Formwork, matrices, concrete matrices and methods of manufacture

1 . A formwork configured to receive and retain concrete therein, the formwork comprising:

a frame comprising lateral supports, each lateral support defining a volume within the lateral support, the volume defined by a base, sides, and an at least partially open top;

at least four legs, each leg comprising:

a tapering wall structure defining a hollow interior;

a leg first end and a leg second end, both the leg first end and the leg second end opening to the hollow interior;

the leg first end having a first diameter opening tapering to a second diameter opening about the second end, the first diameter opening being larger than the second diameter opening;

the legs connected to the frame at the first end of each leg, the legs extending orthogonally away from the frame to the second ends of the legs;

the leg second end of the legs comprising a vertical coupling, the vertical coupling configured to couple with a further vertical coupling located on a second end of a leg from a further formwork and, wherein the vertical coupling is configured to provide a smooth and continuous interior face flush within the hollow interior between the second ends of the legs so as to facilitate concrete flow from one leg to a further leg, the vertical coupling including elongated tabs extending from the second end of the legs, the elongated tabs arranged to nest and snug fit into complementary regions of the second end of the leg of the further formwork; wherein the vertical coupling includes a retention feature configured to lock the formwork to the further formwork;

wherein the frame couples the first end of the legs together via the lateral supports; and,

wherein the formwork defines:

an external void space outside of the lateral supports and legs; and,

an internal void space located inside the hollow interior of the legs and the volume within the lateral supports, wherein the internal void space is continuous and not segmented and is configured to receive and retain concrete therein.

2 . The formwork as claimed in claim 1 , wherein the formwork defines a generally cuboid volume and the frame defines a generally square cross-section shape in a horizontal plane.

3 . The formwork as claimed in claim 1 , wherein the lateral supports include internal lateral supports between the legs and external lateral supports extending from the legs, and

wherein each external lateral support comprises a horizontal coupling formed in one piece with, and integral to, the external lateral support at a distal second end of the external lateral support, the horizontal coupling comprising a male fitting or a female fitting configured to directly interlock with a complementary horizontal coupling of an adjacent further formwork about a horizontal plane without any intervening plate or separate connector.

4 . The formwork as claimed in claim 1 , wherein the frame comprises internal lateral supports between the legs and comprises external lateral supports extending from the legs wherein:

the internal lateral supports are of a uniform length and link each of the legs together;

the external lateral supports are of a uniform length substantially half the length of the internal lateral supports; and

the external lateral supports extend from the legs in a direction parallel to and coincident with, the direction of an adjoining internal lateral support.

5 . The formwork as claimed in claim 4 , wherein each external lateral support comprises a first end about the leg first end and a second end distal to the leg first end of the leg.

6 . The formwork as claimed in claim 5 , wherein the second end of each external lateral support comprises a horizontal coupling configured to allow the formwork and a further formwork to be coupled together in a horizontal alignment.

7 . The formwork as claimed in claim 1 , wherein the first end of the leg comprises a recess and shoulder adapted to nestingly receive a grill or a blank, the grill or blank having an outer frame with a complementary peripheral shoulder configured to seat within the recess and shoulder at the leg first end to cover the opening to the hollow interior, the grill or blank being configured to connect to and/or interact with the legs and the lateral supports to fix the grill or blank in place.

8 . The formwork as claimed in claim 1 , wherein the internal void space is formed as one integral molded volume and the legs and lateral supports are integral and not separate parts.

9 . The formwork of claim 6 , wherein the horizontal coupling of each external lateral support includes at least one of: a male fitting or a female fitting.

10 . The formwork of claim 6 , wherein the second ends of the external lateral supports include alternating male fittings and female fittings, and wherein the alternating male fittings and female fittings are configured for alternating formwork coupling about a horizontal plane.

11 . The formwork as claimed in claim 1 wherein the leg first end comprises a recess and shoulder adapted to nestingly receive a removable grill or blank therein;

wherein the lateral supports comprise a recess and shoulder adapted to also nestingly receive part of the grill or blank; and

wherein the grill or blank is configured to seat within the recess and shoulder at the leg first end to cover the opening to the hollow interior and to connect to and/or interact with the legs and the lateral supports.

12 . The formwork as claimed in claim 1 , wherein each lateral support comprises, at a distal end, a horizontal coupling formed as an open channel that is continuous with the volume within the lateral support and has an at least partially open top, the horizontal coupling configured to directly interlock with a complementary horizontal coupling of an adjacent further formwork about a horizontal plane so that, when interlocked, the open channel defines a through-passage that permits unhindered concrete flow between the internal void spaces.

