Patent Application
20110278765
The present invention relates generally to methods and systems utilized for forming shaped concrete structures. More specifically, the present invention relates to a method and system whereby a dry concrete powder mixture is packaged in a form having a desired shape, which is then placed in a desired location, and water is added to the mixture, ultimately resulting in a hardened concrete structure. Additionally, a modular concrete form may be used to form desired shapes for the concrete structures.
Concrete (which may be used interchangeably herein with the term cement) is used for creating concrete structures such as paved surfaces, patio slabs, sidewalks, curbs, bases for fence posts and mailboxes, and the like. Concrete slurry is poured into the void or inner cavity created by concrete forms, which may be either permanent or temporary. Permanent forms remain attached to the solidified concrete with the exterior surface of the permanent form creating an edge surface. Temporary forms, in contrast, are removed after the concrete solidifies to reveal a concrete edge. For most home or do-it-yourself jobs, temporary forms are used. For instance, if a person wishes to install a concrete patio at their home, the person would first construct a concrete form, usually out of wood, which is shaped as desired and used to hold the wet concrete in place temporarily until the concrete hardens. Then, the concrete form is removed and discarded. The preparation of the form is a time consuming and expensive process.
Therefore, it would be desirable to provide a system where a dry concrete mixture is packaged in a container having a desired shape, such as a square or rectangular slab, and where the packaging itself serves as the concrete form. In this way, the consumer purchases the dry concrete mixture in the pre-formed packaging, places the item in the desired location, and simply adds water to the concrete mixture. Then, after the concrete is allowed to dry, the packaging may be cut or peeled away from the concrete structure, thereby obviating the steps of building the form and then removing it after drying.
It would also be desirable to provide an alternate embodiment, whereby a modular concrete form is provided so that a user could assemble various components of a form assembly into a desired shape.
The present invention includes, in a first embodiment, a concrete structure kit comprising a dry powdered concrete mixture contained within a shaped container or packaging. In use, the packaged concrete mixture is placed in a desired location, water is added to the dry mixture in an appropriate amount, and the concrete is allowed to set in the shape of the packaging. After the concrete has hardened, the packaging may be removed from the outside of the concrete structure. Although prefabricated concrete structures are commercially available, this system has several advantages. One advantage is that the shaped container with a dry powdered cement mixture weighs much less than a corresponding prefabricated concrete structure, thus making transport easier. Additionally, a prefabricated concrete structure may be broken or damaged during transport, while the shaped packaging and dry powdered cement unit is unlikely to be similarly affected.
In a second embodiment, a modular concrete mold system is provided, which includes a series of interlocking pieces having various shapes, such as straight sides, curved sides, corners, acute and obtuse angles, and the like. This system allows a user to construct a concrete form by attaching the shaped components of the modular system, resulting in a concrete form that has a specific, creative, desired shape.
The present invention also includes methods associated with the concrete form systems provided herein.
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
A first embodiment of the concrete form system 2 is shown in
The shaped container 6 may be made from any suitable material including cardboard or plastic, and may be formed into any desired shape. The dry concrete powder mixture 4 may include other ingredients and aggregates, including fly ash, silica fume, calcinated shale or clay, natural sand, manufactured sand, gravel, light weight aggregates, air entrained additives and blast furnace slag. Any suitable dry concrete powder mixture 4 may be used. Additionally, colors, patterns, or other decorative features may be included; as well, using any known and commercially available colorants, pigments, dyes or techniques.
In a second embodiment illustrated in
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein. All features disclosed in this specification may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
