Wall Forming Apparatus

Abstract

A barrier forming system is described that includes a plurality of studs, rails and barrier reinforcement members interconnected between top and bottom plates. The interconnected studs, rails, reinforcement members, top plate and bottom plate may be precisely bent or curved in either or both the vertical and horizontal directions. The interconnected studs, rails, barrier reinforcement members, top plate, and bottom plate may be embedded in a filler material to form a curved concrete barrier having a complex geometry.

Claims

1. A barrier forming apparatus for load bearing surface structures, the barrier forming apparatus comprising: corrugated spaced apart studs defining a curvature of the barrier; a top plate coupled to top ends of the studs; a bottom plate coupled to bottom ends of the studs; first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs; second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs; wherein an inner side of the curvature of the barrier is defined by the first rails and first edges of the studs; wherein an outer side of the curvature of the barrier is defined by the second rails and the second edges of the studs; and a filler material that embeds the studs and rails.

2. The barrier forming apparatus as recited in claim 1, further including a first barrier reinforcement network coupled to the first edges of the studs and coupled to the first rails.

3. The barrier forming apparatus as recited in claim 1, further including a second barrier reinforcement network coupled to the second edges of the studs and coupled to the second rails.

4. The barrier forming apparatus as recited in claim 1, wherein the top plate and the bottom plate are constructed from a corrugated plate.

5. The barrier forming apparatus as recited in claim 1, further including a sheathing attached to the first rails.

6. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and first rails together.

7. The barrier forming apparatus as recited in claim 1, further including clips that couple the studs and second rails together.

8. The barrier forming apparatus as recited in claim 1, wherein the filler material is of the shotcrete type.

9. The wall forming apparatus as recited in claim 1, wherein the inner side and outer side of the barrier are exposed above ground level.

10. A barrier forming apparatus for concrete wall structures, the barrier forming apparatus comprising: corrugated spaced apart studs defining a curvature of the concrete wall; a top plate coupled to top ends of the studs; a bottom plate coupled to bottom ends of the studs; first rails that correspond with the studs, the first rails being coupled to first edges of the corresponding studs; a first wall reinforcement network coupled to the first edges of the studs and coupled to the first rails; second rails that correspond with the studs, the seconds rails being coupled to second edges of the corresponding studs; a second wall reinforcement network coupled to the second edges of the studs and coupled to the second rails; wherein an inner side of the curvature of the concrete wall is defined by the first rails and first edges of the studs; wherein an outer side of the curvature of the concrete wall is defined by the second rails and the second edges of the studs; and concrete that embeds the studs and rails.

11. The barrier forming apparatus as recited in claim 10, wherein the first wall reinforcement network is comprised of a mesh of rebar.

12. The barrier forming apparatus as recited in claim 10, wherein the second wall reinforcement network is comprised of a mesh of rebar.

13. The barrier forming apparatus as recited in claim 10, wherein the top plate and the bottom plate are constructed from a corrugated plate.

14. The barrier forming apparatus as recited in claim 10, further including a sheathing attached to the first rails.

15. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and first rails together.

16. The barrier forming apparatus as recited in claim 10, further including clips that couple the studs and second rails together.

17. The barrier forming apparatus as recited in claim 10, wherein the concrete is of the shotcrete type.

18. The barrier forming apparatus as recited in claim 10, wherein the inner side and outer side of the concrete wall are exposed above ground level.

19. A method of forming a barrier, the method comprising the steps of: determining a desired horizontal curvature of the barrier; determining a desired vertical curvature of the barrier; bending a top plate and bending a bottom plate to match the desired horizontal curvature of the barrier; bending studs and bending rails to match a desired vertical curvature of the barrier; aligning bent studs with the top plate and bottom plate; fastening the bent studs to the top plate and the bottom plate; fastening rails to the studs; wherein an inner side of the curvature of the barrier is defined by first rails and first edges of the studs; setting barrier reinforcement members between the studs and rails; attaching sheathing to the first rails; and embedding the studs and rails in a filler material.

20. The method as recited in claim 19, further including the steps of smoothing the filler material and curing the filler material.

Description

DESCRIPTION OF THE DRAWINGS

[0012] In the various figures, which are not necessarily drawn to scale, like numerals throughout the figures identify substantially similar components.

[0013] FIG. 1 is an inner perspective view of a barrier forming apparatus of the present invention shown with one attached sheathing member;

[0014] FIG. 2 is an outer perspective view of a barrier forming apparatus of the present invention;

[0015] FIG. 3 is an inner perspective view of a barrier forming apparatus of the present invention shown with one attached sheathing member;

[0016] FIG. 4 is an inner perspective view of the barrier forming apparatus of the type illustrated in FIG. 3;

[0017] FIG. 5 is an inner perspective view of the barrier forming apparatus of the type illustrated in FIG. 3;

[0018] FIG. 6 is an inner perspective view of the barrier forming apparatus of the type illustrated in FIG. 3;

[0019] FIG. 7 is a left perspective view of a profiled stud of the present invention;

[0020] FIG. 8 is a right perspective view of a profiled stud of the type illustrated in

