combinations and sub-combinations of the features described hereinabove as well as modifications and variations thereof which would occur to a person of skill in the art upon reading the foregoing description and which are not in the prior art. Furthermore, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example, the illustrated embodiments show variable connections that are smooth, or having click-in surface contours, or having alternating perpendicular ribs and gaps, however it is to be understood that any reasonable variable connection is intended to be included within the scope of the invention, including dovetails, rounded protrusions and other suitable variations. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.