The present invention relates generally to the formation of pre-cast panels, and more particularly to elongate bodies for providing architectural and structural features in pre-cast panels.
Pre-cast construction of concrete wall panels for tilt-up and other types of construction is well known in the art. In the tilt-up approach, forms, also known as form liners, are placed on a flat casting surface in the shape and dimension of the desired panel and filled with concrete. When the concrete cures, the forms may be removed, and the panel tilted up into a preferred, typically vertical, orientation, where it can be joined to structural frames or other panels. The panels may have architectural features such as reveal bands or structural features formed therein by providing an elongate body that is attached to the casting surface inside the form.
The present inventor has recognized a need for elongate bodies that may be used with a variety of pre-cast systems to provide panels having architectural or structural features. An additional need exists for such bodies that can be easily attached, removed, and reused.
This need is met by the present invention that provides elongate bodies for use with precast panel forming systems. As used herein, pre-cast panel forming systems include any panel forming system that allows panels to be formed from a cast material that upon curing hardens, thereby allowing the panel to be subsequently placed in a desired location within a building structure.
In accordance with one embodiment, an elongate body comprising a cross-section comprising a set portion, a hinged portion, and a hinge is provided. The set portion comprises a first member defining a base plane, at least a portion of which is configured to engage a panel forming surface. The set portion and the hinged portion are configured to define an engagement. The hinge couples the set portion and the hinged portion such that the hinged portion is movable about the hinge to an engaged state and disengaged state of the engagement, and one of the set portion and the hinged portion define a first beveled edge extending away from the base plane. The elongate body may comprise an extruded member, and the elongate body may comprise a substantially uniform extruded cross-section extending along substantially the entire length of the elongate body. In an engaged state, the first beveled edge may intersect the base plane.
In accordance with another embodiment, the elongate body may also have, in an engaged state, the hinged portion defining a face plane opposite the base plane, the first beveled edge defined by the set portion, the first beveled edge defined by the set portion extending away from the base plane toward the face plane, and the hinged portion further comprising a second beveled edge extending away from the base plane toward the face plane. The first and second beveled edges may comprise inwardly canted edges, and the first and second beveled edges may intersect the base plane. The hinge may be located proximate to the face plane. The hinged portion may further comprise a second member along the face plane between the first and second beveled edges.
In accordance with yet another embodiment, the elongate body may also have, in an engaged state, the set portion further comprising a first sidewall extending away from the first member of the set portion and a second sidewall extending away from the first member of the set portion, the first beveled edge defined by the set portion, the first beveled edge defined by the set portion extending away from the base plane to a portion of the first sidewall of the set portion displaced from the base plane, the hinged portion further comprising a second member extending from a portion of the first sidewall of the set portion displaced from the base plane to a portion of the second sidewall of the set portion displaced from the base plane and a second beveled edge extending away from the base plane to a portion of the second sidewall of the set portion displaced from the base plane.
The hinge may be located proximate to the second member of the hinged portion or adjacent to the first sidewall along the second member of the hinged portion. The engagement may comprise an inwardly extending portion and an outwardly extending portion. The inwardly extending portion may extends from a portion of the second sidewall displaced from the base plane, and the outwardly extending portion of the engagement may extend from the second member such that the inwardly and outwardly extending portions are capable of being engaged. The inwardly extending portion may extend from a portion of the second beveled edge displaced from the base plane, and the outwardly extending portion may extend from the second member such that the inwardly and outwardly extending portions are capable of being engaged.
In accordance with a further embodiment, the elongate body may also have, in an engaged state, the set portion further comprising a first sidewall extending away from the first member of the set portion, the first beveled edge defined by the set portion, and the first beveled edge extending away from the base plane to a portion of the first sidewall of the set portion displaced from the base plane. The hinged portion may further comprise a second member extending away from a portion of the first sidewall of the set portion displaced from the base plane, a second sidewall extending from the second member of the hinged portion to the first member of the set portion, and a second beveled edge extending away from the base plane to a portion of the second sidewall of the hinged portion displaced from said base plane. The hinge may be located proximate to the second member of the hinged portion or adjacent to the first sidewall of the set portion along the second member of the hinged portion.
The engagement may comprise an inwardly extending portion and an outwardly extending portion. The outwardly extending portion may extend from a portion of the second sidewall proximate to the base plane, and the inwardly extending portion may extend from the first member of the set portion such that the inwardly and outwardly extending portions are capable of being engaged. The inwardly extending portion may extend from a portion of the second sidewall proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.
In accordance with another embodiment, the elongate body may also have, in an engaged state, the hinged portion further comprising a first sidewall extending away from the first member, the first beveled edge defined by the hinged portion, and the first beveled edge extending from the first member to a portion of the first sidewall displaced from the base plane. The hinge may be located proximate to said first member of said set portion.
The engagement may comprise an inwardly extending portion and an outwardly extending portion, and the hinge may be located proximate to the first member along the first sidewall. The inwardly extending portion may extend from a portion of the first beveled edge proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.
