Plastic Stay-In-Place Concrete Forming System

Abstract

A plastic stay-in-place concrete forming system used for one or more sides of a multi-sided form and is based upon a form panel comprised of a thin plastic sheet reinforced on its interior side and capable of bonding to the concrete cast inside the form to create a solid composite structure. In one configuration the form panels are connected to internal bracing that connects to a second form side. The internal bracing is comprised of plastic connecting frames, lateral supports or individual connectors that may further reinforce the form panels or may be used solely for connecting purposes. The second side form may be any type of form including the form panel or a stud supporting foam board. The form panel may also be shaped to form two or more sides of an internally braced, multi-sided form. It may also be externally braced on one or more sides of a form.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is a continuation-in-part of application Ser. No. 12 / 927,379 filed Nov. 12, 2010 which claims the benefit of the filing date of provisional application Nos. 41 / 281,166 and 41 / 281.121 both filed Nov. 13, 2009. This application claims the benefit of copending application Ser. No. 13 / 374,839 filed Jan. 17, 2012 claiming the benefit of the filing date of provisional application Nos. 61 / 461,437 filed Jan. 18, 2011 and 61 / 462,463 filed Feb. 3, 2011. All the above cited applications are incorporated herein by reference.BACKGROUND OF THE INVENTIONPrior Art[0002]The following is a tabulation of some prior art that presently appears relevant:U.S. Patents[0003]Patent NumberKind CodeIssue DatePatentee7,146,773B22006 Dec. 12Wilson6,247,280B12001 Jun. 19Grinshpun et al.6,167,669B12001 Jan. 2Lane5,974,7511999 Nov. 2De Zen5,729,9441998 Mar. 24De Zen5,706,6201998 Jan. 13De Zen5,092,0931992 Mar. 3Lu4,876,0541989 Oct. 24Goodwin3,238,6841963...

AI Technical Summary

Benefits of technology

This patent is about a new method for reinforcing plastic forms used in construction. The forms are reinforced to be able to withstand the weight and pressure of wet concrete. Connectors are used to connect the forms, but they are spaced apart to allow for more flexibility in strengthening the form based on the pressure gradient. The forms are also coated with a thin plastic sheet to further protect them during the process. Additionally, the patent discusses the use of individual connectors that allow for more efficient use of materials and provide flexibility in their placement. The plastic forms can also be used with a method to reduce hydrostatic pressure, allowing for the use of weaker and less expensive plastic forms. Overall, this patent provides a novel way to reinforce plastic forms while still withstanding the pressure of wet concrete.

Problems solved by technology

The foam forms must also be covered to provide an aesthetically pleasing finished appearance and the foam provides an inadequate base for structural connections between concrete members or to facilitate cladding materials.

However, these plastic sheets that comprise the forms do not attach or otherwise bond to the concrete cast inside the form.

The plastic forms only enclose the concrete and since all concrete shrinks as it cures the concrete pulls away from the plastic form which results in a loose and flimsy plastic covering.

Such a loose or flimsy covering is not only unsightly; it also inhibits the attachment of cladding materials to the exterior of the plastic form.

These thicker forms and large number of lateral connectors / webs substantially increases the amount of plastic material needed for a sufficiently strong concrete form.

All of the prior art uses closed connectors / webs to connect the two sides of the form which makes it difficult to place steel reinforcement bars and impractical to use less expensive welded wire fabric sheets as a concrete reinforcement.

As such, the horizontal rebars must be laterally fished through the openings of the connectors / webs which is difficult and time consuming, especially for the standard 20′ sections of rebar.

Moreover, it is difficult to tie the lapped rebar inside these plastic forms as required by some building codes.

None of the prior art provides any flexibility to strengthen the bottom with additional support or use less support near the top of the form.

The support is uniform throughout the form which results in an inefficient and costly use of materials.

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