Elongated foldable polygonal casting member

Abstract

An elongated foldable polygonal casting member (100) being foldable to a flat-packed state and unfolded and assembled form a polygonal three-dimensional concrete receiving mold.

Description

[0001] Elongated foldable polygonal casting member

[0002] The disclosed embodiments relate to an elongated foldable polygonal casting member.

[0003] The disclosed embodiments further relate to an elongated foldable polygonal casting member enabling the elongated foldable polygonal casting member to be folded into a compressed state having a mainly flat shape for transport, and unfolded to form an elongated three-dimensional concrete receiving mold that is self-supporting and being open in both axial distal ends for receiving concrete to form a concrete structure.

[0004] Background

[0005] In the construction art, it is common to use elongated mainly tubular casting pipes or similar as casting molds, configured to receive concrete for forming a concrete structure when cured. These cured concrete structures are commonly used to form a support structure for a concrete floor, outdoor porch or patio or the like. The mentioned mainly elongated tubular casting pipes are usually inserted into a hole in the ground, and wherein the soil supports and carries the load of the structure.

[0006] Commonly most used are rigid elongated tubular tubes or pipes of a prefabricated length and diameter. These can be formed by plastic, cardboard or other suitable materials. The main disadvantages with the prefabricated solutions are that they are space-demanding to store, as well as are space-demanding to transport to remote sites for use, as well as transport to and from stores. This also brings along unnecessary costs both for required space for storage and transportation, as well as is not an environmentally friendly solution as this results in unnecessary high CO2 emission.

[0007] From US6220564 Bl is known a concrete column forming tube stored and displayed for sale in the flat, and under the urging of a pivotal traverse of an internal ring is projected into the much larger three-dimensional shape necessary for forming the concrete column, this reshaping occurring at a site of use having no space limitations.

[0008] In US2013037979 Al are described systems and methods for forming concrete footings, wherein the concrete form includes a sleeve with top edge and a bottom portion with a bottom edge generally parallel to the top edge. The bottom portion includes a plurality of bottom severance lines extending from the bottom edge to the top portion, and the top portion includes a plurality of top creases extending from the top edge to the bottom portion. The top creases are generally perpendicular to the top and bottom edges. The top creases, at least partially, define a plurality of top panels around a periphery of the sleeve, and the bottom severance lines at least partially define a plurality of bottom panels configured to flare out when concrete is poured into the sleeve.

[0009] The main disadvantages of both US6220564 Bl and US2013037979 Al are that they are not self-supporting and require the use of additional structures to both secure the structure and retain the structure in shape. They further both suffer from small overlap area that requires the use of additional structure elements.

[0010] Another disadvantage of US6220564 Bl is that the interior circumference of the mold will form a void in the concrete structure.

[0011] Another disadvantage with the prior art solutions is that they are not suitable for being adapted or joined without the use of additional tools or other accessories.

[0012] A further disadvantage with some prior art solutions is that it is required to process the material with a wax or other chemical treatment, which makes the production complicated and has negative environmental impact.

[0013] The prior art solutions are further not adapted according to standard transport pallets (Euro-pallet) for easy transport and storage.

[0014] Due to the material used and shape of the prior art solutions they have limited opportunities for production at different locations.

[0015] Further, as the prior art solutions cannot be completely flat-packed, at least in assembled state, this makes them vulnerable to transport and storage.

[0016] There is thus a need for an elongated foldable polygonal casting member solving the issues of the prior art solutions.

[0017] Summary

[0018] The disclosed embodiments provide an elongated foldable polygonal casting member (EFPCM).

[0019] Provided herein is an EFPCM being foldable to a transport state, wherein the EFPCM occupies minimum space, and unfoldable to a casting state, wherein the EFPCM forms a polygonal three-dimensional concrete receiving mold for receiving concrete to form a concrete structure.

[0020] Also provided herein is an EFPCM overcoming the foregoing and other shortcomings of the prior art. Provided herein is an EFPCM with multiple axially extending folding sections enabling the EFPCM to be folded and flat-packed on a standard transport pallet.

[0021] Also provided herein is an EFPCM with transversally or circumferentially extending folding sections enabling the EFPCM to be folded and flat-packed on a standard transport pallet.

[0022] Provided herein is an EFPCM that is manufactured in an environmentally friendly degradable material.

[0023] Also provided herein is an EFPCM that is adaptable / adjustable on site.

[0024] Provided herein is an EFPCM that is pre-assembled or can be assembled on site.

[0025] Also provided herein is an EFPCM that reduces the space / volume required fortransport and storage.

[0026] Provided herein is an EFPCM that is tool free.

[0027] Provided herein is an EFPCM that may be joined to other EFPCMs without the use of tools or requiring additional means.

[0028] Also provided herein is an EFPCM that, after being unfolded and assembled , is self-supporting and capable of standing upright without the need for additional support structures or devices.

[0029] Also provided herein is an EFPCM that is pre-assembled and that can be folded for transport and unfolded to form the a polygonal three-dimensional concrete receiving mold.

[0030] Further features of the present invention will appear from the following description, claims and attached drawings.

[0031] The invention

[0032] An elongated foldable polygonal casting member according to the present invention is defined by the technical features of claim 1. Preferable features of the elongated foldable polygonal casting member are described in the dependent claims.

