Field of the invention:

The present invention relates generally to the field of walls made from the hardening of flowable materials. More particularly, it relates to a hybrid connector used to tie panels together so as to create a form for receiving the flowable material, and an assembly and method related thereto.

Background of the invention

A number of different techniques currently exist for using insulating forms for casting a concrete wall. Often, these systems comprise pairs of opposed foam panels generally made of a rigid foam like polystyrene which define concrete- receiving cavities therebetween. Once the concrete is solidified, the form walls remain in place to insulate the wall. These form walls are typically fixed apart from each other before the pouring of concrete by means of spacers comprising a pair of parallel lateral attachment flanges, each flange being embedded or inserted in one of the two opposed foam panels, and a connecting web interconnecting the flanges.

The following US patent documents disclose examples of different prior art walls and methods: 7,082,732 B2; 7,024,833 B1 ; 6,668,503; 6,609,340 B2; 6,401 ,419; 6,256,962; 4,889,310; 2006/0179135 A1 ; and 2009/0179135.

The following patent documents are also known: CA 2,256,261 ; CA 2,358, 195; and JP 2001317142.

It is sometimes desired or indeed necessary to remove a form wall or foam panel, for example the one facing toward the inside of a structure, from the concrete so as to expose the surface of the concrete wall. This can be the case with stair cases in buildings, for example, where the regulatory environment or building code sometimes requires that the interior concrete walls be free of any material so as to improve the walls fire-resistant characteristics. These exposed concrete walls are desired for other structures as well, such as underground garages.

However, it is known that removing the foam panels from the concrete wall is difficult. Since the foam panels are often well integrated with the concrete wall, they must be torn from the wall, typically by hand, which can be extremely labour-intensive for large wall areas. Furthermore, such a removal operation creates significant waste because the torn panel is not reusable, and it may also result in additional disposal costs. US 6,314,694 B1 discloses a one-sided, insulated formwork used in the construction of walls from pourable building material, such as concrete, including an insulating panel connectable to a removable panel by a connecting structure, which may include a permanent reinforcement embedded in the insulating panel. The connecting structure may have a tie removably attachable to the reinforcement, or the reinforcement and tie may constitute a monolithic structure. The tie may be asymmetric in shape to facilitate distribution of loads across the insulating panel, detachment of the removable panel, and enhance the structural integrity of the finished wall. One drawback of such a formwork is that, upon removal of the removable panel, a channel or fixture may be left integrated in the finished wall and visible to an observer of the wall. This can be unsightly or unnecessary, and it may be required to remove or conceal such a channel, further adding to labour and material costs. Another drawback of the formwork is that it may not allow for the formation of anchor points within the finished wall. A further disadvantage of such foam panels is that they are not often designed to form a smooth exposed wall surface, or one that is free of projecting objects such as reinforcing bars orfasteners which must be chiselled from the exposed wall. This can result in a visually unappealing exposed wall, or one that must be reworked or touched-up, further increasing labour and material costs.

The following references disclose other examples of systems to create concrete walls: US 6,681 ,539 B2; US 5,497,592; US 4,085,495; US 3,995,825; and JP 2007291758.

There is thus a need for a wall form having panels which can be easily arranged on site so as to facilitate installation, and where at least one of the panels can be easily removed so as to leave a smooth exposed wall surface.

Summary of the invention An object of the present invention is to provide a wall form or a connector for making a wall form that will satisfy the above-mentioned need, and more particularly to propose a hybrid connector and an assembly therefor which aim to overcome the drawbacks of the presently available methods and apparatus for making wall forms. In accordance with the present invention, there is provided a hybrid connector for tying together a detachable panel and a foam panel in opposed and parallel spaced relation along a longitudinal direction. This creates a form for receiving a flowable material that sets and hardens into a wall. The hybrid connector includes a first and a second opposed elongated side members. The first side member is devised to be inserted, optionally embedded, longitudinally inside the foam panel, and the second side member is devised to removably secure the detachable panel. The hybrid connector also includes a web member for connecting together longitudinally the first and second side members. The second side member includes an elongated support frame which is connectable to the web member, as well as at least one screw-receiving sleeve extending transversally from the support frame for removably securing the detachable panel.

It is worth mentioning that by hybrid connector, it is meant a connector with asymmetric or non-identical side or flange members.

