Method and means for prefabrication of 3D construction forms

Abstract

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.

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, said connectors comprising a plurality of transverse rods; 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 an alignment mechanism associated with said frame so that a first end of each of said transverse rods is substantially simultaneously aligned with and received in a corresponding perforation of said first panel;    iii) placing said second panel in a position so that a second end opposite said first end of each of said transverse rods is substantially simultaneously aligned with and received in a corresponding perforation of said second panel;    iv) securing said panels in said parallel spaced apart relationship by attaching fasteners to said first and second end of said transverse rods.    
   
   
       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 a construction form as claimed in  claim 1 , 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.  
   
   
       5 . A method of forming perforations in a panel of thermoplastic material comprising the steps of: 
 heating an elongated tube so as to emit radiant heat creating a thermal field around a portion of said tube including at an end of said tube sufficient to raise the temperature of said material at a location sufficient to melt said material at said location without said tube touching said material;    advancing said tube and its associated thermal field toward said thermoplastic material at a rate sufficient to melt said material without touching it; advancing said tube until the material is perforated therethrough by the heated atmosphere surrounding said tube providing a shape that corresponds to the thermal field provided around the body of said tube, and then withdrawing said tube.    
   
   
       6 . A method as claimed in  claim 5  in which said thermoplastic material is foamed polystyrene.  
   
   
       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;    c) moving one or both of said panel and said plurality of transverse connectors towards the other or each other such that substantially simultaneously an end portion of each of said plurality of 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.    
   
   
       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 plurality of 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 panel is foamed polystyrene.  
   
   
       10 . A method as claimed in  claim 7  in which said plurality of connectors comprises a plurality of generally transverse rods.  
   
   
       11 . A method as claimed in  claim 10 , 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.  
   
   
       12 . A method as claimed in  claim 7 , further comprising a gripping mechanism for holding said plurality of connectors in said generally fixed transverse orientation.  
   
   
       13 . A method as claimed in  claim 12  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, and wherein said gripping mechanism holds said first and second transverse rods.  
   
   
       14 . 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.    
   
   
       15 . A method a claimed in  claim 14  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.