[0021] FIG. 7;

[0022] FIG. 9 is a left perspective view of a profiled rail of the present invention;

[0023] FIG. 10 is a right perspective view of a profiled rail of the type illustrated in FIG. 9;

[0024] FIG. 11 is a left perspective view of an alternative profiled rail of the present invention;

[0025] FIG. 12 is a perspective view of an attachment clip of the present invention;

[0026] FIG. 13 is a left side view of the barrier forming apparatus of the type illustrated in FIG. 1;

[0027] FIG. 14 is a partial sectional perspective view of the barrier forming apparatus of the present invention;

[0028] FIG. 15 is a partial sectional left side view of a bottom portion of the barrier forming apparatus of the present invention;

[0029] FIG. 16 is a bottom left partial sectional perspective view of a portion of the barrier forming apparatus of the present invention; and

[0030] FIG. 17 is a flowchart illustrating the process of forming a curved concrete wall utilizing the barrier forming apparatus of the present invention.

DETAILED DESCRIPTION

[0031] The following description provides detail of various embodiments of the invention, one or more examples of which are set forth below. Each of these embodiments are provided by way of explanation of the invention, and not intended to be a limitation of the invention. Further, those skilled in the art will appreciate that various modifications and variations may be made in the present invention without departing from the scope or spirit of the invention. By way of example, those skilled in the art will recognize that features illustrated or described as part of one embodiment, may be used in another embodiment to yield a still further embodiment. Thus, it is intended that the present invention also cover such modifications and variations that come within the scope of the appended claims and their equivalents.

[0032] The barrier forming apparatus 10 of the present invention is particularly well suited for creating a curved concrete wall having complex geometries. Those skilled in the art will appreciate that the barrier forming apparatus may also be utilized to form a barrier or partition such as ceilings or domes without departing from the scope of the invention. Thus, references to a curved concrete wall is not intended to be limiting to a vertically extending wall but also includes other barriers and partitions including a curved dome or ceiling. The present invention is further particularly well suited to reduce the time needed to create and construct an accurate barrier having a complex geometry. With reference to FIGS. 1 and 2 the barrier forming apparatus 10 is shown assembled with a plurality of rails 40, studs 20, and opposing grid works 92 of rebar, wherein the plurality of rails and studs are aligned and spaced apart with top and bottom plates 60 and 70. The grid work 92 of rebar is comprised of spaced apart horizontally oriented rebar 94 and spaced apart vertically oriented rebar 96. The assembly of studs 20, rails 40, top plate 60, bottom plate 70 and grid works 92 are held in place with clips 80 and fasteners. The curvature and complex geometry of the barrier forming apparatus 10 is defined by the curvature of the spaced apart studs 20 and rails 40. The inner curvature of the barrier forming apparatus includes sheathing attached to the inner rails. Although the Figures illustrate only one panel of sheathing 100 those skilled in the art will appreciate that the entire inner side may be covered with sheathing 100. Once the sheathing 100 is attached to the rails 40, pneumatically applied or sprayed filler such as concrete 14 is applied to the structure 10 to embed the studs 20, rails 40 and rebar 90.

[0033] FIGS. 3-6 further illustrates the barrier forming assembly 10, the position of the sheathing 100, and the suitability of the form 10 for pneumatic applied filler applications. Those skilled in the art will appreciate that the grid work or wall reinforcement 92 may comprise a series of space apart rebar 90 or other suitable network of rods, wire mesh, or fibers. The rods are preferably tied together with wire so that the wall reinforcement network may be placed between the studs and rails in a secure manner to allow the spraying of the filler material. After the filler is applied, the outer surface of the wall may covered with a plaster, gypsum, sheathing or other barrier finishing product. The clips 80 include holes or apertures 86 that are well suited for wire, screws or other fasteners to extend there through. The wires or screws fasten the clips to the wall reinforcement network, the rails 40 and the studs 20. The length of the clip 80 determines the thickness of the filler into which the barrier reinforcement network is embedded. The top plate 60 includes a main body 62 and sides 64. The bottom plate 70 similarly includes a main body 72 and sides 74.

[0034] FIGS. 7 and 8 further illustrate the construction of a preferred corrugated stud 20 suitable for the present invention. The stud 20 includes a main body or channel member 22, substantially opposed sides 24 extending upward from the main body, and inwardly extending flanges 30 extending inwards from the opposing sides 24. Preformed creases 26 are formed in the main body 22 and preformed crease 28 is formed in a side of the stud. The method of forming the preformed creases is further described in U.S. Pat. Nos. 7,458,188 and 6,138,359 the entire disclosures of which are incorporated herein by reference. The preformed creases allow the stud to be bent to have a desired curvature. The studs may also be twisted to provide a still further geometric complexity to the barrier or wall. Of course bendable studs having different structure may be utilized without departing from the scope of the invention.