Optionally, the at least one screw- receiving member abuts against the detachable panel during installation such that it is flush with the exposed outer surface once the detachable panel is removed. Further optionally, the at least one screw-receiving member has a frangible and removable head. The frangible head can be broken using a suitable tool and its broken pieces removed, so as to create a cavity within the exposed outer surface. In one possible embodiment, the second side member has a reinforcing structure which supports the at least one screw-receiving member against the loads which are generated when the flowable material is poured into the form. The reinforcing structure can take the shape of a substantially triangular projection, which expands from a free end of the at least one screw-receiving member toward the elongated support frame.

The present invention is also directed to a wall form assembly for receiving a flowable material that sets and hardens into a desired formation. The wall form assembly comprises:

a detachable panel;

a foam panel; and

a hybrid connector for tying together the detachable panel and the foam panel in opposed and parallel spaced relation along a longitudinal direction so as to create a form for receiving the flowable material, the hybrid connector comprising: a first and a second opposed elongated side members, the first side member being inserted, optionally embedded, longitudinally inside the foam panel and the second side member being removably secured to the detachable panel; and

a web member for connecting longitudinally the first and second side members together,

wherein the second side member comprises:

an elongated support frame connectable to the web member; and at least one screw-receiving sleeve extending transversally from the support frame for removably securing the detachable panel.

The present invention is also directed to a method for creating a desired formation from a flowable material that sets and hardens. The method comprises the steps of:

a) providing a detachable panel and a foam panel;

b) tying together the detachable panel and the foam panel using a hybrid connector, the detachable and foam panels being tied in opposed and parallel spaced relation along a longitudinal direction so as to create a form for receiving the flowable material, the hybrid connector comprising:

a first and a second opposed elongated side members, the first side member being devised to be inserted, optionally embedded, longitudinally inside the foam panel and the second side member being devised to removably secure the detachable panel; and

a web member for connecting longitudinally the first and second side members together,

wherein the second side member comprises:

an elongated support frame connectable to the web member; and at least one screw-receiving sleeve extending transversally from the support frame for removably securing the detachable panel;

c) pouring the flowable material into the form;

d) allowing the flowable material to set and harden within the form so as to create the formation; and

e) removing the detachable panel from the formation so as to expose an outer surface thereof. The present invention thus allows for the creation of a wall form which can be easily manufactured, compacted and stored without requiring a lot of space, and which can be easily transported to the construction site. The detachable panel allows for one of the outer surfaces of the wall, or a part thereof, to be exposed and thus accessible, if need be. The detachable panel can also help to ensure that such an exposed outer surface is relatively smooth, and free of protrusions and nicks resulting from the setting and hardening of the flowable materials.

Advantageously also, the wall form can be completely pre-assembled at the factory and is more easy to transport to the site of construction as disassembled prior art wall forms. Other features and objects of the present invention will become more apparent from the description that follows of optional embodiments thereof, having reference to the appended drawings and given as examples only as to how the invention may be put into practice.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a wall form assembly provided with a plurality of hybrid connectors, according to an optional embodiment of the present invention; Figure 2 is a perspective view of a hybrid connector for tying together a detachable and a foam panel, according to an optional embodiment of the present invention;

Figure 3 is another perspective view of the hybrid connector of Figure 2; Figure 4 is a side view of the hybrid connector of Figure 2;

Figure 5 is a perspective view of a plurality of hybrid connectors being shown without the foam panel but removably connected to a detachable panel, according to an optional embodiment of the present invention;

Figure 6 is a perspective view showing mechanical fasteners being used to removably connect a detachable panel to a plurality of hybrid connectors, according to an optional embodiment of the present invention;

Figure 7 is a perspective view of a plurality of assemblies being arranged into a mold for creating a wall formation, according to an optional embodiment of the present invention; Figure 8 is a perspective view of the assemblies of Figure 7, being shown filled with a flowable material;

Figure 9 is a perspective view of the filled assemblies of Figure 8, where a detachable panel is shown removed so as to expose an outer surface of the wall formation; and Figures 10A to 10D are enlarged views of the circled area of Figure 9, showing the insertion of a tool into the recess of at least one screw-receiving sleeve so as to break a head of said sleeve, according to an optional embodiment of the present invention. Figure 1 1 is a perspective view of a foam panel, according to an optional embodiment of the present invention.