13 . A matrix comprising a plurality of formwork as claimed in claim 1 , wherein:

the formwork forming the matrix are aligned vertically with each said frame of the formwork alternating in orientation from:

a first matrix layer of the formwork located below the at least four legs;

a second matrix layer of the formwork located above the at least four legs; and

wherein the vertical coupling of each formwork couples the first matrix layer of formwork with the second matrix layer of the further formwork.

14 . The matrix as claimed in claim 13 , wherein the matrix comprises multiple layers of three or more formwork comprising:

a third matrix layer of the formwork located on the second matrix layer of the formwork and below a further at least four legs of the formwork.

15 . The matrix as claimed in claim 14 , wherein the multiple layers of the matrix alternate in a manner from leg to leg vertical coupling to frame to frame vertical coupling.

16 . The matrix as claimed in claim 13 , wherein the matrix comprises a top, a bottom, and sides, and wherein at least one side panel is fitted to the side or sides of the matrix,

wherein the at least one side panel has an interior side with fastening members configured to snap fit to a formwork or multiple formwork of the matrix, and

wherein the at least one side panel has a height corresponding to a height of two formwork of the plurality of formwork stacked in an alternating manner, so as to span vertically adjacent formwork and be secured to the matrix.

17 . The matrix as claimed in claim 13 , wherein the matrix comprises a top, a bottom, and sides, and wherein at least one side panel is fitted to the side or sides of the matrix, the side panel having an interior side with fastening members configured to snap fit to a formwork or multiple formwork of the matrix, a length spanning at least two formwork horizontally along a side of the matrix, and a height corresponding to a height of two formwork stacked in an alternating manner so as to span vertically adjacent formwork and be secured to the matrix.

18 . A concrete matrix comprising:

a matrix comprising a plurality of formwork with concrete within an internal void space of the formwork in the matrix;

the formwork comprising:

a frame comprising lateral supports, each lateral support defining a volume within the lateral support, the volume defined by a base, sides and an at least partially open top;

at least four legs, each leg comprising:

a tapering wall structure defining a hollow interior;

a leg first end and a leg second end, both the leg first end and the leg second end opening to the hollow interior;

the leg first end having a first diameter opening tapering to a second diameter opening about the second end, the first diameter opening being larger than the second diameter opening;

the legs connected to the frame at the first end of each leg, the legs extending orthogonally away from the frame to the second ends of the legs;

the second end of the legs comprising a vertical coupling, the vertical coupling configured to couple with a further vertical coupling located on a second end of a leg from a further formwork and, wherein the vertical coupling is configured to provide a smooth interior face between the second ends of the legs so as to facilitate concrete flow from one leg to a further leg, wherein the vertical coupling includes an elongated tab with a hook-shaped cross-section configured to engage the further formwork with a snap fit and to thereby secure the second end of the legs to the further formwork;

wherein the frame couples the first end of the legs together via the lateral supports; and

wherein the formwork defines:

an external void space outside of the lateral supports and legs; and

the internal void space located inside the hollow interior of the legs and the volume within the lateral supports, wherein the internal void space is continuous and not segmented and is configured to receive and retain concrete therein, wherein both the first and second ends of each leg are open and remain open in the concrete matrix, and wherein, when two formworks are vertically coupled, the hollow interiors of the coupled legs together with the vertical coupling define a continuous axial-flow passage aligned with the hollow interiors of the coupled legs and permitting concrete to flow from an upper formwork through the coupled legs into a lower formwork without any intervening plate, web, cross-bar, or closure.

19 . The matrix of claim 18 configured for pouring of concrete therein, by:

selecting a plurality of formwork;

forming a first matrix layer by placing, on a substrate, the plurality of formwork, the plurality of formwork orientated in a configuration with the frame located below the second ends of the legs; and

forming a second matrix layer, over the first matrix layer, by vertically coupling the second ends of the legs of each formwork in the second matrix layer to the second ends of the legs in the first matrix layer, the formwork of the second matrix layer orientated in a configuration with the frame located above the second ends of the legs, and pouring concrete into the second matrix layer such that the concrete flows axially through the continuous axial-flow passages defined by the coupled legs and vertical couplings into the first matrix layer.

20 . The matrix as claimed in claim 19 , wherein pouring concrete therein further comprises a coupling of the formwork of the first matrix layer, or the second matrix layer, or both the formwork of the first or the second matrix layer, together in a horizontal plane, while maintaining the continuous axial-flow passages between vertically coupled legs to permit unhindered axial flow of concrete between layers.

