FORMWORK PANEL AND FORMWORK SYSTEM COMPRISING SUCH A PANEL

Abstract

 Formwork panel that comprises: a formwork element that comprises a formwork surface; a series of structural reinforcement ribs; and a frame that surrounds the formwork element at least along two parallel sides, the frame comprising a hollow profile that comprises a zone for receiving the formwork element and a face that comprises two rib-connection zones and a support zone for panel-connection means, in which the support zone protrudes relative to at least one of the rib-connection zones.

Description

[0001] The present invention relates to formwork systems and, more particularly, to a formwork panel. More specifically, the present invention relates to innovations in panels which are especially useful in the field of light or 'hand-portable' panels, that is, formwork panels that are designed to be moved manually, without the intervention of machinery, such as cranes.

[0002] Said panels are characterised with respect to non-hand-portable panels in being lighter. However, it should be borne in mind that the reduction in weight of the panel must not be achieved at the cost of the necessary rigidity of the panel and, in general, of the entire formwork system.

[0003] Formwork panels usually comprise:

• a moulding element which comprises the moulding surface; said element is usually a panel or set of panels made of timber,
• a series of structural reinforcement ribs (usually made with a rectangular or open U- or C-shaped profile), and
• a frame which surrounds the formwork element at least along two parallel sides.

[0004] In ultra-light panels, and with the object of reducing weight, it is usual for the frame to be formed by a hollow profile, usually made of sheet metal. The profile has a projection or fin and an adjacent surface for receiving the formwork element with the formwork surface. In addition, the profile has a face with two zones to which the rib is connected by welding and a recess between said zones, the object of which is to receive panel-connection means. In ultra-light panels, it is usual for the wall of said face to come in contact with the wall of the opposite face of the profile in the recess zone. The edge of the ribs is flush with that of the profile less the thickness of the moulding element, or in other words, flush with the edge of said face with the zone or zones to which the rib and the recess are connected. Thus, rib and frame are level, and neither projects relative to the other.

[0005] An object of the present invention is to disclose means that allow a reduction in the weight of these types of systems and panels without a reduction in strength, obtaining an excellent compromise between strength and weight.

[0006] More particularly, the present invention discloses a formwork panel which comprises:

• a moulding element which comprises the moulding surface; said element is usually a panel or set of panels made of timber
• a series of structural reinforcement ribs, and
• a frame which surrounds the formwork element at least along two parallel sides

the frame comprising a hollow profile which comprises a zone for receiving the moulding element and a face which comprises two rib-connection zones and a support zone for panel-connection means,
in which
the support zone projects relative to at least one of the rib-connection zones.

[0007] Preferably, the two rib-connection zones are not aligned. More preferably, the support zone is a straight length of wall which forms an oblique angle with the rib-connection zones.

[0008] According to another aspect of the present invention, the edge of the rib may be lower than that of the face of the profile which comprises said connection and support zones, so that the profile projects relative to the rib.

[0009] According to the present invention, the ribs may be connected to the profile by welding and the profile may be made of sheet metal.

[0010] More preferably, the support zone is neither parallel nor perpendicular to any of the other faces of the profile.

[0011] Preferably, both connection zones are parallel, with the outermost connection zone positioned closer to the centre of the panel than the innermost connection zone.

[0012] The present invention also comprises a formwork system which comprises panels according to the present invention. Advantageously, the formwork system comprises at least one panel in which the rib is set back relative to the profile and one panel in which the rib is set back relative to the profile. Preferably, the system will also comprise at least one clamp for connecting adjacent panels in which the shape of the clamp matches that of the support zone of the panels.

[0013] According to the present invention, the support zone is formed as a projection and not as a recess. This signifies a reduction in weight for the following reasons:

• It allows the ribs to be cut to match the shape of the profile. As the support zone projects, the amount of material of the ribs is reduced.
• With regard to the profile with a recess, the profile gains rigidity without an increase in the surface area of sheet metal required to produce said profile. Because said profile has greater rigidity, the thickness thereof can be reduced and, hence, the weight thereof.

[0014] Because the support zone is formed as a face which is neither parallel nor perpendicular to any of the other faces of the profile, errors in placing the connection clamps are avoided.

[0015] The fact that the outermost connection zone is positioned closer to the centre of the panel than the innermost connection zone helps ensure the viability of the ribs which are set back relative to the profile.

[0016] Moreover, the configuration of the present invention helps ensure that the outermost support zone is larger than the innermost, further enhancing the possibility of using ribs that are set back relative to the profile.

[0017] For a better understanding, the accompanying drawings show an embodiment of the present invention given as an explanatory but non-limiting example.

Fig. 1 is a transverse cross section along a horizontal plane of an ultra-light formwork panel according to the prior art, in which can be seen the moulding element, the profile that forms the frame and the rib.

Fig. 2 is a view in transverse cross section of an embodiment of a profile for a formwork panel according to the present invention.

Fig. 3 is a transverse cross section along a horizontal plane of an embodiment of an ultra-light formwork panel according to the invention, in which can be seen the moulding element, the profile of Fig. 2 and a rib.