Description of optional embodiments

The present invention can be employed to make a form, or plurality of forms, for receiving a pour of a flowable material, such as concrete, cement, or the like, into a cavity defined by the form. Once the flowable material sets or hardens into a formation, the present invention allows for an outer surface of the formation to be exposed, thereby providing an exposed outer surface which can be smooth, visually appealing, and free from protrusions and abrasions. According to an aspect of the present invention, there is provided a hybrid connector 10, examples of which are shown in Figure 1 . The hybrid connector 10 is used to tie together a detachable panel 50 and a foam panel 60. The panels 50,60 can be of any suitable shape and size to create the desired wall form or formation. The detachable panel 50 can be made of plywood or another suitable material. The foam panel 60 can be made of polystyrene foam, or any other suitable insulating material. The foam panel 60 can also take any suitable form. For example, and as shown in Figure 1 1 , the foam panel 60 can have an "undulated" or "ridged" inner surface. In addition, the inner surface of such a foam panel 60 can have mounts integrated therein for mounting to the connector 10 or a portion thereof. The foam panel 60 can also have joints mounted on the top and bottom surfaces of the foam panel 60 for connecting vertically to other respective foam panels 60.

The hybrid connector 10 maintains the panels 50,60 in opposed and parallel spaced relation. The expression "opposed and parallel spaced relation" refers to the orientation of the panels 50,60 when connected to the hybrid connector 10. Such an orientation allows for the panels 50,60 to be distanced or "spaced" from each other so as to define a void 55, and further allows the panels to be aligned parallel with each other. Although shown in Figure 1 as being parallel and in a horizontal alignment, the panels 50,60 can also have other alignments, such as vertical, angled, or any combination in between. The hybrid connector 10 maintains the panels 50,60 along a longitudinal direction. The expression "along a longitudinal direction" refers to the orientation of the connector 10 when connected to the panels 50,60. An example of such an orientation is provided in Figure 1 . As shown, the connector 10 is vertically positioned between both panels 50,60. It can thus be appreciated that the tying together of the panels 50,60 by the connector 10 creates a form or assembly 70, having a void 55, which can receive the flowable material. The connectors 10 can be affixed to adjacent connectors 10 in a vertical orientation, so as to combine multiple assemblies 70. In addition, the connector 10 can be symmetrical for providing "reversibility" functionality, meaning that it can be used regardless of which side is up or down. Upon setting and hardening, this flowable material will create the desired formation, as further explained below.

The connector 10 will now be further described with reference to Figures 2 to 4, which provide examples of the connector 10 shown in isolation.

The connector 10 has a first elongated side member 20 (or simply "first member") and an opposed second elongated side member 30 (or simply "second member"). The term "opposed" when used to describe the relationship of the first and second members 20,30 refers to their position on distinct, or "opposite" sides of the connector 10. The first member 20 is typically embedded longitudinally within the foam panel 60, and forms an integral part thereof. Such integration of the first member 20 can occur during the manufacture or assembly of the foam panel 60, during which the first member20 can be inserted along an orientation perpendicular to the length of the foam panel 60 (i.e. a "vertical" orientation). The embedding of the first member 20 can allow for the connector 10 to better support the loads generated by the flowable material as it is poured into the void 55, or as it settles or hardens. The second member 30 is intended to be removably secured to the detachable panel 50. As such, the second member 30 can facilitate the removal of the detachable panel 50 from an exposed outer surface of the formation, as further explained below. The expression "removably secure" refers to the ability of the second member 30 to be affixed to the detachable panel 50 during the creation of the form, or during the pouring of the flowable material, for example. The expression also refers to the ability of the second member 30 to be relatively easily removed from the detachable panel 50 when desired, such as upon the flowable material hardening, for example.

The connector 10 also has a web member 40 which connects longitudinally (i.e. in a vertical orientation) the first member 20 with the second member 30. The web member 40 also helps to support the connector 10 against the loads produced by the flowable material. As an example, the pouring of the flowable material into the void 55 formed between the panels 50,60 can place significant pressure on the panels 50,60, forcing them to move or separate. In connecting the panels 50,60 together, the web member 40 thus "anchors" the panels 50,60, and helps them better resists these loads. It is thus apparent that the web member 40 is not limited to the shape shown in Figures 2 to 4, and can have a different shape, size, or configuration depending upon the following non- exhaustive list of factors: the anticipated loads produced by the flowable material, the size of the panels 50,60, the cost of materials, etc. Optionally, the web member 40 can have one or more retaining members 42 into which can be inserted and maintained a corresponding reinforcement bar, disposed horizontally. Referring to Figure 2, the second member 30 also includes an elongated support frame 32. The support frame 32 can extend along the entire length of the second member 30, or only along a portion thereof. The support frame 32 connects with the web member 40, so as to provide a link between the second member 30 and the first member 20. The support frame 32 can connect to the web member 40 using many different techniques. In one possible embodiment, the support frame 32 can consist of an elongated rod extending the length of the second member 30, which can be slid into corresponding grooves protruding from one side of the web member 40. In another possible embodiment, the support frame 32 and the web member 40 can interlock with each other, using a "click"-producing mechanism. In yet another possible embodiment, the support frame 32 is mounted like a hinge to the web member 40, which can permit the support frame 32 (and thus the second member 30) to pivot or rotate about the web member 40. This last configuration may be suitable for transportation and storage purposes, because it may allow the connector 10 to collapse unto itself.

