A connector device for permanent formwork panels

Abstract

 A permanent formwork wall system (1) according to the invention comprises a first permanent concrete formwork panel (2), a second permanent concrete formwork panel (3), and a plurality of connector devices. Each connector device comprises a male member (5) attached to the first formwork panel (2), and a female member (6) attached to the second formwork panel (3). The male member (5) comprises a first attachment foot for attaching the male member (5) to the first formwork panel (2), and a second attachment foot for attaching the male member (5) to the first formwork panel (2). Similarly the female member (6) comprises a first attachment foot for attaching the female member (6) to the second formwork panel (3), and a second attachment foot for attaching the female member (6) to the second formwork panel (3). The male member (5) is engagable with the female member (6) to connect the first formwork panel (2) to the second formwork panel (3). The male member (5) comprises a protruding element insertable through a corresponding opening in the female member (6) to engage the male member (5) with the female member (6). The space between the first formwork panel (2) and the second formwork panel (3) is filled with concrete on site.

Description

Introduction

[0001] This invention relates to a connector device. The connector device may be employed to connect formwork panels during the assembly of a permanent formwork wall system.

Statements of Invention

[0002] According to the invention there is provided a connector device comprising
a first member configured to be attached to a first wall, and
a second member configured to be attached to a second wall,
the first member being engagable with the second member to connect the first wall to the second wall.

[0003] Each wall may comprise a formwork panel.

[0004] In one embodiment of the invention the first member comprises one or more protruding elements insertable through one or more openings in the second member to engage the first member with the second member. Preferably the protruding element protrudes along a protruding axis, and the protruding element has a substantially elongate cross section perpendicular to the protruding axis. This arrangement minimises the possibility of material, such as concrete, being clogged or piled up on the first member during casting of the material between the first wall and the second wall. Ideally the protruding element protrudes along a protruding axis, and the protruding element has a substantially rectangular cross section perpendicular to the protruding axis. The protruding element may protrude along a protruding axis, and the protruding element may be insertable through the opening in a direction substantially parallel to the protruding axis. The protruding element may protrude along a protruding axis, and the protruding element may be insertable through the opening in a direction substantially perpendicular to the protruding axis. Preferably the protruding element comprises means to retain the protruding element inserted through the opening. This arrangement prevents inadvertent disengagement of the first member from the second member. Ideally the retaining means comprises an enlarged tip. The retaining means may comprise an arrow head shaped tip. The retaining means may comprise a wedge shaped tip.

[0005] In another embodiment the second member comprises a first gripping element and a second gripping element to grip the protruding element. Preferably the first gripping element is spaced apart from the second gripping element to define the opening therebetween. Ideally the first gripping element is movable relative to the second gripping element between an insertion configuration and a gripping configuration. Most preferably the gripping element is biased towards the gripping configuration. The first member may be engagable with the second member in a snap-fit manner. This arrangement provides a simple and fast means of engaging the first member with the second member. Preferably the opening is substantially elongate. Ideally the opening comprises a slot.

[0006] In one case the first member comprises one or more attachment elements for attaching the first member to a first wall. Preferably the first member comprises a first attachment element and a second attachment element. Ideally the first attachment element is spaced apart from the second attachment element. In the case of a permanent formwork wall system, this arrangement maximises the area of contact between the concrete and the wall. Most preferably the first member is substantially 'V'-shaped. The first member may extend from the first attachment element to the protruding element to the second attachment element in a substantially elongate first plane. This arrangement minimises the possibility of material, such as concrete, being clogged or piled up on the first member during casting of the material between the first wall and the second wall. Preferably the first plane is configured to extend substantially perpendicular to the plane of a first wall.

[0007] In another case the second member comprises one or more attachment elements for attaching the second member to a second wall. Preferably the second member comprises a first attachment element and a second attachment element. Ideally the first attachment element is spaced apart from the second attachment element. In the case of a permanent formwork wall system, this arrangement maximises the area of contact between the concrete and the wall. Most preferably the second member is substantially 'V'-shaped. The second member may extend from the first attachment element to the opening to the second attachment element in a substantially elongate second plane. This arrangement minimises the possibility of material, such as concrete, being clogged or piled up on the second member during casting of the material between the first wall and the second wall. Preferably the second plane is configured to extend substantially perpendicular to the plane of a second wall. Ideally upon engagement of the first member with the second member, the first plane extends substantially parallel to the second plane. Most preferably upon engagement of the first member with the second member, the first plane extends substantially in-line with the second plane.