The hinge may be located proximate to the first member along the first beveled edge of the hinged portion, and the engagement may comprise an inwardly extending portion and an outwardly extending portion. The inwardly extending portion may extend from a portion of the first sidewall proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.
In accordance with another embodiment, the elongate body may also have, in an engaged state, the set portion further comprising a first sidewall extending away from the first member, the first beveled edge defined by the hinged portion, and the first beveled edge extending from the first member to a portion of the first sidewall opposite the base plane. The hinge may be located adjacent to the first sidewall of the set portion. The hinge may be located adjacent to a portion of the first sidewall opposite the base plane along the first beveled edge, and the engagement may comprise an inwardly extending portion and an outwardly extending portion. The inwardly extending portion may extend from the first beveled edge proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.
In accordance with another embodiment, a method of manufacturing a pre-cast panel is provided. The method comprises configuring an elongate body comprising a cross-section comprising a set portion, a hinged portion, and a hinge wherein: the set portion comprises a first member defining a base plane, at least a portion of which is configured to engage a panel forming surface; the set portion and the hinged portion are configured to define an engagement; the hinge couples the set portion and the hinged portion such that the hinged portion is movable about the hinge to an engaged state and disengaged state of the engagement; and one of the set portion and the hinged portion define a first beveled edge extending away from the base plane. The method comprises placing the elongate body on the panel forming surface, pouring pre-cast material at least around the elongate body while said pre-cast material is in an uncured state, curing said precast material, removing the elongate body from the panel forming surface. The method may further comprise securing the elongate body to the panel forming surface prior to pouring the pre-cast material. The elongate body may be secured to the panel forming surface with the engagement disengaged, and the engagement may be subsequently engaged.
In accordance with another embodiment, a pre-cast panel forming system is provided. The system comprises at least one pre-cast panel form having a length and at least one elongate body for use with the said at least one pre-cast panel form. The elongate body comprises a cross-section comprising a set portion, a hinged portion, and a hinge. The set portion comprises a first member defining a base plane, at least a portion of which is configured to engage a panel forming surface. The set portion and the hinged portion are configured to define an engagement, and the hinge couples the set portion and the hinged portion such that the hinged portion is movable about the hinge to an engaged state and disengaged state of the engagement. One of the set portion and the hinged portion define a first beveled edge extending away from the base plane, and the elongate body has a length configured to be less than the length of the at least one precast panel form.
The following detailed description of the preferred embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
The present invention is directed toward elongate bodies for use with pre-cast panel forming systems. The elongate bodies may be used to provide architectural or structural features in pre-cast panels.
Referring to
Referring to
The hinged portion 14 may define a face plane 28 opposite the base plane 20, and the first beveled edge 22 defined by the set portion may extend away from the base plane 20 toward the face plane 28. The hinged portion 14 may have a second beveled edge 34 extending away from the base plane 20 toward the face plane 28. The first and second beveled edges 22, 34 may be inwardly canted edges as shown in
The hinged portion 14 may have a second member 26 that extends along the face plane 20. The set portion 12 may have a first sidewall 30 extending away from said first member 18. The first beveled edge 22 may extend to a portion of the first sidewall 30 displaced from the base plane 20.
The hinge 16 may be formed in any suitable manner. For example, the hinge 16 may comprise relatively pliant portions of the extruded cross section and the set portion 12 and hinged portion 14 may define relatively rigid portions of the cross section. In this manner, hinge 16 comprises a living hinge formed with the set portion 12 and the hinged portion 14. For the purposes of defining and describing the present invention, it is noted that a living hinge may be bent multiple times without breakage or fracture of the hinge material. Living hinges may be formed from soft, flexible thermoplastic elastomers that exhibit high endurance to flexural fatigue. Although the hinge 16 is shown along the second member 26 adjacent to the first sidewall 30, it will be understood by those having skill in the art at that hinge 16 may be formed in any suitable position that allows the hinged portion 14 to be moved into an engaged and disengaged state of the engagement 24. For example, the hinge 16 may be proximate to the face plane 28.
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For example, as shown in
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The engagement 24 may have an inwardly extending portion and an outwardly extending portion, and inwardly and outwardly extending portion may be formed in a variety of positions. For example, as shown in
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Referring to
A method of manufacturing pre-cast panels would include configuring an elongate body as described in conjunction with the embodiments herein, placing the elongate body on a panel forming surface, securing the elongate body to the surface through conventional means, such as tape, screws, nails, rivets or a soluble glue, pouring pre-cast material into a panel at least partially defined by the elongate body, curing the poured concrete, and removing the elongate body from the panel forming surface. The elongate body may be secured with the engagement disengaged and the engagement may be subsequently engaged.
Referring to
It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification.
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2442962 | Rumble | Jun 1948 | A |
3754729 | Maynan | Aug 1973 | A |
3872195 | Stegmeier | Mar 1975 | A |
4629155 | Dula | Dec 1986 | A |
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D428162 | Eyring et al. | Jul 2000 | S |
6279868 | Eyring et al. | Aug 2001 | B1 |
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Number | Date | Country | |
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20040118070 A1 | Jun 2004 | US |