초록 ▼

The invention involves a manner of fabricating 3D construction forms by preparing first and second standard sized panels with a predetermined pattern of perforations and assembling same in spaced apart relationship by connecting the panels together with connectors designed to engage the perforations

The invention involves a manner of fabricating 3D construction forms by preparing first and second standard sized panels with a predetermined pattern of perforations and assembling same in spaced apart relationship by connecting the panels together with connectors designed to engage the perforations in the panels. The perforations of the panels are arranged in a specific pattern suitable for the assembly and use of the construction forms by means of an apparatus designed to form the perforations. The method also uses apparatus which assist in the orientation and alignment of the connectors to engage the panels. Modifications of the panels and connectors will allow the formation of 3D construction forms with corners of various configuration.

대표청구항 ▼

1. A method of fabricating 3D construction forms comprising the steps of:preparing a first panel with a predetermined pattern of perforations through a thickness of said first panel; preparing a second panel with a corresponding predetermined pattern of perforations through a thickness of said secon

1. A method of fabricating 3D construction forms comprising the steps of:preparing a first panel with a predetermined pattern of perforations through a thickness of said first panel; preparing a second panel with a corresponding predetermined pattern of perforations through a thickness of said second panel; assembling said first and second panels in a fixed parallel spaced apart relationship by connecting said panels together with connectors designed to engage said perforations of respective panels, and wherein said panels are assembled by the steps comprising: i) placing a first panel in a fixed position held by a frame; ii) placing a plurality of connectors in a clamping mechanism associated with said frame so that said connectors are aligned with and engaged to the perforations of said first panel; iii) placing a second panel to be mounted on said connectors by aligning and engaging said second panel perforations to the other ends of said transverse rods; iv) securing said panels in said parallel spaced apart relationship by attaching fasteners to said transverse rods; and v) wherein said first panel is a standard sized panel, and wherein said method includes the step of extending the dimension of said form by adding at least a portion of a standard panel to said standard sized panel in edge to edge relationship at a joint so as to form a construction form of non-standard size dimensions, and fastening said portion of said standard panel to said first panel by a plate extending between adjacent connectors on either side of said edge to edge joint. 2. A method as claimed in claim 1 in which said panels are foamed polystyrene.3. A method as claimed in claim 1 in which said connectors comprise transverse rods extending between the perforations of said first and second panels and tie rods extending between and fixed to said transverse rods to maintain spacing between said transverse rods corresponding to the pattern of perforations in said first and second panels.4. A method of fabricating 3D construction forms as claimed in claim 3 to form a corner comprising the steps of:cutting the tie rods of said connectors to form two pieces of connectors; arranging one piece of said connector in angular orientation to the remainder of said connector; placing reinforcing bars, bent at angles corresponding to said angular orientations, across the intermediate portion of said transverse rods and fastening said fastening said connectors thereto; cutting a first panel to fit the dimension of the first outer panel of said corner and attaching said transverse rods to the perforation of said cut panel; cutting a second panel to form the dimensions of the second outer panel of said corner and attaching same to the ends of the transverse rods to form a second outer panel of said corner; cutting a first inner piece of said first panel to form the first inner portion of said corner and attaching same to the inner ends of said transverse rods; cutting a second inner panel of said second panel to form the second inner surface of said corner and attaching same to the inner ends of said transverse rods. 5. A method as claimed in claim 4 including welding a portion of transverse rod in the intermediate part of the endmost transverse rod at a spacing equal to the spacing between perforations in said panel.6. A method as claimed in claim 5 including the steps of inserting vertical reinforcing bars adjacent to the said reinforcing bars and positioned between the transverse rods which are offset in relation to the next adjacent transverse rods.7. A method of fabricating a 3D construction form comprising the steps of:a) providing a panel with a thickness, said panel having a plurality of transverse axially oriented perforations through said thickness and being arranged in a pre-determined pattern, said panel being oriented in a generally longitudinal orientation; b) holding a plurality of connectors in a generally fixed transverse orientation, said connectors having an end portion that is generally axially aligned with said axial orientation of said perforations, said plurality of connectors comprises a plurality of generally transverse rods; c) moving one or both of said panel and said plurality of transverse connectors towards the other or each other such that an end portion of each of said connectors is received axially into one said plurality of perforations; d) affixing a fastener proximate said end portion of each of said connectors to fix each of said connectors to said panel; and e) tie rods oriented generally longitudinally and extending between and fixed to at least first and second transverse rods of said plurality of transverse rods to maintain spacing between said first and second transverse rods corresponding to the pattern of perforations in said panel, and wherein said gripping mechanism holds said first and second transverse rods. 8. A method a claimed in claim 7 wherein said panel has an inner surface which is generally planar and wherein an end portion of each of said connectors is received axially into one said plurality of perforations at said inner surface of said panel at substantially the same time.9. A method as claimed in claim 7 wherein said panels are foamed polystyrene.10. A method as claimed in claim 7 further comprising tie rods oriented generally longitudinally and extending between and fixed to at least first and second transverse rods of said plurality of transverse rods to maintain spacing between said first and second transverse rods corresponding to the pattern of perforations in said panel.11. A method as claimed in claim 7, further comprising a gripping mechanism for holding said plurality of connectors in said generally fixed transverse orientation.12. A method as claimed in claim 7 further comprising:a) providing a second panel with a thickness, said second panel having a second plurality of transverse axially oriented perforations through said thickness and being arranged in a second pre-determined pattern, said second panel being oriented in a generally longitudinal orientation; b) moving one or both of said second panel and said plurality of transverse connectors towards the other or each other such that a second end portion of each of said connectors, opposite to said first end portion, is received axially into one said second plurality of perforations; c) affixing a fastener proximate said second end portion of each of said connectors to fix each of said connectors to said second panel. 