The second member 30 further includes at least one screw-receiving sleeve 34 (or simply "sleeve"). The at least one sleeve 34 can be many sleeves 34 distributed throughout the second member 30. Optionally, the plurality of vertical sleeves 34 can be aligned vertically with each other. The sleeve 34 allows the second member 30 to be mounted to the detachable panel 50, and also allows for the detachable panel 50 to be removed from the second member 30. Each sleeve 34 can extend transversally from the support frame 32. The expression "extend transversally" refers to the orientation of the sleeve 34, in that the sleeve 34 extends substantially perpendicularly from the support frame 32. The sleeve 34 is "screw-receiving", meaning that it can receive a screw or other suitable mechanical fastener which would permit the sleeve 34 to be secured to the detachable panel 50, and removed therefrom.

In some optional embodiments, the sleeve 34 has a free end 36 which can abut against an interior surface of the detachable panel 50 when the second member 30 is secured to thereto. The free end 36 can be located at one end of the sleeve 34 and away from the support frame 32. It is therefore "free" because it corresponds to the end of the sleeve 34 not joined to the support frame 32. The free end 36 has an exterior face 41 which may face away from the support frame 32, and which can be arranged flush with the interior surface of the detachable panel 50 when the second member 30 is secured thereto. The exteriorface 41 may include a recess 39 or pit, which can receive a suitable tool, or which can serve to hide any fastener inserted into the open passage formed by a hollow sleeve 34 when the flowable material hardens. The flush arrangement of the exterior face 41 with the interior surface of the detachable panel 50 allows for exteriorface 41 to be flush with the exposed outer surface of the formation when the detachable panel 50 is removed.

In some optional embodiments, the free end 36 of the sleeve 34 can have and/or consist of a cylindrical head 38. The cylindrical head 38 can be made of any suitable material, or manufactured in such a fashion, that it can be easily broken by a worker on site. Optionally, the head 38 can be made of a frangible material or link such as a hollow thermoplastic. Further optionally, the head 38 can be manufactured to have loose fracture links integrated within it, which would permit the head 38 to be fractured or broken along those links. The removal of the broken head 38 leaves a cavity, described in more detail below, in the exposed outer surface of the formation once the detachable panel 50 is removed. The cavity advantageously may allow for the mounting of appropriate fixtures or supports to the exposed outer surface. Alternatively, the cavity can be filled in, or the head 38 can be left in place unbroken. In some optional embodiments, the sleeve 34 has a main portion 35, which extends from the support frame 32 and links to the cylindrical head 38 by means of frangible links. The main portion 35 can take on any suitable configuration or shape. Optionally, the main portion 35 is a hollow tube. Such a hollow tube allows for the formation of an open passage in the exposed outer surface of the formation. Indeed, once the flowable material is poured into the void 55, the hollow tube main portion 35 prevents the flowable material from filling the volume enclosed by the hollow tube, which results in this volume forming the open passage when the flowable material sets and hardens. In some optional embodiments, the second member 30 includes a reinforcing structure 31 , better shown in Figure 4. The reinforcing structure 31 reinforces the sleeve 34 against the loads which may be generated by the flowable material. The reinforcing structure 31 can thus take any suitable form or configuration to achieve such functionality. In one possible configuration, an example of which is shown in Figure 4, the reinforcing structure 31 expands between the free end 36 of each sleeve 34 toward the support frame 32, thereby forming a shape that is substantially triangular. Such a triangular reinforcing structure 31 may better support the load or weight of the flowable material, and thus help to keep the panels 50,60 together.

In another possible configuration, the expanded reinforcing structure 31 can expand until just short of the support frame 32, and form a continuous link with the adjacent reinforcing structure 31 via a force link 33, which may help in distributing and resisting the loads generated by the flowable material. Optionally, the reinforcing structure 31 can have a retaining member 37 into which a corresponding horizontal retaining bar (i.e. rebar) can be inserted and retained, such as through press-fitting, as but one example. The retention of such a retaining bar in the retaining member 37 can help the connector 10 better resist the loads, and also serve to support the formation when the flowable material sets and hardens.