[0035] FIGS. 9-11 illustrate a suitable rail 40, however, those skilled in the art will appreciate that other known hat channel or DIN rail may be utilized without departing from the scope of the invention. The rail 40 includes a base 42, flange 44 and channel 46. The rail 40 may be bent either towards or away from the channel 46. In this manner, the flange 44 may be placed against the wall reinforcement network or grid work 92 and while matching the curvature of the outer barrier 48 or matching the curvature of the inner barrier 50. Numeral 48 identifies the curvature that corresponds with an outer barrier while numeral 50 identifies the curvature that corresponds with an inner barrier. Further, by way of example and without limitation intended, the rail may be constructed in accordance with the teachings of U.S. Pat. No. 8,621,823 the entire disclosure of which is incorporated herein by reference.

[0036] FIG. 12 illustrates a clip suitable to couple the studs, rails and sheathing while retaining a grid work of rebar in a fixed position until the filler such as concrete is applied and cured. Clip 80 may be attached to either the main body 62 and 72 or the sides 64 and 74 corresponding to the respective top plate 60 and bottom plate 70. Clip 80 may be further attached to the base 42 or flange 44 of the rail 40. Fasteners, weld, wires, screws or other known suitable fastener may be utilized to attach the clip to the corresponding parts in the desired location.

[0037] FIGS. 13-16 illustrates the barrier components and how they interrelate and attach together. The corrugated, spaced apart plurality of studs 20 define a curvature of the barrier such as a concrete wall. The studs 20 may extend in a vertical direction and curve in only the vertical direction or alternatively the studs may curve in the vertical direction and twist in the horizontal direction. The top plate 60 and bottom plate 70 are straight when the barrier only curves in the vertical direction. When the formed barrier includes a curve in both the vertical direction and the horizontal direction (in the case of a dome, for example), the studs are at least curved vertically and the top plate 60 and bottom plate 70 are curved and aligned in the approximately horizontal direction. The curved top and bottom plates may be corrugated to aid in the bending of the plates.

[0038] Those skilled in the art will appreciate that many complex barrier or wall geometries may be precisely formed utilizing the barrier forming apparatus 10 of the present invention. When the barrier forming apparatus 10 is assembled, the top plate 60 couples to top ends of the plurality of studs 20. Similarly, when the barrier forming apparatus 10 is assembled, the bottom plate 70 couples to bottom ends of the plurality of studs 20. The curved studs 20 of the assembly further include curved rails that correspond with the studs, attached to opposing edges of each stud. The inner side of the curvature of the barrier is defined by the curvature of a first plurality of rails 40 attached to corresponding first edges of the studs 20. Likewise, the outer side of the curvature of the barrier is defined by the curvature of a second plurality of rails 40 attached to corresponding second edges of the studs 20. A first barrier reinforcement network 92 may be sandwiched or set between and coupled to the first edges of the studs and the first rails. Further, a second barrier reinforcement network 92 may be coupled to the second edges of the studs and coupled to the second rails. The sheathing 100 may be held in place and attached to the first plurality of rails forming the inner curve of the barrier. Clips 80 may be utilized to couple the studs 20 and rails 40. Once the barrier forming apparatus 10 is assembled a filler material such as concrete is pneumatically applied to the sheathing from the outer side of the barrier. The concrete may be of a shotcrete type and the plates, studs, rails and network of reinforcement are all embedded in the concrete.

[0039] FIG. 17 is a representative flowchart that illustrates a process 110 suitable for forming a curved concrete wall having a complex geometry. Although the process is described in terms of forming a curved concrete wall, those skilled in the art will appreciate that a similar process may be utilized to form other barriers such as a curved ceiling or fiberglass filled walls without departing from the scope of the inventive process. Referring to FIG. 17, a user determines a desired horizontal curvature of the concrete wall 120 and a desired vertical curvature of the wall 122. The top plate and bottom plate are bent to match the desired horizontal curvature of the concrete wall 124. Likewise, the studs and rails are bent to match a desired vertical curvature of the concrete wall 126. The bent studs are spaced apart and aligned with the top plate and bottom plate. Once aligned, the bent studs may be fastened or otherwise attached to the top plate and the bottom plate 128. A desired network of reinforcement or rebar grid is determined 130 the grid work is set between the studs and rails 132. The rails and studs are then fastened or otherwise attached or coupled together 134. An inner side of the curvature of the concrete wall is defined by first rails and first edges of the studs. The sheathing 100 is attached to the inside wall portion or the first plurality of rails 40 as described above in greater detail 136. A user may then embed the studs and rails and grid 92 in concrete 138. After the concrete is pneumatically applied the concrete may be troweled or otherwise smoothed and then allowed to cure 140.

[0040] These and various other aspects and features of the invention are described with the intent to be illustrative, and not restrictive. This invention has been described herein with detail in order to comply with the patent statutes and to provide those skilled in the art with information needed to apply the novel principles and to construct and use such specialized components as are required. It is to be understood, however, that the invention can be carried out by specifically different constructions, and that various modifications, both as to the construction and operating procedures, can be accomplished without departing from the scope of the invention. Further, in the appended claims, the transitional terms comprising and including are used in the open ended sense in that elements in addition to those enumerated may also be present. Other examples will be apparent to those of skill in the art upon reviewing this document.