21 . The matrix of claim 18 configured to be formed by:

selecting a plurality of formwork;

forming a first matrix layer by placing, on a substrate, the plurality of formwork, the plurality of formwork orientated in a configuration with the frame located below the second ends of the legs; and

forming a second matrix layer, over the first matrix layer, by vertically coupling the second ends of the legs of each formwork in the second matrix layer to the second ends of the legs in the first matrix layer, the formwork of the second matrix layer orientated in a configuration with the frame located above the second ends of the legs; and

pouring concrete into an internal volume of the plurality of formwork and allowing the poured concrete to cure and harden in the internal void space of the plurality of formwork, wherein both the first and second ends of every leg are open and remain open after vertical coupling, and wherein the vertical couplings between the second ends of the legs define continuous axial-flow passages aligned with the hollow interiors of the coupled legs to permit the concrete to flow axially from the second matrix layer through the coupled legs into the first matrix layer without any intervening plate, web, cross-bar, or closure.

22 . A method of forming a concrete matrix, comprising:

attaching a formwork to a further formwork, wherein the formwork comprises:

a frame comprising lateral supports, each lateral support defining a volume within the lateral support, the volume defined by a base, sides and an at least partially open top;

at least four legs, each leg comprising:

a tapering wall structure defining a hollow interior;

a leg first end and a leg second end, both the leg first end and the leg second end opening to the hollow interior;

the leg first end having a first diameter opening tapering to a second diameter opening about the second end, the first diameter opening being larger than the second diameter opening;

the legs connected to the frame at the first end of each leg, the legs extending orthogonally away from the frame to the second ends of the legs;

the second end of the legs comprising a vertical coupling, the vertical coupling configured to couple with a further vertical coupling located on a second end of a leg of the further formwork, wherein the vertical coupling includes snap-fit retention elements disposed entirely within the hollow interiors at the second ends of the legs when coupled, the retention elements comprising elongated tabs that are radially resilient and configured to deflect inwardly during insertion and to expand outwardly to snap behind an internal annular shoulder of a mating leg, thereby locking the formworks together while maintaining a smooth interior face that is flush and uninterrupted over 360° within the legs, and wherein no intermediate socket, collar, or plate is interposed between the second ends of vertically coupled legs;

and, wherein the vertical coupling is configured to provide a smooth interior face between the second ends of the legs so as to facilitate concrete flow from one leg to a further leg,

wherein the frame couples the first end of the legs together via the lateral supports, and

wherein the formwork defines: an external void space outside of the lateral supports and legs, and an internal void space located inside the hollow interior of the legs and the volume within the lateral supports, wherein the internal void space is continuous and not segmented and is configured to receive and retain concrete therein; and

filling an internal volume of the formwork with concrete and thereby causing the concrete to also fill an internal volume of the further framework via the second end of the legs and via the vertical coupling.

23 . The method of claim 22 , wherein the vertical coupling includes a retention feature configured to lock the formwork to the further formwork.

24 . The method of claim 22 , wherein the vertical coupling includes an elongated tab with a hook-shaped cross-section configured to engage the further formwork with a snap fit and to thereby secure the second end of the legs to the further formwork, the elongated tab being positioned entirely on an exterior surface of the tapering wall structure at the second end and configured to deflect during insertion and snap over a complementary external return shape of a mating leg while maintaining an uninterrupted smooth interior wall over 360° within the coupled legs and without any slot, groove, rib, or projection extending into the hollow interior.

25 . The method of claim 22 , wherein the vertical coupling includes a retention feature comprising an annular return lip moulded on an exterior perimeter of the second end of a leg and configured to lock the formwork to the further formwork.

26 . The method of claim 22 , wherein the elongated tab includes an outward barb configured to snap over an annular return lip of a mating leg so as to effect locking engagement while maintaining a smooth interior wall over 360° within the legs when coupled and without any slot, groove, rib, or projection extending into the hollow interior.

27 . The method as claimed in claim 22 , wherein the vertical coupling includes snap-fit retention elements disposed entirely within the hollow interiors at the second ends of the coupled legs, the retention elements comprising elongated tabs that are radially resilient and integrally molded in one piece with the tapering wall structure and configured to elastically deflect during insertion and to expand outwardly to snap behind an internal annular shoulder of a mating leg, thereby locking the formworks together while maintaining a smooth interior face that is flush over 360° within the coupled legs.