[0008] In one embodiment the member defines an attachment axis extending from the first attachment element to the second attachment element, and the first gripping element is movable relative to the second gripping element in a direction non-parallel to the attachment axis. Preferably the attachment axis extends from the centroid of the first attachment element to the centroid of the second attachment element. Ideally the first gripping element is movable relative to the second gripping element in a direction substantially perpendicular to the attachment axis.

[0009] In another embodiment the member is of a non-metallic material. This arrangement minimises sound transmission between the first wall and the second wall. Preferably the member is of a polymeric material.

[0010] In one case the first member is engagable with the second member to connect the first wall to the second wall with the first wall extending substantially parallel to the second wall. Preferably the member is configured to be attached to a wall of a permanent formwork wall system.

[0011] In another aspect the invention provides a wall system comprising
a first wall,
a second wall, and
a connector device of the invention.

[0012] In one embodiment of the invention the member of the connector device is attached to the wall. Preferably the wall has a vertical axis which is configured to extend substantially vertically when the wall is erected, and the attachment axis extends non-perpendicular to the vertical axis. This arrangement minimises the possibility of material, such as concrete, being clogged or piled up on the member during casting of the material between the first wall and the second wall. Ideally the attachment axis extends substantially parallel to the vertical axis.

[0013] In another embodiment the first wall is connected to the second wall by the connector device. Preferably the first wall extends substantially parallel to the second wall. Ideally the wall comprises a wall of a permanent formwork wall system.

[0014] In a further aspect of the invention there is provided a method of assembling a wall system, the method comprising the steps of
attaching a first member to a first wall,
attaching a second member to a second wall, and
engaging the first member with the second member to connect the first wall to the second wall.

[0015] In one embodiment of the invention the member comprises a first attachment element for attaching the member to the wall and a second attachment element for attaching the member to the wall, the member defines an attachment axis extending from the first attachment element to the second attachment element, the wall has a vertical axis which is configured to extend substantially vertically when the wall is erected, and the member is attached to the wall with the attachment axis extending non- perpendicular to the vertical axis. This arrangement minimises the possibility of material, such as concrete, being clogged or piled up on the member during casting of the material between the first wall and the second wall. Preferably the member is attached to the wall with the attachment axis extending substantially parallel to the vertical axis.

[0016] In another embodiment after connecting the first wall to the second wall, the first wall extends substantially parallel to the second wall.

Brief Description of the Drawings

[0017] The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:

Fig. 1 is an isometric view of a connector device according to the invention,

Fig. 2 is an isometric view of a first member of the connector device of Fig. 1,

Fig. 3 is an isometric view of a second member of the connector device of Fig. 1,

Figs. 4 to 13 are isometric views illustrating a first wall being connected to a second wall using a plurality of the connector devices of Fig. 1,

Fig. 14 is a plan view of the first wall of Figs. 4 to 13 connected to the second wall of

Figs. 4 to 13 using the plurality of the connector devices of Figs. 4 to 13,

Fig. 15 is an enlarged plan view of the first wall of Fig. 14 connected to the second wall of Fig. 14 using one of the connector devices of Fig. 14,

Fig. 16 is an isometric view of a plurality of second members of other connector devices according to the invention,

Fig. 17 is an isometric view of a first member of another connector device according to the invention,

Fig. 18 is an isometric view of another connector device according to the invention,

Fig. 19 is an isometric view of a first member of the connector device of Fig. 18,

Fig. 20 is an isometric view of a second member of the connector device of Fig. 18,

Fig. 21 is another isometric view of the connector device of Fig. 18,

Fig. 22 is an isometric view of the second member of Fig. 20 attached to a wall,

Fig. 23 is an isometric view of the first member of Fig. 19 in a flattened configuration,

Fig. 24 is an isometric view of the second member of Fig. 20 in a flattened configuration,

Fig. 25 is an isometric view of a plurality of the first members of Fig. 19 in a stacked configuration,

Fig. 26 is an isometric view of a plurality of the second members of Fig. 20 in a stacked configuration,

Fig. 27 is an isometric view of another connector device according to the invention,

Fig. 28 is an isometric view of another connector device according to the invention,

Fig. 29 is an isometric view of another connector device according to the invention, and

Fig. 30 is an end view of another connector device according to the invention.

