Corner wedge lock and related systems and methods

Abstract

Devices for securing sections of formwork together in a manner that reduces safety risk and operator labor. The formwork system may use a drive wedge design to allow for fast and secure connection of individual sections of formwork. This approach enables workers to assemble and secure formwork sections efficiently while remaining at ground level, thereby mitigating fall hazards and expediting the construction process.

Description

CROSS-REFERENCES & RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application , filed , and entitled , which is hereby incorporated herein by reference in its entirety for all purposes.TECHNICAL FIELD

[0002] The disclosure relates to construction generally, and to connecting formwork, more specifically.BACKGROUND

[0003] Existing techniques to secure sections of formwork together require the use of bolts or clamps, which are used to secure the sections while the overall form is being assembled. As workers need to apply these bolts or clamps along each seam between each portion of formwork, ladders or scaffolding often must be used to provide access to the entirety of each seam. The use of these ladders and scaffolding introduces an inherent safety risk to workers. Additionally, setting up the ladders or scaffolding and bolting or clamping the sections of formwork requires additional time and labor, incurring additional labor costs and resulting in slowed form assembly time.

[0004] There is a need in the art for a system that allows for the assembly of sections of formwork with improved speed and reduced labor demand.BRIEF SUMMARY

[0005] The various implementations disclosed herein relate to a system for securing sections of formwork together with improvements in speed, worker safety, and scaffolding requirements, as well as related devices and methods. While the various implementations discussed have a wide range of applications, one specific application is in connecting sections of concrete forms together to allow for the casting of concrete structures.

[0006] In Example 1, a system for securing formwork panels comprising an active panel comprising a plate, a wedge assembly, a wedge-lock aperture, and an actuator in communication with the wedge assembly. The system also comprising a passive panel comprising a plate and at least one tab configured to slotted through the wedge-lock aperture to form a tapered crevice, wherein the wedge assembly is extended into the tapered crevice by actuation of the actuator, thereby locking the passive panel and the active panel together.

[0007] Example 2 relates to the system of any of Examples 1 and 3-6, wherein the actuator is a hydraulic actuator.

[0008] Example 3 relates to the system of any of Examples 1-2 and 4-6, wherein the hydraulic actuator is powered by a remote power source.

[0009] Example 4 relates to the system of any of Examples 1-3 and 5-6, wherein extending the at least one wedge assembly into the tapered crevice forms a fluid tight juncture between the passive panel and the active panel.

[0010] Example 5 relates to the system of any of Examples 1-4 and 6, further comprising at least one box section mounted to the active panel and slidably retaining the wedge assembly to constrain the wedge assembly in two dimensions while permitting motion along a guided path.

[0011] Example 6 relates to the system of any of Examples 1-5, wherein the system includes a plurality of passive panels and a plurality of active panels configured to assemble into a form.

[0012] In Example 7, a formwork system comprising a passive panel having a passive plate and at least one tab projecting from the passive plate, an active panel having an active plate and at least one wedge lock aperture with an opening sized to receive the at least one tab, and a locking assembly mounted to the active panel and including at least one wedge assembly and at least one actuator configured to advance the at least one wedge assembly along a guided path, wherein insertion of the at least one tab through the opening positions the passive wear plate and the active wear plate to cooperate and define a tapered crevice, and advancement of the at least one wedge assembly into the tapered crevice by the at least one actuator drives the passive panel and the active panel into a clamped condition.

[0013] Example 8 relates to the system of any of Examples 7 and 9-13, wherein the at least one tab comprises a base plate, a passive brace affixed to the base plate, and a passive wear plate removably attached to the passive brace.

[0014] Example 9 relates to the system of any of Examples 7-8 and 10-13, wherein the active panel further comprises an active brace affixed to the active plate and an active wear plate removably attached to the active brace.

[0015] Example 10 relates to the system of any of Examples 7-9 and 11-13, wherein the actuator is a hydraulic actuator.

[0016] Example 11 relates to the system of any of Examples 7-10 and 12-13, further comprising at least one box section mounted to the active panel and slidably retaining the at least one wedge assembly to constrain the at least one wedge assembly in two dimensions while permitting motion along the guided path.

[0017] Example 12 relates to the system of any of Examples 7-11 and 13, wherein the at least one box section retains a pair of wedge assemblies in a coaxial configuration and the at least one actuator is positioned between the pair of wedge assemblies to force the pair apart when extended.

[0018] Example 13 relates to the system of any of Examples 7-12, wherein driving the at least one wedge assembly into the tapered crevice forms a fluid tight juncture between the passive panel and the active panel.