[0033] The inventive embodiments of the present invention are related to an elongated foldable polygonal casting member (EFPCM) being foldable to a transport state and unfoldable and assembled to form an elongated three-dimensional concrete receiving mold being self-supporting and open at axial distal ends for receiving concrete. By self-supporting is herein meant a structure that is capable of staying up or upright, with the direction of elongation in parallel to gravitational direction, without being supported by something else.

[0034] The EFPCM according to the present invention has a first axial side and a second axial side, as well as a first axial distal end and a second axial distal end.

[0035] The EFPCM according to the present invention is further formed by x axially extending sections, wherein x is an integer number larger than six.

[0036] The EFPCM is further provided with y axially extending folding sections, extending mainly in parallel between the first and second axial distal ends. In accordance with the EFPCM according to the present invention, they axially extending folding sections are distributed in circumferential direction thereof and dividing the elongated foldable polygonal casting member into x foldable axially extending sections of approximately the same width.

[0037] In accordance with the EFPCM according to the present invention, the EFPCM, when unfolded and assembled, form a polygonal three-dimensional concrete receiving mold being self-supporting. The first axially extending section and xthaxially extending section overlap forming an interior circumference of the polygonal three-dimensional concrete receiving mold that is mainly without voids and is open at axial distal ends for receiving concrete.

[0038] According to one embodiment of the EFPCM according to the present invention, at least the first axially extending section or xthaxially extending section, or both, at facing surface(s) is / are provided with an adhesive fastening material.

[0039] In accordance with one embodiment of the EFPCM according to the present invention, the EFPCM is pre-assembled by that the first axially extending section and xthaxially extending section are attached to each other, and wherein the EFPCM is configured to be folded into a compressed state having a mainly flat shape for transport and unfolded to form the polygonal three-dimensional concrete receiving mold. In an alternative embodiment of the EFPCM according to the present invention, the EFPCM is configured for post assembly of the first axially extending section and xthaxially extending section on site after being unfolded.

[0040] According to one embodiment of the EFPCM according to the present invention, the EFPCM is formed by cardboard, recycled cardboard or degradable cardboard.

[0041] The term degradable as used herein in connection with different materials refers to biodegradable and being capable of being decomposed by biological activity, especially by microorganisms like bacteria. A person skilled in the art will know how to select the appropriate standard method for assessing degradability based on the type of material. For plastics EN 13432 is appropriate, for cardboard and paper-based materials with polymer coatings EN13432 is also appropriate. A degradable EPPCM will comply with the requirements of receiving the DIN CERTCO Compostable Mark.

[0042] In accordance with one embodiment of the EFPCM according to the present invention, the EFPCM is provided with one or more transversally or circumferentially extending perforated ripping sections, enabling the EFPCM to be axially length adjusted.

[0043] According to one embodiment of the EFPCM according to the present invention, the adhesive fastening material is pre-applied to the first axially extending section and / or xthaxially extending section. In an alternative embodiment of the EFPCM according to the present invention, the adhesive fasting material is configured to be manually applied to the first axially extending section and / or xthaxially extending section prior to assembly of the elongated foldable polygonal casting member by means of a manual gluing mechanism.

[0044] In accordance with one embodiment of the EFPCM according to the present invention, the adhesive fastening material in addition is pre-applied to one or more intermediate axially extending sections. In an alternative embodiment of the EFPCM according to the present invention, the adhesive fasting material is configured to be manually applied to the one or more intermediate axially extending sections prior to assembly of the elongated foldable polygonal casting member by means of a manual gluing mechanism.

[0045] According to one embodiment of the EFPCM according to the present invention, the adhesive fastening material is a glue or degradable glue.

[0046] In accordance with one embodiment of the EFPCM according to the present invention, the glue or degradable glue is covered by a removable enclosure. The removable enclosure is removed prior to assembly of the EFPCM.

[0047] The unfolded and assembled EFPCM according to the present invention as mentioned form a self-supporting polygonal three-dimensional concrete receiving mold. The properties making the EFPCM self-supporting, when unfolded and assembled, is the material in the form of cardboard, recycled cardboard or degradable cardboard, the retaining force by the adhesive fastening material and shape formed by the unfolding of the elongated foldable polygonal casting member. The cardboard, recycled cardboard or degradable cardboard is according to one embodiment of the EFPCM according to the present invention formed by a core of corrugated cardboard with Kraftliner forming both an outer layer at both sides of the corrugated cardboard, resulting in high strength and durability, i.e. robustness. Kraftliner is mainly made from virgin fibers from softwood trees, which provide greater strength than paper made from recycled fibers, although it may contain recycled fibers in the bottom layer.

[0048] In accordance with one embodiment of the EFPCM according to the present invention, the core is formed by hard-pressed layers of paper making a core of high strength and resistance for water.

[0049] According to one embodiment of the EFPCM according to the present invention, the cardboard, recycled cardboard or degradable carboard is laminated with the Kraftliner, the Kraftliner is glued to the core and high pressure is applied to both sides to make the formed EFPCM compact.