Detailed Description

[0018] Referring to the drawings, and initially to Figs. 1 to 15 thereof, there is illustrated a permanent formwork wall system 1 according to the invention.

[0019] The permanent formwork wall system 1 comprises a first permanent concrete formwork panel 2, a second permanent concrete formwork panel 3, and a plurality of connector devices 4.

[0020] Each formwork panel 2, 3 of the permanent formwork wall system 1 has a vertical axis which is configured to extend substantially vertically when the formwork panel 2, 3 of the permanent formwork wall system 1 is erected at a desired site of use.

[0021] In this case each of the first formwork panel 2 and the second formwork panel 3 is of cement bonded particle board (CBPB).

[0022] The formwork panels 2, 3 may have any suitable dimensions. The height of each formwork panel 2, 3 may be approximately 3 m, the width of each formwork panel 2, 3 may be approximately 1.25 m, the thickness of each formwork panel 2, 3 may be approximately 25 mm. Adjacent first formwork panels 2 and/or adjacent second formwork panels 3 may be joined together to any desired total width, for example approximately 6 m.

[0023] Each connector device 4 comprises a male member 5 configured to be attached to the first formwork panel 2, and a female member 6 configured to be attached to the second formwork panel 3.

[0024] Each member 5, 6 is of a polymeric material to minimise sound transmission between the formwork panels 2, 3. The polymeric material may be ABS, or Nylon, or PC-ABS, or any other suitable material. By using plastic members 5, 6 it helps with regards to sound insulation for the entailed building as opposed to using other materials which may compromise the wall sound insulation properties.

[0025] The male member 5 is engagable with the female member 6 to connect the first formwork panel 2 to the second formwork panel 3 with the first formwork panel 2 extending substantially parallel to the second formwork panel 3 (Fig. 14). The distance between the inner face of the first formwork panel 2 and the inner face of the second formwork panel 3 may be any desired distance, for example approximately 177 mm. The space between the first formwork panel 2 and the second formwork panel 3 will be filled with concrete on site. In this case the distance between adjacent connector devices 4 in the vertical direction may be approximately 400 mm, and the distance between adjacent connector devices 4 in the horizontal direction may be approximately 400 mm to prevent the integrity of the formwork panels 2, 3 being compromised by excessive deflection or failure while casting concrete. The permanent formwork wall system 1 is capable of withstanding the pressures exerted on the formwork panels 2, 3 during casting on site.

[0026] In particular the male member 5 comprises a protruding element 7 insertable through a corresponding elongate slot opening 8 in the female member 6 to engage the male member 5 with the female member 6.

[0027] The male member 5 comprises a first attachment foot 11 for attaching the male member 5 to the first formwork panel 2, and a second attachment foot 11 for attaching the male member 5 to the first formwork panel 2. As illustrated in Fig. 2, the first attachment foot 11 is spaced apart from the second attachment foot 11, and the male member 5 is substantially 'V'-shaped. The male member 5 extends from the first attachment foot 11 to the protruding element 7 to the second attachment foot 11 in a substantially elongate first plane, which extends substantially perpendicular to the plane of the first formwork panel 2. Because the male member 5 is fixed to the first formwork panel 2 with the two feet 11 spaced apart, this arrangement minimises the possibility of gaps or voids in the concrete during casting and maximises the amount of concrete in contact with the first formwork panel 2. Fig. 11 illustrates that the footprint of the base is minimised so that cured concrete adhesion to the CBPB formwork panel 2 is kept as high as possible.

[0028] The male member 5 has an attachment axis B-B extending from the centroid of the first attachment foot 11 to the centroid of the second attachment foot 11. The male member 5 is attached to the first formwork panel 2 with the attachment axis B-B extending substantially parallel to the vertical axis of the first formwork panel 2. The male member 5 is positioned with the low profile in the vertical direction to minimise the possibility of concrete becoming piled up on top of the male member 5 during casting of concrete. Fig. 14 illustrates a plan view from above in which concrete is cast from above. The male member 5 has minimal cross sectional area in this direction thus preventing accumulation of concrete. The members 5, 6 are lean so that air voids within the concrete are minimised thus improving the performance qualities of the permanent formwork wall system 1.