[0019] In Example 14, a formwork system comprising a passive panel comprising a plate and at least one tab extending from the plate, comprising a base plate, a passive brace affixed to the base plate, and a passive wear plate attached to the passive brace. The formwork system also comprising an active panel comprising a plate, at least one wedge lock aperture, each configured to receive one of the at least one tabs, an active brace affixed to the plate, an active wear plate affixed to the active brace, and a locking assembly mounted to the plate comprising at least one wedge assembly and at least one actuator configured to advance the at least one wedge assembly along a guided path, wherein insertion of the at least one tab through the at least one wedge lock aperture causes the passive wear plate and the active wear plate to form a tapered crevice, and advancement of the at least one wedge assembly into the tapered crevice locks the passive panel and the active panel together.

[0020] Example 15 relates to the formwork system of any of Examples 14 and 16-20, wherein at least the passive wear plate, the active wear plate, and the wedge are modular components independently removable and replaceable without replacement of the passive plate or the active plate.

[0021] Example 16 relates to the formwork system of any of Examples 14-15 and 17-20, wherein the passive panel includes a plurality of tabs disposed at corners of the passive plate and the active panel includes a corresponding plurality of wedge lock apertures disposed at corners of the active plate to form a tapered crevice at each corner when the panels are joined.

[0022] Example 17 relates to the formwork system of any of Examples 14-16 and 18-20, wherein the locking assembly comprises a pair of wedge assemblies in a coaxial configuration and the at least one actuator is positioned between the pair of wedge assemblies to force the pair apart when extended.

[0023] Example 18 relates to the formwork system of any of Examples 14-17 and 19-20, wherein the actuator is a hydraulic actuator powered by a remote power source.

[0024] Example 19 relates to the formwork system of any of Examples 14-18 and 20, wherein extending the at least one wedge assembly into the tapered crevice forms a fluid tight juncture between the passive panel and the active panel.

[0025] Example 20 relates to the formwork system of any of Examples 15-19, wherein the formwork system comprises a plurality of passive panels and a plurality of active panels configured to assemble into a form.

[0026] While multiple embodiments are disclosed, still other embodiments of the disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative implementations of the invention. As will be realized, the disclosure is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.BRIEF DESCRIPTION OF DRAWINGS

[0027] FIG. 1 is an illustration of the assembled system, according to one implementation.

[0028] FIG. 2A is an isometric illustration of a passive panel in the system, according to one implementation.

[0029] FIG. 2B is a front-facing illustration of a passive panel in the system, according to one implementation.

[0030] FIG. 2C is a close-up illustration of a tab on a passive panel in the system, according to one implementation.

[0031] FIG. 3A is an isometric illustration of an active panel in the system, according to one implementation.

[0032] FIG. 3B is a front-facing illustration of an active panel in the system, according to one implementation.

[0033] FIG. 3C is a close-up illustration of a wedge-lock aperture on an active panel in the system, according to one implementation.

[0034] FIG. 4 is an illustration of a wedge assembly, according to one implementation.

[0035] FIG. 5A is an illustration of a wedge of a wedge assembly, according to one implementation.

[0036] FIG. 5B is an illustration of a shaft of a wedge assembly, according to one implementation.

[0037] FIG. 6 is an illustration of the wedge entering a tapered crevice, according to one implementation.

[0038] FIG. 7 is a close-up illustration of the wedge entering a tapered crevice, according to one implementation.

[0039] FIG. 8 is an illustration of a tab of a passive panel that is configured to be removable, according to one implementation.DETAILED DESCRIPTION

[0040] The disclosed system provides improved techniques and tools for securing sections of formwork together with improvements in speed, worker safety, and scaffolding requirements. The system may allow workers to assemble sections of formwork into common configurations without the need to bolt or clamp sections together. Additionally, in various implementations of the system, the sections of formwork can be secured together while the workers remain at ground level. Additionally, in various implementations the system includes several features that are modular, in that they may be removed and replaced as needed without needing to replace large portions of or the entire system.

[0041] Turning to FIG. 1, the system 10 may have one or more passive panels 12 and one or more active panels 14. The passive panels 12 and active panels 14 may be joined together into a form 16. The specific form 16 shown in FIG. 1 may be used to form a square column. However, the form 16 may be configured to various geometries through modifications in how the passive panels 12 and active panels 14 interlock or the shapes of the panels themselves, as would be understood by those of skill in the art in light of this disclosure.

[0042] In various implementations, the passive panels 12 and active panels 14 may fit into a base 15. In certain implementations, the passive panels 12 and active panels 14 may be rotatably attached to the base 15 through one or more hinges 17, which may be attached to the passive panels 12 and / or active panels 14.