[0050] In accordance with one embodiment of the EFPCM according to the present invention, the mentioned applied pressure is between 500 to 1500 N / cm2, more preferably between 750 to 1250 N / cm2and even more preferably between 900 to 1100 N / cm2. Other suitable pressure ranges will be within the knowledge of a skilled person. By applying sufficiently high pressure in the mentioned process one ensures that no air pockets or holes arise between the layers of the RFPCM, which results in an EFPCM that is extra strong and resistant against moisture and temperature. Tests made by the applicant have shown that applying a pressure of approximately 1000 tons results in an EFPCM with the desired properties.

[0051] In accordance with one embodiment of the EFPCM according to the present invention, the composition of the glue for lamination with the Kraftliner is adapted according to the season of the year.

[0052] According to one embodiment of the EFPCM according to the present invention, the corrugated core is formed with a score height / thickness between 20-25 mm, more preferable 21-24 mm and even more preferable between 22-24 mm. Other suitable score height / thickness ranges will be within the knowledge of a skilled person.

[0053] In accordance with one embodiment of the EFPCM according to the present invention, the distance between two scores of the corrugated core is between 3-10 mm, more preferable between 4-8, and even more preferable between 5-7 mm. The smaller the distance the stronger compression strength. Other suitable distance ranges will be within the knowledge of a skilled person. According to one embodiment of the EFPCM according to the present invention, the board quality is between 1-3 mm, more preferable between 1.2-2.5 mm and even preferable between 1.3-1.8 mm. Other suitable board quality ranges will be within the knowledge of a skilled person.

[0054] According to one embodiment of the EFPCM according to the present invention it is formed with a Cobb value between 10-40%, more preferable between 15-30% and even more preferable between 20-25 %. The Cobb value may be different for the core and the outer layer, and often will also be of different values wherein the core has a higher Cobb value than the outer Krafliner layer. Other suitable cobb value ranges will be within the knowledge of a skilled person.

[0055] In accordance with one embodiment of the EFPCM according to the present invention, the cardboard, recycled cardboard or degradable cardboard has two or more of the above-mentioned properties.

[0056] In accordance with one embodiment of the EFPCM according to the present invention, the adhesive fastening material is a glue with high stickiness (adhesive strength and tackiness) towards cardboard, and especially the Kraft(liner) to ensure that, when two sections of the EFPCM are attached together, they stay together. The stickiness may be tested with known methods, such as a Peel test, Shear Test, Pull-Off Adhesion Test or some other suitable test.

[0057] According to one embodiment of the EFPCM according to the present invention, the adhesive fastening material is a glue providing a higher retention force than the strength of the cardboard.

[0058] In accordance with one embodiment of the EFPCM according to the present invention, the adhesive fastening material is a glue having elastic or flexible properties to allow the glue to handle temperature changes. The elastic or flexible properties of the glue may be tested with known methods, such as the Tensile Test, Peel test. Shear Test, Dynamic Mechanical Analysis, bending / flex test or some other suitable test.

[0059] According to one embodiment of the EFPCM according to the present invention, the adhesive fastening material is glue that is biodegradable and compostable making it environmentally friendly and degradable together with the cardboard.

[0060] In accordance with one embodiment of the EFPCM according to the present invention, the adhesive fastening material is a glue that is water resistant, at least to the same degree as the cardboard. According to one embodiment of the EFPCM according to the present invention, the adhesive fastening material is a glue that has a short initial set time enabling the EFPCM to be unfolded and assembled to form the polygonal three-dimensional concrete receiving mold without requiring long waiting time.

[0061] According to one embodiment the adhesive fastening material is a glue configured to provide the required retention force prior to being completely cured. For embodiments of the EFPCM that are assembled on site, the initial set of the adhesive fastening material could be instant, between 1-5 minutes, between 5-10 minutes, between 10-20 minutes or longer than 20 minutes. For applications requiring instant use, the adhesive fastening material will be configured accordingly. However, using an adhesive fastening material with short initial set time also results in an adhesive fastening material that has lower flexibility than an adhesive fastening material with longer initial set time. As regards the curing time, the curing time to full cure will typically be between 1-5 hours, 5-10 hours or 12-24 hours. To enable use within reasonable time, the full cure should be within 5 hours, especially for applications that are assembled on site. For applications that are pre-assembled, both the initial set time and the curing time may be chosen to be longer than for the applications where the EFPCM is assembled on site. The formed a polygonal three-dimensional concrete receiving mold cannot be filled with concrete until one is sure that the adhesive fastening material has cured sufficiently to provide the required retention force. This amount of concrete that is to be filled will also affect when the adhesive fastening material can be considered to have cured sufficiently, due to that lower amount of concrete needed will result in lower forces affecting the EFPCM and thus the required retention force of the adhesive fastening material. Other ranges for initial set time and curing time will be within the knowledge of the skilled person.

[0062] In accordance with one embodiment of the EFPCM according to the present invention, the adhesive fastening material is glue having two or more of the above-mentioned properties.

[0063] In other words, the combination of the properties of the cardboard, the properties of the adhesive fastening material and the polygonal three-dimensional shape that is formed when the EFPCM is unfolded and assembled that is self-supporting and capable of standing upright without any need for additional supporting structures or devices as is the case with prior art solutions.