[0029] Fig. 4 illustrates the plurality of male members 5 of the permanent formwork wall assembly system 1 screwed to the first formwork panel 2.

[0030] The protruding element 7 protrudes along a protruding axis A-A. The protruding element 7 has a substantially elongate rectangular cross section perpendicular to the protruding axis A-A. The protruding element 7 is insertable through the opening 8 in a direction substantially parallel to the protruding axis A-A. The protruding element 7 comprises an enlarged arrow head shaped tip 9 to retain the protruding element 7 inserted through the opening 8.

[0031] Similarly the female member 6 comprises a first attachment foot 12 for attaching the female member 6 to the second formwork panel 3, and a second attachment foot 12 for attaching the female member 6 to the second formwork panel 3. As illustrated in Fig. 3, the first attachment foot 12 is spaced apart from the second attachment foot 12, and the female member 6 is substantially 'V'-shaped. The female member 6 extends from the first attachment foot 12 to the opening 8 to the second attachment foot 12 in a substantially elongate second plane, which extends substantially perpendicular to the plane of the second formwork panel 3. Because the female member 6 is fixed to the second formwork panel 3 with the two feet 12 spaced apart, this arrangement minimises the possibility of gaps or voids in the concrete during casting and maximises the amount of concrete in contact with the second formwork panel 3.

[0032] The female member 6 has an attachment axis C-C extending from the centroid of the first attachment foot 12 to the centroid of the second attachment foot 12. The female member 6 is attached to the second formwork panel 3 with the attachment axis C-C extending substantially parallel to the vertical axis of the second formwork panel 3. The female member 6 is positioned with the low profile in the vertical direction to minimise the possibility of concrete becoming piled up on top of the female member 6 during casting of concrete. Fig. 14 illustrates a plan view from above in which concrete is cast from above. The female member 6 has minimal cross sectional area in this direction thus preventing accumulation of concrete.

[0033] The female member 6 comprises a first gripping jaw element 10 and a second gripping jaw element 10 to grip the protruding element 7. The first gripping jaw element 10 is spaced apart from the second gripping jaw element 10 to define the opening 8 therebetween. The first gripping jaw element 10 is movable relative to the second gripping jaw element 10 between a temporarily widened insertion configuration and a relaxed gripping configuration (Fig. 3). The first gripping jaw element 10 is movable relative to the second gripping jaw element 10 in a direction D-D substantially perpendicular to the attachment axis B-B and substantially perpendicular to the attachment axis C-C. Both the first gripping jaw element 10 and the second gripping jaw element 10 are biased towards the relaxed gripping configuration. In this manner the male member 5 is engagable with the female member 6 in a snap-fit manner. The force required to engage the male member 5 with the female member 6 is sufficiently low to enable ease of assembly. The force to snap compress together the formwork panels 2, 3 is minimal to ensure a simple fluid assembly process.

[0034] Fig. 13 illustrates that to ensure that the protruding element 7 can withstand the large force exerted from wet concrete, the wedge effect 9 is incorporated into the connector 4 so that the male component 5 upon retraction pulls the two wings 10 of the female member 6 together thus preventing them from splaying outward whilst under loading conditions.

[0035] As illustrated in Fig. 1, upon engagement of the male member 5 with the female member 6, the first plane extends substantially parallel to and in-line with the second plane, and the attachment axis B-B of the male member 5 extends substantially parallel to the attachment axis C-C of the female member 6.

[0036] Fig. 8 illustrates the base of one of the male members 5.

[0037] In use, to assemble the permanent formwork wall system 1, the male members 5 of a plurality of connector devices 4 are attached to the first formwork panel 2 with the attachment axes B-B extending substantially parallel to the vertical axis of the first formwork panel 2. The female members 6 of the plurality of connector devices 4 are attached to the second formwork panel 3 with the attachment axes C-C extending substantially parallel to the vertical axis of the second formwork panel 3.