[0043] FIGS. 2A and 2B show an isolated passive panel 12 of the implementation shown in FIG. 1. The passive panel 12, in various implementations, may consist of a plate 18 reinforced by various braces 20. Shown in FIG. 2C, the passive panel 12 may also have one or more tabs 22, which may be made of a base plate 24 with an affixed passive brace 26 and passive wear plate 28. In various implementations, the passive brace 26 may be permanently affixed to the base plate 24, such as, but not exclusively, by being welded. The passive wear plate 28 may, in various implementations, then be removably attached to the passive brace 26, such as through the use of temporary fasteners like, but not limited to, bolts. In various implementations, each passive wear plate 28 and each passive brace 26 may be decoupled to allow for replacement of wear parts, such as the passive wear plate 28, and for assembly of the system 10.

[0044] FIGS. 3A and 3B show an isolated active panel 14 of the implementation shown in FIG. 1. The active panel 14, in various implementations, may consist of a plate 18 reinforced by various braces 20. Shown in FIGS. 3A and 3C, the active panel 14 may also have one or more wedge-lock apertures 30, which may have openings 32 configured to allow the tabs 22 of the passive panels 12 to pass through the plate 18 of the active panels 14. The wedge-lock apertures 30 may also have an active brace 34 disposed on the passive panel 12. In various implementations, the active brace 34 may be permanently affixed to the active panel 14 such as, but not limited to, by being welded. In various implementations, there may be an active wear plate 36 removably attached to the active brace 34, such as through the use of temporary fasteners like, but not limited to, bolts. In various implementations, each active wear plate 36 and each active brace 34 may be decoupled to allow for replacement of wear parts, such as the active wear plate 36, and for assembly of the system 10.

[0045] Turning back to FIGS. 3A and 3B, the active panels 14 may have one or more locking assemblies 38. In various implementations, the locking assemblies 38 may have one or more wedge assemblies 40 attached to one or more actuators 42, optionally a hydraulic actuator, a mechanical ratchet binder, or a mechanical over center lever binder. In various implementations, the wedge assemblies 40 may be slidably attached to the active panel 14 by one or more box sections 44, which may be configured to hold the wedge assemblies 40 in position relative to the active panel 14 in two dimensions but allow for movement in a third dimension. In some specific implementations, the box sections 44 may hold one or more pairs of wedge assemblies 40 to the active panel 14 so that each pair of wedge assemblies 40 is positioned to be coaxial. In such implementations, an actuator 42 may be positioned between each pair of wedge assemblies 40, such that when the actuator 42 extends, the pair of wedge assemblies 40 to which the actuator 42 is positioned between and attached, is forced apart.

[0046] FIG. 4 shows one implementation of an individual wedge assembly 40. In some implementations, the wedge assembly 40 may have a shaft 46 and a wedge 48, which may be removably affixed, such as through the use of temporary fasteners like, but not limited to, bolts. FIG. 5A shows the wedge 48 independently, and FIG. 5B shows the shaft 46 independently, according to one implementation. In various implementations, the wedge 48 and shaft 46 may be decoupled to allow for replacement of wear parts, such as the wedge 48, and for assembly of the system 10.

[0047] FIGS. 6 and 7 show implementations of the system 10, where a tab 22 of the passive panel 12 is inserted through the opening 32 of the wedge-lock apertures 30. In such implementations, the passive wear plate 28 and active wear plate 36 may form a tapered crevice 50. The wedge 48 may be inserted into the tapered crevice by extending the actuator 42. As the wedge 48 is extended into the tapered crevice 50, the tab 22 and passive panel 12 may be pressed into a secure position against the active panel 14.

[0048] Turning back to FIG. 1, the passive panels 12 may have tabs 22 at each corner and the active panels 14 may have openings 32 at each corner, such that a tapered crevice 50 is formed at the corner of each passive panel 12 and active panel 14 when joined together. As would be understood, when wedges 48 are extended into each tapered crevice 50, each passive panel 12 and active panel 14 will be pressed together to form a fluid-tight juncture between the same.

[0049] In various implementations, the wedges 48 may extend into each tapered crevice 50 by extending the actuators 42 while the workers remain at a safe distance from any pinch points because the actuators 42 may operate using a remote power source, such as a hydraulic pump (not shown). This minimizes the risk of worker injuries resulting from body parts becoming trapped in nips and pinch points, such as between panels as they would be joined together in traditional techniques.

[0050] FIG. 8 shows an implementation of the system 10, where the tabs 22 are removably attached to the passive panels 12. In certain implementations, each tab 22 may be inserted between two raised supports 54 which may hold the tab 22 in place relative to two dimensions. An anchor plate 56 may then be secured to both each tab 22 and to the passive panel 12, which may prevent movement in the remaining direction, thereby securing the tab 22. In various implementations, the anchor plates 56 may be removably attached to each tab 22 and the passive panel 12, such as through the use of temporary fasteners like, but not limited to, bolts.