[0064] The polygonal three-dimensional shape chosen, as well as the diameter thereof, will affect the stability of the EFPCM when standing upright, as well as this will have an affection on the concrete structure to be formed as concrete cures from the outside and inwards. In addition, considerations of the requirement of how even or uniform the outer surface the concrete structure is to be, must be considered when considering the polygonal three-dimensional shape that is to be formed by the EFPCM. According to one embodiment of the EFPCM according to the present invention, the respective axially extending folding sections in addition are perforated enabling adjustment of the elongated foldable polygonal casting member in circumferential or transversal direction.

[0065] In accordance with one embodiment of the EFPCM according to the present invention, the EFPCM in addition is provided with one or more transversally or circumferentially extending folding sections, enabling the elongated foldable polygonal casting member to also be folded in axial direction.

[0066] According to one embodiment of the EFPCM according to the present invention, the EFPCM, at the first axial distal end and / or second axial distal end, or both, is provided with axially protruding joining members, configured for enabling joining of at least two EFPCMs in series in axial direction.

[0067] In accordance with one embodiment of the EFPCM according to the present invention, the axially extending sections are provided with an axially protruding joining member.

[0068] According to one embodiment of the EFPCM according to the present invention, the axially protruding joining member of alternating axially extending sections, seen in circumferential or transversal direction of the EFPCM, have a respective first and second axial length. At joining of two EFPCMs axially in series, the axially protruding joining members of opposite first and second axial lengths are accommodated one within the other and joining the two EFPCMs together.

[0069] In accordance with one embodiment of the EFPCM according to the present invention, the axially extending folding sections, in transversal direction of the EFPCM, are successively wider in the circumferential or transversal direction of overlapping axially extending sections of the EFPCM, from the first axial side of the EFPCM towards the second axial side of the EFPCM, enabling the EFPCM to be assembled in several layers for increased rigidity and structural stiffness.

[0070] According to one embodiment of the EFPCM according to the present invention, the EFPCM in folded state is configured to be stacked on a standard transport pallet (Euro-pallet).

[0071] The EFPCM according to the present invention has considerable environmental benefits over the most commonly used prior art solutions.

[0072] Today 55 pieces of the 20x120 cm prior art casting pipe are shipped on one individual singular standard transport pallet (Euro-pallet), wherein the casting pipes are packed at a height of 2.3 meters. By means of the EFPCM according to the present invention one can ship 500 on a singular standard transport pallet (Euro-pallet - a pallet that can be re-used) at a height of only 1 meter. For a volume of 200.000 EFPCMs according to the present invention one will reduce the number of transport pallets required from 3660 to 400 and save large amounts of CO2emissions on transportation alone.

[0073] Reducing the number of transport pallets significantly further results in lower transport requirements. Assuming that each transport pallet represents a certain travel distance (e.g., km per transport pallet), one with the EFPCM according to the present invention will reduce the total km travelled by 90 %, which translates into a proportional reduction in fuel consumption and CO2emissions.

[0074] By means of the EFPCM according to the present invention enabled is the use of thinner carboard, compared to prior art solutions. By the EFPCM according to the present invention one can reduce the amount of material by over 50 %.

[0075] By reducing the material use by over 50 % for the cardboard, the production footprint is halved, reducing energy consumption and waste from materials. Additionally, thinner materials would likely reduce the weight of shipments, leading to further CO2savings.

[0076] A further advantage with the EFPCM according to the present invention is that the simplicity of the production will enable the EFPCM to be produced on multiple production facilities and reduce the need for long-distance transportation.

[0077] An advantage with one of the embodiments of the EFPCM according to the present invention is that the EFPCM is 100 % degradable.

[0078] A further advantage with the present invention is that the EFPCM can be completely flat-packed reducing the need for storage space in warehouses and during customer transport. Flat packing increases the number of units that can be stored per cubic meter, reducing the storage footprint in warehouses and transportation trucks, leading to lower operational costs and reduced CO2emissions from logistics. Further, the flat-packed EFPCMs reduce the damage that can occur during transportation and storage.

[0079] The EFPCM according to the present invention further has considerable production benefits. With the EFPCM according to the present invention one can wary the width of the folding lines to accommodate the way the EFPCM is stored on the transport pallet. It will also increase the durability of the construction by not having bigger folds than necessary (which could impair the construction). By adding perforated ripping sections in various heights of the EFPCM according to the present invention one can make the EFPCM a "tool free" product, as there is no need for knives, scissor or similar to cut the EFPCM into desired lengths.

[0080] A further advantage of the EFPCM according to the present invention is that the production method and the material used will allow the design of a user's manual directly on the product, with no need for extra packaging or other information leaflets.

[0081] A further advantage with the EFPCM according to the present invention is that one can implement visual measurements with both cm / inches, on the EFPCM to indicate length and volume needed to fill with concrete.

[0082] The EFPCM according to the present invention is further a one element product and due to the adaptability / adjustment features, different shapes and dimensions can be achieved from the same product.

[0083] Due to the EFPCM according to the present invention can be provided with additional transversally or circumferentially folding sections adding foldability, the EFPCM can have extra length and still be able to be flat-packed on a standard transport pallet.

[0084] Even though degradable cardboard may be the preferred material, the EFPCM may be produced by different materials depending on the size and the construction.

[0085] The EFPCM according to the present invention, in addition to the above, provides optimized palletization due to the flat-packed design not only reduces volume, but also provides stable and secure stacking, minimizing the risk of damage during transport.