[0038] Each male member 5 is engaged with each corresponding female member 6 by inserting each protruding element 7 through each corresponding opening 8 to connect the first formwork panel 2 to the second formwork panel 3 with the first formwork panel 2 extending substantially parallel to the second formwork panel 3 (Fig. 14). As each protruding element 7 is inserted through each corresponding opening 8, the first gripping jaw element 10 and the second gripping jaw element 10 are pushed outwardly by the enlarged arrow head shaped tip 9 from the relaxed gripping configuration (Fig. 3) to the temporarily widened insertion configuration. After the enlarged arrow head shaped tip 9 has passed by the gripping jaw elements 10, the first gripping jaw element 10 and the second gripping jaw element 10 are free to revert from the temporarily widened insertion configuration back to the relaxed gripping configuration (Fig. 3). The first gripping jaw element 10 moves relative to the second gripping jaw element 10 in the direction D-D substantially perpendicular to the attachment axis B-B and substantially perpendicular to the attachment axis C-C.

[0039] Fig. 5 illustrates that when the female members 6 are screwed to the second formwork panel 3, both formwork panels 2, 3 are pushed together.

[0040] The assembled permanent formwork wall system 1 may be transported to a desired site of use as a single unit. The space between the first formwork panel 2 and the second formwork panel 3 is filled with concrete on site.

[0041] In Fig. 16 there is illustrated the female members 6 of a plurality of connector devices 4 of another permanent formwork wall system according to the invention, which is similar to the permanent formwork wall system 1 of Figs. 1 to 15, and similar elements in Fig. 16 are assigned the same reference numerals.

[0042] In this case each female member 6 is attached to a base layer 20. The first attachment foot 12 and the second attachment foot 12 of each female member 6 are attached to the base layer 20. The base layer 20 is configured to be attached to the second formwork panel 3.

[0043] In Fig. 16 several of the components 6 are moulded together to make production assembly faster.

[0044] Fig. 17 illustrates a male member 30 of a connector device 4 of a further permanent formwork wall system according to the invention, which is similar to the permanent formwork wall system 1 of Figs. 1 to 15, and similar elements in Fig. 17 are assigned the same reference numerals.

[0045] In this case the male member 30 comprises two protruding elements 31 insertable through a corresponding elongate slot opening 8 in the female member 6 to engage the male member 30 with the female member 6.

[0046] The male member 30 comprises four attachment feet 11 for attaching the male member 30 to the first formwork panel 2. As illustrated in Fig. 17, the attachment feet 11 are spaced apart from one another, and the male member 30 is substantially pyramid shaped. The male member 30 extends from each attachment foot 11 to the protruding elements 31 at the apex. Because the male member 30 is fixed to the first formwork panel 2 with the feet 11 spaced apart, this arrangement minimises the possibility of gaps or voids in the concrete during casting and maximises the amount of concrete in contact with the first formwork panel 2.

[0047] Fig. 17 illustrates the four leg version of the plastic connector.

[0048] Referring to Figs. 18 to 26 there is illustrated a connector device 40 of another permanent formwork wall system according to the invention, which is similar to the permanent formwork wall system 1 of Figs. 1 to 15, and similar elements in Figs. 18 to 26 are assigned the same reference numerals.

[0049] In this case the male member 41 is of a metallic material, and the female member 42 is of a metallic material.

[0050] The male member 41 comprises two protruding elements 7 insertable through two corresponding elongate slot opening 8 in the female member 42 to engage the male member 41 with the female member 42.

[0051] The male member 41 is substantially 'U'-shaped.

[0052] The female member 42 comprises three attachment feet 12 for attaching the female member 42 to the second formwork panel 3. The three attachment feet 12 are spaced apart from one another.

[0053] Fig. 18 illustrates the metal component design in which the two components 41, 42 snap together.

[0054] In Fig. 27 there is illustrated a connector device 50 of another permanent formwork wall system according to the invention, which is similar to the permanent formwork wall system 1 of Figs. 1 to 15, and similar elements in Fig. 27 are assigned the same reference numerals.

[0055] In this case the male member 51 comprises the protruding element 7 insertable through a corresponding circular opening in the female member 52 to engage the male member 51 with the female member 52.

[0056] The male member 51 comprises a single circular attachment foot 11 for attaching the male member 51 to the first formwork panel 2. The protruding element 7 has a substantially circular cross section perpendicular to the protruding axis A-A.