Fig. 4 is a variant of the panel of Fig. 3.

Fig. 5 shows two panels according to the present invention connected by a clamp belonging to a formwork system according to the present invention.

Fig. 6 is a perspective view of a clamp according to the present invention.

Fig. 7 is a view in cross section along a horizontal plane of a formwork system according to the present invention, with sets of parallel panels which leave a moulding space internally.

Fig. 8 is a variant of the embodiment of Fig. 7.

Fig. 9 is another variant of the embodiment of Fig. 7.

Fig. 10 is yet another variant of the embodiment of Fig.7.

Fig. 11 is a view in elevation of an assembly of a formwork system according to the present invention, in which four panels define the moulding space of a column.

Fig. 12 is a plan view from above which corresponds to the plane XII-XII of Fig. 11.

Fig. 13 is a detail of Fig. 12 which shows the support of the head of a threaded connection bolt in the connection zone of the profile of the frame of the panel.

[0018] Fig. 1 shows an ultra-light formwork panel according to the prior art. More specifically, said figure shows a transverse cross section of one of the side edges of a panel, in order to show clearly the elements that make up said panel.

[0019] The panel is made up of a moulding element -11- which comprises a moulding surface -111-. The moulding surface -111- has the function of limiting the space occupied by the concrete, while possibly remaining in contact therewith. On the rear portion, that is to say, on the portion opposite the moulding portion a series of ribs -12- runs over the panel from side to side. The panel also has a frame which runs round said panel at the perimeter thereof. The frame is formed by a hollow profile -13-, made of folded sheet metal. The profile has a seat formed by the moulding element -11- which is formed by a projection -131- or fin which protects the side of the moulding element and a seat surface -132- formed by an adjacent wall of the profile. Immediately adjacent to the seat is a first zone -133- for connection by welding to the rib. Following the first connection zone -133- is a support zone -134- for connection means which is formed as a recess in the profile. The most set back wall of the support zone, in this case, comes in contact with the opposite wall of the profile -137-. An edge wall -136- is situated between the two opposite walls which defines the point of the profile -13- that projects most relative to the moulding element -11-. The rib -12- is flush with the profile at the height of said edgewise wall -136-. The opposite wall -137- in turn has a slight recess to facilitate handling the panel.

[0020] Fig. 2 shows a profile -13- which corresponds to a formwork panel according to the present invention. Elements that are the same or similar to those shown in the previous figure have been identified with identical reference numerals and will therefore not be explained in detail. Compared with the profile -13- of Fig. 1, it can be seen that one difference is that the support zone -134- is not formed as a recess in the profile -13-, but rather is a zone which projects relative to the first connection zone -133-. In particular, the support zone -134- is formed as an oblique wall zone relative to the first and second support zones -133-, -135-. More particularly, it will be seen that the support zone is neither parallel nor perpendicular to any of the walls -131-, -132-, -133-, -135-, -136-, -137- of the profile -13-. In this profile it can be seen that the first support zone -133- and the second support zone -135- are not aligned, although, in this case, said zones are parallel. Furthermore, it can be seen that in this case, the length (and consequently the area) of the second connection zone -135- is greater than that of the first connection zone -133-. This facilitates the use of ribs that are not flush with the profile. This effect is also enhanced by the fact that the second connection zone -135-, which is the outermost connection zone, is positioned closer to the centre of the panel than the first connection zone -133-. This makes it more difficult for the rib to come out of position and consequently limits the connection requirements, for example, by welding. This will allow, if required, the rib to be connected effectively only to one of said connection zones, if desired.

[0021] As can be seen, unlike in the prior art, the present invention may use stepped profiles. In particular, there may be no depressed zones in the contact face with the rib.

[0022] A comparison of the profiles -13- of Fig. 1 and 2 shows that the production of the profile -13- in the example shown in Fig. 2 requires the same amount of sheet metal as that in Fig. 1, but has greater rigidity relative to the forces to which said profile is exposed inside the formwork panel. This means that, if required, the profile of Fig. 2 can be produced, for the same strength, with a smaller thickness, producing a panel with less weight. In addition, and given that the width of the profile is greater, smaller ribs are required with the profile of Fig. 2, resulting in an additional loss of weight.

[0023] Fig. 3 and 4 show two embodiments of a formwork panel -1- according to the present invention. Elements that are the same or similar to those shown in the previous figures have been identified with identical reference numerals and will therefore not be described in detail. The panels -1- of Fig. 3 and 4 have a similar outline to that described in Fig. 2, and have a frame that uses a profile -13-, with the consequent saving of material in profile -13- and rib -12- compared to the case in Fig. 1. In Fig. 4, both the profile and the rib are flush, as can be seen by comparing the positions of the end wall -136- of the profile -13- and the free end -126- of the rib. In Fig. 3, on the contrary, it can be seen that the rib -12- has smaller dimensions and the free end -126- thereof is set back, or closer to the moulding element -11- than the end wall -136- of the profile -13- which forms the frame, with the consequent saving in weight. This configuration is particularly suitable for frames with small dimensions, that is, with a smaller rib length, or distance between supports, or with lower functional requirements, that is, designed for a lower pressure of formed concrete, or in panels with a small distance between ribs. This allows the weight of the panels to be optimised still further, by adjusting said panels to the dimensions and/or mechanical requirements thereof.