[0086] Moreover, the EFPCM according to the present invention results in lower customs costs due to reduced unit volume will lead to lower shipping and customs fees, especially for international transport.

[0087] Further, the EFPCM according to the present invention will result in reduced storage costs due to the flat-packed design allowing more units to be stored in the same warehouse space, lowering storage expenses.

[0088] A further advantage with the EFPCM according to the present invention is that it will not be subjected to deformation during transport and storage. It is well known that prior art solutions, which are not flat-packed during transport and storage, when exposed to moisture, become some deformed. The present invention does not suffer from being deformed even if it is exposed to moisture due to it will be transported and stored in a flat-packed position.

[0089] Further preferable features and advantageous details of the present invention will appear from the following example description, claims and attached drawings.

[0090] Example

[0091] The present invention will below be described in further detail with references to the attached drawings, where:

[0092] Fig. la-d are principle drawings of an elongated foldable polygonal casting member according to a first embodiment of the present invention,

[0093] Fig. 2a-d are principle drawings of a second embodiment of an elongated foldable polygonal casting member according to a second embodiment of the present invention,

[0094] Fig. 3a-b are principle drawings of a further embodiment of an elongated foldable polygonal casting member according to the present invention.

[0095] Fig. 4a-b are principle drawings of further embodiments of an elongated foldable polygonal casting member according to the present invention, and

[0096] Fig. 5 is a principle drawing of a further embodiment of an elongated foldable polygonal casting member according to the present invention.

[0097] The present invention is related to an elongated foldable polygonal casting member (EFPCM) 100 enabling casting of concrete structures.

[0098] Reference is now made to Fig. la-d showing principle drawings of a first embodiment of an EFPCM 100 according to the present invention. The EFPCM 100 according to the present invention has a first axial side 101 and a second axial side 102, as well as a first axial distal end 103 and a second axial distal end 104.

[0099] The EFPCM 100 according to the present invention is formed by x axially extending sections llOa-x, wherein x is an integer number larger than six. In accordance with the present invention, the EFPCM 100 is further provided with y axially extending folding sections 120a-y, wherein y = x-1. The mentioned axially extending folding sections 120a-y are extending mainly in parallel between the first 103 and second 104 axial distal ends. According to the present invention, they axially extending folding sections 120a-y are distributed in circumferential or transversal direction of the EFPCM 100 and dividing the EFPCM 100 into x foldable axially extending sections llOa-x of approximately the same width.

[0100] In the EFPCM 100 according to the present invention, when unfolded and assembled to form a polygonal concrete receiving mold, the first axially extending section 110a and xthaxially extending section llOx overlap to form an interior circumference mainly without voids, which mold further is self-supported.

[0101] In accordance with one embodiment of the EFPCM 100 according to the present invention, at least the first axially extending section 110a or xthaxially extending section llOx, or both, at facing surface(s) is / are provided with an adhesive fastening material 130. In accordance with the EFPCM 100 according to the present invention, the adhesive fastening material 130 is applied in axial direction of the first axially extending section 110a or xthaxially extending section llOx, or both, and has properties to ensure that the first axially extending section 110a and xthaxially extending section llOx are retained securely to each other. In addition to the properties of the adhesive fastening material 130 being of importance, the adhesive fastening material 130 has to be applied over a sufficient area of the first axially extending section 110a or xthaxially extending section llOx and with a sufficient amount to ensure the required retention effect is achieved.

[0102] In the embodiment of Fig. la-d, the EFPCM 100 is formed by seven axially extending sections 110a-g and six axially extending folding sections 120a-f that when unfolded and assembled to form the polygonal concrete receiving mold, forming an elongated hexagonal three-dimensional concrete receiving mold being open in both axial distal ends. In folded state the EFPCM 100 is flat-packed as shown in Fig. Id.

[0103] In Fig. 2a-d is shown a second embodiment of the EFPCM 100 according to the present invention, wherein the EFPCM 100 is formed by eleven axially extending sections llOa-k and ten axially extending folding sections 120a-j that when unfolded and assembled to form the polygonal concrete receiving mold, forming an elongated decagonal three-dimensional concrete receiving mold being open in both axial distal ends. In folded state the EFPCM 100 is flat-packed as shown in Fig. 2d.

[0104] In Fig. lc is shown a state where the first embodiment of the EFPCM 100 is partly flat-packed and in Fig. Id the EFPCM 100 is shown in a state where it is fully flat-packed by folding along the axially extending folding sections 120c and 120f. In contrast to many prior art solutions that cannot be folded beyond this partly flat-packed state, the present invention allows the EFPCM 100 to be completely flat-packed.

[0105] In Fig. 2c is shown a state of the second embodiment of the EFPCM 100 where it is partly flat-packed and in Fig. 2d the EFPCM 100 is shown in a state where it is fully flat-packed by folding along the axially extending folding sections 120e and 120j. In contrast to many prior art solutions that cannot be folded beyond this partly flat-packed state, the present invention allows the EFPCM 100 to be completely flat-packed.

[0106] In the fully flat-packed / folded state, the EFPCM 100 in the shown embodiments has a mainly rectangular shape and is configured / designed for being stacked on a standard transport pallet, such as a Euro-pallet, in an optimized manner.