According to another aspect of the present invention, there is provided a wall form assembly 70, and example of which is shown in Figure 1 . The assembly 70 receives the flowable material and acts as a form in which the flowable material can set and harden so as to create the desired formation. The assembly 70 has a detachable panel 50 and a foam panel 60, as well as a hybrid connector 10, such as the one described above. Multiple assemblies 70 can be used to create the formation, as will be discussed further below, and can be stacked one atop another or side-to-side, depending on the formation to be created. According to another aspect of the present invention, there is provided a method for creating a desired formation from a flowable material. Examples of the steps of the method are provided in Figures 5 to 10D.

The method includes the step of providing a detachable panel 50 and a foam panel 60. The method further includes the step of tying these panels 50,60 together using a hybrid connector 10 such as the one described above, or multiple such connectors 10, which creates an assembly 70 into which the flowable material can be poured. Figure 5 illustrates an optional embodiment where multiple connectors 10 are removably joined along their respective second members 30 to an interior surface 52 of the detachable panel 50. Optionally, the exterior face 41 of the sleeve 34 is mounted flush to the interior surface 52 of the detachable panel 50, as previously explained. As shown in Figure 6, as the exterior face 41 of the sleeve 34 is brought flush with the interior surface 52, fasteners 12 (e.g. nails) can be inserted into each main portion 35 so as to fix the detachable panel 50 to the connector 10. Alternatively, the detachable panel 50 can be prefabricated with the connectors 10 attached. Once the panels 50,60 are brought together by the connector 10, the form or assembly 70 thus made is ready to create the formation.

A plurality of assemblies 70 can be provided so as to create an appropriate form for the formation, an example of which is shown in Figure 7. The method includes the steps of pouring the flowable material into such a form, and allowing the flowable material to harden within the form so as to create the formation 90. An example of multiple assemblies 70 being filled with a flowable material is shown in Figure 8. Once the formation 90 is suitably set and hardened, the method includes the step of removing at least one detachable panel 50 from the formation 90, so as to expose an outer surface 92 of the formation, as exemplified in Figure 9. The removal of the detachable panel 50 can be achieved by unscrewing or removing the mechanical fasteners 12 from the sleeves 34. It can thus be appreciated that the removal of the detachable panel 50 leaves a smooth and protrusion-free exposed outer surface 92, which can include multiple locations having embedded sleeves 34 and exterior faces 41 which are flush with the exposed outer surface 92.

The heads 38 of these sleeves 34 can thus be left embedded within the exposed outer surface 92, or can be broken and removed therefrom so as to form cavity, as exemplified in Figures 10A to 10D. Referring to Figure 10A, the heads 38 of the sleeves 34 are shown being flush with the exposed outer surface 92. Also shown are the recesses 39 which can be included in the exteriorfaces 41 of the sleeves 34. The formation of the cavity 14 in the exposed outer surface 92 can be achieved by inserting a tool 16, such as a ratchet, or the operative end thereof, into the recess 39, as exemplified in Figures 10B and 10C. Once inserted therein, the tool 16 can be rotated so as to break the head 38. This can be achieved, for example, with a recess 39 which is substantially rectangular in shape. If the tool 16 has a round or non-rectangular shape, the rotation of the tool 16 once it is inserted in the recess 39 will cause the frangible head 38 to break. Once so broken, the tool 39 can be removed, as well as the broken head 38, leaving only a cavity 14, as exemplified in Figure 10D.

In light of the preceding, it can thus be appreciated that the present invention allows for the creation of a wall formation from which an exposed outer surface thereof can be quickly and easily revealed, said exposed outer surface providing a smooth and protrusion-free surface for being used or displayed as desired.

More particularly, the removable mounting of the sleeve 34, and thus the second member 30, to the detachable panel 50 prior to receiving the pour of flowable material allows for the formation of a substantially smooth outer surface, as well as the creation of an interior passage therein.

As can be appreciated from Figure 1 , thanks to the specific characteristics of the connector 10 according to the present invention, the panels 50,60 once tied with the help of the connectors 10 are easily foldable with respect to one another and thus can be shipped to the site of construction in a well compacted form.

Once a form for receiving flowable material is mounted using a plurality of stacked horizontal rows of form wall assemblies 70, the empty cavity 55 existing between the form wall made of foam and detachable panels 50,60 can be easily filled with concrete or with a cement-based material. After hardening of the flowable material, a composite wall 90 is obtained with the panels 60 firmly attached through the connectors 10 to the concrete inside-wall, having an exposed outer surface 92. Although optional embodiments 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 those precise embodiments and that various changes and modifications may be effected therein without departing from the scope of the invention.