[0024] In both cases, the ribs are cut according to a profile that matches the profile that forms the frame. The shape of the profile of the panel according to the present invention permits welding even though the edge of the rib is smaller than the usual edge and/or, in particular, than that of the frame.

[0025] Fig. 5 shows an embodiment of a portion of a formwork system according to the present invention, in which two formwork panels -1-, -1'- positioned next to each other are connected by a clamp -2-. The clamp -2- is adapted to the shape of the support zone -134- of the profile -13-, each of the arms -21-, -21'- of the clamp having a matching support surface -211-, -211'-. Fig. 6 shows an embodiment of the clamp in detail.

[0026] Fig. 7 to 10 show other embodiments of formwork systems according to the present invention. In particular, said figures show configurations in which different adjacent panels, with the profiles thereof -13-, -13'- in contact and others parallel thereto, form the formwork space of, for example, a wall. Accordingly, both sides of the formwork are connected, as is known, by tie bars -4- and the corresponding nuts -5- which act on distribution plates -3-. In the case of systems according to the present invention, the distribution plates -3- provide for the existence of panels with different types of rib -12-, -12'-.

[0027] In Fig. 7 the distribution plate -3- must act on two panels that have ribs -12-, -12'- that are set back relative to the profiles -13-, -13'- at different heights. Accordingly, two projections -31-, -32- are arranged on the distribution plate -3-, the length of each of the projections corresponding to the difference between the edge of the profile -13-, -13'- of one type of panel and the edge of the profile -12-, -12'- of said type of profile. This allows the same distribution plate to be used in the configurations of Fig. 7 and 8. In the example shown, the projections -31- and -32- are arranged on opposite faces of the distribution plate -3-. Fig. 9 and 10 show two more configurations obtained with a distribution plate -3- which varies with respect to that shown in Fig. 7 and 8 in that said plate has only one projection -32'- at one end, and the other end -31'- has no projection. As can be seen in Fig. 9, the length of the projection -32'- coincides with the difference between the edges of rib and profile. In Fig. 10, the absence of an edge at one of the ends is used for configurations in which the rib -12"- and the profile -13"- have the same edge and are therefore flush.

[0028] It has been possible in the previous figures to see how the provision of projections on the distribution plate allows a single type of distribution plate to be used for two different panel types.

[0029] Fig. 11 to 13 shown another example of a configuration of a system according to the present invention, in which a formwork for square or rectangular columns is produced. Elements that are the same or similar to those shown in the previous figures have been designated with identical reference numerals and will therefore not be described in detail. For this type of connection, a partly threaded bar -3- is used with a head -61- shaped as an asymmetrical T which has a projection -611- with a shape that matches the support zone -134- of the profile -13- of the panels, so as to ensure good contact between said surfaces.

[0030] Although the invention has been presented and described with reference to embodiments thereof, it will be understood that said embodiments do not limit the invention, and therefore many structural or other details which may be evident to persons skilled in the art after interpreting the subject matter disclosed in the present description, claims and drawings, may vary. Thus, all variants and equivalents will be included within the scope of the present invention if said variants and equivalents may be considered to fall within the most extensive scope of the following claims.

Claims

1. Formwork panel which comprises:

- a moulding element which comprises a moulding surface;

- a series of structural reinforcement ribs, and

- a frame which surrounds the formwork element at least along two parallel sides

the frame comprising a hollow profile which comprises a zone for receiving the moulding element and a face which comprises two rib-connection zones and a support zone for panel-connection means,
in which
the support zone projects relative to at least one of the rib-connection zones.

2. Panel, according to the preceding claim, in which the rib-connection zones are not aligned.

3. Panel, according to the preceding claim, in which both connection zones are parallel, with the outermost connection zone positioned closer to the centre of the panel than the innermost connection zone.

4. Panel, according to any one of the preceding claims, in which the support zone is a straight length of wall which forms an oblique angle with the rib-connection zones.

5. Panel, according to the preceding claim, in which the support zone is neither parallel nor perpendicular to any of the other faces of the profile.

6. Panel, according to any one of the preceding claims, in which the edge of the rib is lower than that of the face of the profile which comprises said connection and support zones, so that the profile projects relative to the rib.

7. Panel, according to any one of claims 1 to 5, in which the edge of the rib is such that rib and profile are flush, and do not project relative to one another.

8. Panel, according to any one of the preceding claims, in which the profile is made of sheet metal.

9. Panel, according to any one of the preceding claims, in which the ribs are connected to the profile by welding.

10. Formwork system which comprises panels according to any one of the preceding claims.

11. System, according to the preceding claim which comprises a panel according to claim 6 and a panel according to claim 7.

12. System, according to either claim 10 or claim 11, which comprises at least one clamp for connecting adjacent panels in which the shape of the clamp matches that of the support zone of the panels.

Drawing