[0107] In accordance with one embodiment of the present invention, the EFPCM 100 is pre-assembled by that the first axially extending section 110a and xthaxially extending section llOx are attached by means of the adhesive fastening material 130. In the embodiments of Fig. la-d this means that the first axially extending section 110a and the 7thaxially extending section 110g are attached to each other by means of the adhesive fastening material 130, while in Fig, 2a-d the first axially extending section 110a and the 11thaxially extending section 110k are attached to each other by means of the adhesive fastening material 130. As shown in Fig. Id and 2d, the EFPCM 100 can still be folded to a flat-packed state.

[0108] According to one embodiment of the EFPCM 100 according to the present invention, the first axially extending section 110a and xthaxially extending section llOx are configured for post assembly by means of the adhesive fastening material 130, i.e. attached to each other during the assembly phase at a construction site.

[0109] In accordance with one embodiment of the present invention, the adhesive fastening material 130 is pre-applied to the first axially extending section 110a and / or xthaxially extending section llOx, or both. In embodiments where the EFPCM 100 is not pre-assembled, the adhesive fasting material 130 is configured to be manually applied to the first axially extending section 110a or xthaxially extending section llOx, or both, prior to assembly of the EFPCM 100 by means of a manual gluing mechanism. In an alternative embodiment, the adhesive fastening material 130 is covered by a removable enclosure such as tape, film, foil or similar that after removal exposes the adhesive fastening material 130 and enabling the axially extending section 110a and llOx to be attached. In accordance with one embodiment of the EFPCM 100 according to the present invention, the adhesive fastening material 130 is glue or a degradable glue.

[0110] In accordance with one embodiment of the present invention, the EFPCM 100 is formed / manufactured by cardboard or degradable cardboard. An advantage with using carboard or degradable cardboard is that this is a material that can easily be adapted / adjusted on site by means of a knife or other suitable material.

[0111] Reference is now made to 3a-b showing a further embodiment of the EFPCM 100 according to the present invention, wherein the EFPCM 100 is configured to be adapted at site, both in shape and in the number of axially extending sections llOa-o. In the shown embodiment, the adjustable EFPCM 100 is formed by fifteen axially extending sections llOa-o and fourteen axially extending folding sections 120a-n. In adjustable embodiments, it will be preferable that the adhesive fastening material 130 is pre-applied to a number of axially extending sections llOa-o. In the shown embodiment, the adhesive fasting material 130 is pre-applied to the axially extending sections 110g, 110k and llOo as an example, enabling the adjustable EFPCM 100 to adjusted according to the prior described embodiments in shape and size. However, the adhesive fastening material 130 may be arranged to any other of the intermediate axially extending sections llOb-x, enabling the adjustable EFPCM 100 to form any desired cross-sectional shape and interior circumference. In an alternative embodiment, one applies the adhesive fastening material 130 to the axially extending section in question at the time of assembly, as mentioned above by means of, e.g., a gluing mechanism.

[0112] If all the axially extending sections llOa-o in this embodiment are used, a tetradecagon (fourteensided polygon) three-dimensional concrete receiving mold is formed.

[0113] It should be noted that the more axially extending sections llOa-x the EFPCM 100 comprises, the more circular cross-sections for the three-dimensional shape are available. As concrete cures from the outside and inwards, the use of a three-dimensional circular shape will contribute to improved curing of the concrete structure to be formed.

[0114] However, due to the multiple axially extending folding sections 120a-y, more or less any cross-sectional shape can be achieved, such as any polygonal, quadratic, elliptic, rectangular, etc. This makes the present invention usable also for other areas of use. E.g. one can use EFPCM 100 of different shapes and cross-sections arranged inside each other and where concrete is supplied to the spacing between the two EFPCMs 100. Accordingly, the present invention may also be used for forming figurative concrete structures by arranging two or more EFPCMs 100 inside each other or using a EFPCM 100 of a desired shape. E.g. the adjustable EFPCM 100 may be shaped to a desired shape inside or outside another EFPCM 100. Accordingly, the present invention has many different use areas as will be acknowledged by a skilled person.

[0115] In accordance with a further embodiment of the EFPCM 100 according to the present invention, the respective axially extending folding sections 120a-n, or chosen axially extending folding sections 120a-n, are in addition perforated enabling adjustment of the EFPCM 100 in circumferential or transversal direction. Accordingly, by this embodiment, the EFPCM 100 can be adjusted without the use of any tools.

[0116] Reference is now made to Fig. 4a-b showing further embodiments of the EFPCM 100 according to the present invention.

[0117] In accordance with one embodiment of the EFPCM 100 according to the present invention, the EFPCM 100 is further provided with one or more transversally or circumferentially extending perforated ripping sections 140, i.e. extending in transversal direction of the axially extending sections llOa-x, enabling the EFPCM 100 to be axially length adjusted on site without the use of any tools.

[0118] In an alternative embodiment, the EFPCM 100 is length adjusted by using a proper cutting tool, such as a knife, scissors or similar, to cut the EFPCM 100 in appropriate length by performing a cutting in transversal or circumferential direction thereof.

[0119] Accordingly, by means of a proper cutting tool and / or the mentioned perforated axially extending folding sections 120a-y and / or the one or more transversally or circumferentially extending perforated ripping sections 140, the EFPCM 100 can be adjusted both in length and in number of axially extending sections llOa-x.