[0051] In alternative implementations the wedge 48 may be operated in reverse forcing the panels 12, 14 apart.

[0052] Although the disclosure has been described with reference to preferred embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosed apparatus, systems and methods.

Claims

1. A system for securing formwork panels comprising:(a) an active panel comprising:(i) a plate;(ii) a wedge assembly;(iii) a wedge-lock aperture; and(iv) an actuator in communication with the wedge assembly; and(b) a passive panel comprising:(i) a plate; and(ii) at least one tab configured to slotted through the wedge-lock aperture to form a tapered crevice,wherein the wedge assembly is extended into the tapered crevice by actuation of the actuator, thereby locking the passive panel and the active panel together.

2. The system of claim 1, wherein the actuator is a hydraulic actuator.

3. The system of claim 2, wherein the hydraulic actuator is powered by a remote power source.

4. The system of claim 1, wherein extending the at least one wedge assembly into the tapered crevice forms a fluid-tight juncture between the passive panel and the active panel.

5. The system of claim 8, further comprising at least one box section mounted to the active panel and slidably retaining the wedge assembly to constrain the wedge assembly in two dimensions while permitting motion along a guided path.

6. The system of claim 1, wherein the system includes a plurality of passive panels and a plurality of active panels configured to assemble into a form.

7. A formwork system comprising:(a) a passive panel having a passive plate and at least one tab projecting from the passive plate;(b) an active panel having an active plate and at least one wedge-lock aperture with an opening sized to receive the at least one tab; and(c) a locking assembly mounted to the active panel and including at least one wedge assembly and at least one actuator configured to advance the at least one wedge assembly along a guided path,wherein insertion of the at least one tab through the opening positions the passive wear plate and the active wear plate to cooperate and define a tapered crevice, and advancement of the at least one wedge assembly into the tapered crevice by the at least one actuator drives the passive panel and the active panel into a clamped condition.

8. The system of claim 7, wherein the at least one tab comprises a base plate, a passive brace affixed to the base plate, and a passive wear plate removably attached to the passive brace.

9. The system of claim 7, wherein the active panel further comprises an active brace affixed to the active plate and an active wear plate removably attached to the active brace.

10. The system of claim 7, wherein the actuator is a hydraulic actuator.

11. The system of claim 7, further comprising at least one box section mounted to the active panel and slidably retaining the at least one wedge assembly to constrain the at least one wedge assembly in two dimensions while permitting motion along the guided path.

12. The system of claim 11, wherein the at least one box section retains a pair of wedge assemblies in a coaxial configuration and the at least one actuator is positioned between the pair of wedge assemblies to force the pair apart when extended.

13. The system of claim 7, wherein driving the at least one wedge assembly into the tapered crevice forms a fluid-tight juncture between the passive panel and the active panel.

14. A formwork system comprising:(a) a passive panel comprising:(i) a plate; and(ii) at least one tab extending from the plate, comprising:(A) a base plate;(B) a passive brace affixed to the base plate; and(C) a passive wear plate attached to the passive brace; and(b) an active panel comprising:(i) a plate;(ii) at least one wedge lock aperture, each configured to receive one of the at least one tabs;(iii) an active brace affixed to the plate;(iv) an active wear plate affixed to the active brace; and(v) a locking assembly mounted to the plate comprising:(A) at least one wedge assembly; and(B) at least one actuator configured to advance the at least one wedge assembly along a guided path,wherein insertion of the at least one tab through the at least one wedge lock aperture causes the passive wear plate and the active wear plate to form a tapered crevice, and advancement of the at least one wedge assembly into the tapered crevice locks the passive panel and the active panel together.

15. The formwork system of claim 14, wherein at least the passive wear plate, the active wear plate, and the wedge are modular components independently removable and replaceable without replacement of the passive plate or the active plate.

16. The formwork system of claim 14, wherein the passive panel includes a plurality of tabs disposed at corners of the passive plate and the active panel includes a corresponding plurality of wedge lock apertures disposed at corners of the active plate to form a tapered crevice at each corner when the panels are joined.

17. The formwork system of claim 14, wherein the locking assembly comprises a pair of wedge assemblies in a coaxial configuration and the at least one actuator is positioned between the pair of wedge assemblies to force the pair apart when extended.

18. The formwork system of claim 14, wherein the actuator is a hydraulic actuator powered by a remote power source.

19. The formwork system of claim 14, wherein extending the at least one wedge assembly into the tapered crevice forms a fluid-tight juncture between the passive panel and the active panel.

20. The formwork system of claim 14, wherein the formwork system comprises a plurality of passive panels and a plurality of active panels configured to assemble into a form.

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