[0057] The female member 52 comprises a single circular attachment foot 12 for attaching the female member 52 to the second formwork panel 3.

[0058] In Fig. 27 the male and female components 51, 52 are snapped together with the connector 7 at the centre.

[0059] Fig. 28 illustrates a connector device 60 of a further permanent formwork wall system according to the invention, which is similar to the connector device 50 of Fig. 27, and similar elements in Fig. 28 are assigned the same reference numerals.

[0060] In this case the assembly comprises two female and one male components which snap together.

[0061] Referring to Fig. 29 there is illustrated a connector device 70 of another permanent formwork wall system according to the invention, which is similar to the connector device 50 of Fig. 27, and similar elements in Fig. 29 are assigned the same reference numerals.

[0062] In this case the male member 71 comprises the protruding element 7 insertable through a corresponding slot 74 in the female member 72 to engage the male member 71 with the female member 72.

[0063] The protruding element 7 protrudes along the protruding axis A-A. The protruding element 7 has a substantially circular cross section perpendicular to the protruding axis A-A. The protruding element 7 comprises an enlarged wedge shaped tip 73 to retain the protruding element 7 inserted through the slot 74. The female member 72 comprises a cooperating wedge shape in the slot 74 to grip the enlarged wedge shaped tip 73 of the protruding element 7. The enlarged wedge shaped tip 73 of the protruding element 7 is insertable through the slot 74 in a direction substantially perpendicular to the protruding axis A-A.

[0064] In Fig. 29 the male component 73 is dropped into position into the female component 74 which locks the male component 73 into position. One formwork panel 2 is slid into position relative to the other formwork panel 3.

[0065] In Fig. 30 there is illustrated a connector device 80 of another permanent formwork wall system according to the invention, which is similar to the connector device 70 of Fig. 29, and similar elements in Fig. 30 are assigned the same reference numerals.

[0066] In this case the male member 81 comprises the protruding element 83 insertable through a corresponding slot 84 in the female member 82 to engage the male member 81 with the female member 82. The protruding element 83 is insertable through the slot 84 in a direction substantially perpendicular to the protruding axis A-A.

[0067] In Fig. 30 the male female interaction is secured by the wedge effect which occurs when dropped into position.

[0068] The invention is not limited to the embodiments hereinbefore described, with reference to the accompanying drawings, which may be varied in construction and detail.

Claims

1. A connector device comprising
a first member configured to be attached to a first wall, and
a second member configured to be attached to a second wall,
the first member being engagable with the second member to connect the first wall to the second wall.

2. A device as claimed in claim 1 wherein the first member comprises one or more attachment elements for attaching the first member to a first wall.

3. A device as claimed in claim 2 wherein the first member comprises a first attachment element and a second attachment element.

4. A device as claimed in claim 3 wherein the first attachment element is spaced apart from the second attachment element.

5. A device as claimed in claim 3 or 4 wherein the first member extends from the first attachment element to the protruding element to the second attachment element in a substantially elongate first plane.

6. A device as claimed in any of claims 1 to 5 wherein the second member comprises one or more attachment elements for attaching the second member to a second wall.

7. A device as claimed in claim 6 wherein the second member comprises a first attachment element and a second attachment element.

8. A device as claimed in claim 7 wherein the second member is substantially 'V'-shaped.

9. A device as claimed in any of claims 3 to 8 wherein the member defines an attachment axis extending from the first attachment element to the second attachment element, and the first gripping element is movable relative to the second gripping element in a direction non-parallel to the attachment axis.

10. A device as claimed in claim 9 wherein the first gripping element is movable relative to the second gripping element in a direction substantially perpendicular to the attachment axis.

11. A device as claimed in any of claims 1 to 10 wherein the member is of a non-metallic material.

12. A wall system comprising
a first wall,
a second wall, and
a connector device as claimed in any of claims 1 to 11.

13. A system as claimed in claim 12 wherein the member of the connector device is attached to the wall.

14. A system as claimed in claim 13 wherein the wall has a vertical axis which is configured to extend substantially vertically when the wall is erected, and the attachment axis extends non- perpendicular to the vertical axis.

15. A system as claimed in claim 14 wherein the attachment axis extends substantially parallel to the vertical axis.

Drawing