[0120] By adding this feature to the features described above, this results in that shapes with different heights can be formed, such as a stepped structure.

[0121] In accordance with a further embodiment of the EFPCM 100 according to the present invention, the axially extending folding sections 120a-y in transversal direction, for overlapping axially extending sections llOa-x, are successively wider or provided with increased flexibility in the circumferential or transversal direction of the EFPCM 100, from the first axial side 101 of the EFPCM 100 towards the second axial side 102 of the EFPCM 100, enabling the EFPCM 100 to be assembled in several layers for increased rigidity and structural stiffness. Accordingly, by assembling the EFPCM 100 by arranging the axially extending sections llOa-x in several layers, the flexibility or increasing width of the axially extending folding sections 120a-y ensures that the overlapping axially extending sections llOa-x align.

[0122] In an alternative embodiment, the same effect is achieved by the axially extending sections llOa-x to be overlapping being provided with a successively larger width to compensate for the larger circumference occurring for the additional layer of axially extending sections llOa-x.

[0123] Reference is now made to Fig. 5 showing a further embodiment of the EFPCM 100 according to the present invention, wherein the EFPCM 100 in addition is provided with one or more transversally or circumferentially extending folding sections 150, enabling the EFPCM 100 to also be folded in axial direction. In Fig. 5 is shown an embodiment of the EFPCM 100 where one such transversally extending folding section 150 is arranged along a centerline. If it is desired to fold the EFPCM 100 more than once in transversal direction, two or more such transversally or circumferentially extending folding sections 150 are arranged, distributed between the first 103 and second 104 axially distal ends enabling the EFPCM 100 to be folded in multiple layers in transversal direction.

[0124] Reference is again made to Figs. 4a-b. According to a further embodiment of the EFPCM 100 according to the present invention, the EFPCM 100 at the first axial distal end 103 and / or second axial distal end 104, or both, is provided with axially protruding joining members 160a-b, configured for enabling joining of at least two EFPCM 100 in series in axial direction. The mentioned axially protruding joining members 160a-b may be the same or have corresponding shapes enabling joining therebetween.

[0125] In accordance with one embodiment of the EFPCM 100 according to the present invention, all the axially extending sections llOb-x or llOa-(x-l) are provided with an axially protruding joining member 160a or 160b. One will not need axially protruding joining sections on both of the axially extending sections overlapping, so either axially extending section 110a or llOx can be without such an axially protruding joining member 160a-b.

[0126] In embodiments where the EFPCM 100 is adjustable, as described above, the mentioned axially protruding members 160a-b are arranged to the respective axial distal end 103-104 by means of perforated sections, enabling them to be removed, depending on the number of axially extending sections llOa-x the EFPCM 100 comprises after assembly, and prior to joining with another EFPCM 100 in series. In an alternative embodiment, the axially protruding members 160a-b are configured to be folded outwards and downwards, away from the interior thereof. In accordance with one embodiment of the EFPCM 100 according to the present invention, the axially protruding joining members 160a-b of alternating axially extending section llOa-x in circumferential or transversal direction have respective first and second axial lengths, and wherein at joining of two EFPCM 100 the axially protruding members 160a-b of opposite first and second axial lengths are accommodated one within the other and joining the two EFPCM 100 together. In the embodiments of Fig. 4a-b the protruding joining members 160a have a longer axial extension than the protruding joining members 160b. The mentioned protruding joining members 160a-b may further have a curved cross-sectional profile, as shown in Fig. 4a-b, or a rectangular cross-sectional profile at the ends thereof.

[0127] Accordingly, by the present invention is provided an EFPCM 100 that in folded state is configured to be stacked on a standard transport pallet. Depending on the number of axially extending sections llOa-x and axially extending folding sections 120a-y, the EFPCM 100 can be folded and adapted the width of the transport pallet.

[0128] The length of the EFPCM 100 is either adapted to the length of the transport pallet or the EFPCM 100 is provided with transversally or circumferentially extending folding sections 150, enabling the EFPCM 100 to be adapted in length according to the length of the transport pallet.

[0129] In cases where the EFPCM 100 is to be longer than the transport pallet in question, the EFPCM 100 can be formed by sub-EFPCMs 100 with axially protruding joining members 160a-b. In this manner, the sub-EFPCMs 100 can be transported on the transport pallet in question and wherein several sub-EFPCMs 100 are assembled in series in axial direction to the desired total length of the EFPCM 100 at the construction site.

[0130] The principles of the present invention will also be applicable for EFPCMs formed / manufactured by degradable composite, plastics or other degradable material.

[0131] Features of any of the examples or embodiments outlined above may be combined to create additional examples or embodiments without losing the intended effect. It should be understood that the description of an embodiment or example provided above is by way of example only, and various modifications could be made by one skilled in the art. Furthermore, one skilled in the art will recognize that numerous further modifications and combinations of various aspects are possible. Accordingly, the described aspects are intended to encompass all such alterations, modifications, and variations that fall within the scope of the appended claims.