13. A method a claimed in claim 12 wherein said second panel has an inner surface which is generally planar and wherein a second opposite end portion of each of said connectors is received axially into one said plurality of perforations at said inner surface of said second panel at substantially the same time.14. A method of fabricating a 3D construction form comprising the steps of:a) providing a first panel with a thickness, said first panel having a plurality of transverse axially oriented perforations through said thickness and being arranged in a pre-determined pattern, said panel being oriented in a generally longitudinal orientation and having a length of a first distance; b) holding a plurality of connectors in a generally fixed transverse orientation, each of said plurality of connectors having an end portion that is generally axially aligned with said axial orientation of said perforations, said plurality of connectors extending longitudinally a second distance that is greater than said first distance; c) moving one or both of said first panel and a first set of connectors of said plurality of transverse connectors towards the other or each other such that an end portion of each of said first set of connectors is received axially into one said plurality of perforations of said first panel; d) affixing a fastener proximate said end portion of each of said first set of connectors to fix each of said first set of connectors to said first panel; e) providing a second panel with a thickness, said second panel having a second plurality of transverse axially oriented perforations through said thickness and being arranged in a pre-determined pattern, said second panel being oriented in a generally longitudinal orientation and generally in longitudinal alignment with said first panel, said second panel having a length of a third distance; f) moving one or both of said second panel and a second set of connectors of said plurality of connectors towards the other or each other such that an end portion of each of said second set of connectors is received axially into one said plurality of perforations of said second panel; and g) affixing a fastener proximate said end portion of each of said second set of connectors to fix each of said second set of connectors to said second panel. 15. A method a claimed in claim 14 wherein said first and second panels each has an inner surface which is generally planar and wherein an end portion of each of said first set of connectors is received axially into one said plurality of perforations at said inner surface of said first panel at substantially the same time, and wherein an end portion of each of said second set of connectors is received axially into one said plurality of perforations at said inner surface of said second panel at substantially the same time.16. A method as claimed in claim 15 wherein the sum of said first distance and said third distance is substantially the same or greater than said second distance.17. A method as claimed in claim 15 further comprisinga) providing a third panel with a thickness, said third panel being positioned opposite and spaced from said first and second panels, and said third panel having a second plurality of transverse axially oriented perforations through said thickness and being arranged in a second pre-determined pattern, said third panel being oriented in a generally longitudinal orientation and having a length of a fourth distance; b) moving one or both of said third panel and said plurality of transverse connectors towards the other or each other such that a second end portion of each of said connectors, opposite to said first end portion, is received axially at substantially the same time, into one said second plurality of perforations in said third panel; c) affixing a fastener proximate said second end portion of each of said connectors to fix each of said connectors to said third panel. 18. A method as claimed in claim 17 wherein the sum of said first distance and said third distance is substantially the same as said fourth distance.19. A method of fabricating a construction form comprising the steps of:a) providing a first panel with a thickness, said first panel having a plurality of generally transverse axially oriented perforations through said thickness, said panel being oriented in a generally longitudinal orientation and said panel being made from a re-shapeable material; b) providing a plurality of connectors, each of said connectors having an end portion that is generally axially aligned with said axial orientation of said perforations; c) providing a stopper mechanism at an inner surface of said first panel; d) providing a fastener for each of said plurality of connectors, each of said fasteners having a outer surface profile which is enlarges from an inner end toward a outer end; e) engaging each said fastener with said end portion of each of said plurality of connectors through a perforation of said plurality of perforations to mount each of said connectors to said first panel; wherein said fasteners are adapted to be tightened on said connector such that said panel is compressed between said stopper mechanism and at least a portion of said fastener, and said profile of said fastener deforms said panel proximate to block said perforations. 20. A method as claimed in claim 19 wherein said re-shapeable material is foamed polystyrene.21. A method of fabricating a construction form comprising the steps of:a) providing a first panel with a thickness, said first panel having at least generally transverse axially oriented perforations through said thickness, said panel being oriented in a generally longitudinal orientation and said panel being made from a suitable re-shapeable material; b) providing a connectors that is generally axially aligned with said axial orientation of said perforation; c) providing a stopper mechanism at an inner surface of said first panel; d) providing a fastener at an end portion of said connector, said fastener having an outer surface profile which generally enlarges from an inner end toward a outer end; e) engaging said fastener with said end portion of said connector through said perforation to mount said connector to said first panel; wherein said fastener is adapted to be tightened on said connector such that said panel is compressed between said stopper mechanism and at least a portion of said fastener, and said profile of said fastener reshapes said panel to block said perforations. 22. A method as claimed in claim 21 wherein said re-shapeable material is foamed polystyrene.23. A method as claimed in claim 21 wherein said stopper mechanism comprises a stopper device mounted proximate an end portion of said connector, said stopper device abutting at a first end an inner surface of said panel and at a second end an abutment member.24. A method as claimed in claim 21 wherein said abutment member is a generally longitudinally oriented rod that is fixed transversely relative to said connector.25. A method as claimed in claim 21 wherein said stopper mechanism comprises a stopper plate mounted proximate an end portion of said connector, said stopper device abutting at a first side an inner surface of said panel and at a second side an abutment member.26. A method as claimed in claim 23 wherein said abutment member is a flange portion of said connector.27. A method as claimed in claim 25 wherein said abutment member is a flange portion of said connector.28. A method as claimed in claim 21 wherein said stopper mechanism is a generally longitudinally oriented rod that is fixed transversely relative to said connector.29. A method as claimed in claim 21 wherein said profile has an end portion that is generally conical, said portion re-shaping said perforation when said panel is compressed, so as to block said perforation.