Claims

Claims1. An elongated foldable polygonal casting member (100), the elongated foldable polygonal casting member (100) being foldable to a flat-packed state and unfolded and assembled form a polygonal three-dimensional concrete receiving mold,wherein the elongated foldable polygonal casting member (100) is formed by cardboard, recycled carboard or degradable cardboard,wherein the elongated foldable polygonal casting member (100) having a first axial side (101) and a second axial side (102), as well as a first axial distal end (103) and a second axial distal end (104),wherein the elongated foldable polygonal casting member (100) is formed by x axially extending sections, wherein x is an integer number larger than six,wherein the elongated foldable polygonal casting member (100) is provided with y axially extending folding sections (120a-y), extending mainly in parallel between the first (103) and second (104) axial distal ends, wherein y=x-l, the y axially extending folding sections (120a-y) being distributed in circumferential direction thereof and dividing the elongated foldable polygonal casting member (100) into the x axially extending sections (llOa-x) of approximately the same width,wherein at least the first axially extending section (110a) or the xthaxially extending section (llOx), or both, at facing surface(s) is / are provided with an adhesive fastening material (130), for retaining the first axially extending section (110a) and the xthaxially extending section (llOx) securely to each other for assembly of the elongated foldable polygonal casting member (100), when the first axially extending section (110a) and the xthaxially extending section (llOx) are arranged overlapping when assembled,characterized in that the elongated foldable polygonal casting member (100), when unfolded and assembled form the polygonal three-dimensional concrete receiving mold being self-supporting due to being formed by cardboard, recycled cardboard or degradable cardboard, the retaining force by the adhesive fastening material (130) and shape formed by the unfolding of the elongated foldable polygonal casting member (100), wherein the polygonal three-dimensional concrete receiving mold being open at axial distal ends for receiving concrete.

2. The elongated foldable polygonal casting member (100) according to claim 1, wherein being preassembled by that the first axially extending section (110a) and the xthaxially extending section(llOx) are attached or being configured for post assembly of the first axially extending section (110a) and the xthaxially extending section (llOx).

3. The elongated foldable polygonal casting member (100) according to any preceding claim, wherein the elongated foldable polygonal casting member (100) being provided with one or more transversally or circumferentially extending perforated ripping sections (140), enabling the elongated foldable polygonal casting member (100) to be axially length adjusted.

4. The elongated foldable polygonal casting member (100) according to claim 1, wherein the adhesive fastening material (130) is pre-applied to the first axially extending section (110a) and / or the xthaxially extending section (llOx) or the adhesive fasting material (130) is configured to be manually applied to the first axially extending section (110a) and / or xthaxially extending section (llOx) prior to assembly of the elongated foldable polygonal casting member (100) by means of a manual gluing mechanism.

5. The elongated foldable polygonal casting member (100) according to claim 1, wherein the adhesive fastening material (130) in addition is pre-applied to one or more intermediate axially extending sections (llOb-(x-l)) or the adhesive fasting material (130) is configured to be manually applied to the one or more intermediate axially extending sections (110b-(x-l)) prior to assembly of the elongated foldable polygonal casting member (100) by means of a manual gluing mechanism.

6. The elongated foldable polygonal casting member (100) according to claim 1, wherein the adhesive fastening material (130) is a glue or degradable glue.

7. The elongated foldable polygonal casting member (100) according to claim 6, wherein the glue or degradable glue is covered by a removable enclosure.

8. The elongated foldable polygonal casting member (100) according to claim 1, wherein respective axially extending folding sections (120a-y) in addition are perforated enabling adjustment of the elongated foldable polygonal casting member (100) in circumferential or transversal direction.

9. The elongated foldable polygonal casting member (100) according to claim 1, wherein the elongated foldable polygonal casting member (100) in addition is provided with one or more transversally or circumferentially extending folding sections (160), enabling the elongated foldable polygonal casting member (100) to also be folded in axial direction.

10. The elongated foldable polygonal casting member (100) according to any preceding claim, wherein the elongated foldable polygonal casting member (100), at the first axial distal end (103)and / or second axial distal end (104), or both, is provided with axially protruding joining members (160a-b), configured for enabling joining of at least two elongated foldable polygonal casting members (100) in series in axial direction.

11. The elongated foldable polygonal casting member (100) according to claim 10, wherein the axially extending sections (llOb-x or llOa-(x-l)) are provided with an axially protruding joining member (160a-b).

12. The elongated foldable polygonal casting member (100) according to claim 11, wherein the axially protruding joining member (160a-b) of alternating axially extending sections (llOa-x), seen in circumferential or transversal direction of the elongated foldable polygonal casting member (100), have a respective first and second axial length, and wherein, at joining of two elongated foldable polygonal casting members (100) axially in series, the axially protruding joining members (160a-b) of opposite first and second axial lengths are accommodated one within the other and joining the two elongated foldable polygonal casting members (100) together.

13. The elongated foldable polygonal casting member (100) according to any preceding claim, wherein the axially extending folding sections (llOa-x), in transversal direction of the elongated foldable polygonal casting member (100), are successively wider in the circumferential or transversal direction of overlapping axially extending sections (llOa-x) of the elongated foldable polygonal casting member (100), from the first axial side (101) of the elongated foldable polygonal casting member (100) towards the second axial side (102) of the elongated foldable polygonal casting member (100), enabling the elongated foldable polygonal casting member (100) to be assembled in several layers for increased rigidity.

14. The elongated foldable polygonal casting member (100) according to any preceding claim, wherein the elongated foldable polygonal casting member (100) in folded state is configured to be stacked on a standard transport pallet.

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