Patent Application
20080099660
The present invention relates generally to a form connector for use in connecting forms to develop a form structure into which concrete can be poured to construct a sidewalk, driveway or the like. More particularly, the present application involves a form connector that allows the connected forms to ascend or descend a hill or other sloped surface.
Concrete is commonly used in the construction of structures such as sidewalks, driveways and buildings. After cement, aggregate and water are appropriately mixed, the resulting wet mix is generally poured into a form structure that is used to hold the mix into a desired shape while drying. The upper surface of the concrete can be compacted and leveled while in the form structure in order to be both strengthened and shaped. Surfaces of the concrete can then be treated to achieve a desired aesthetic appearance and the form structure can be removed once the concrete has set.
The form structure can be made by a series of interconnected forms. In the construction industry it is common to use forms made of lumber. For instance, 2×4s or 1×4s may be used although it is known to use forms made of other types of material such as metal. The forms are generally elongated members and are arranged in series with one another so as to form a desired frame into which the concrete may be poured. As construction jobs typically vary from site to site, the use of lumber forms is advantageous in that the forms can be quickly and easily cut to various lengths as needed. As the forms are generally elongated members, the forms can be bent or curved over their length to result in a desired shape.
Once the forms have been laid out into a form structure, they are commonly attached to one another through use of an additional, smaller piece of lumber. Here, the ends of adjoining forms are abutted against one another and the additional, smaller piece of lumber is placed against both forms on the side opposite that which will engage the poured concrete. This connecting piece of lumber is then nailed to the sides of the abutting forms in order to result in the abutting forms being connected to one another. Stakes can likewise be driven into the sides of the forms opposite that which contact the concrete in order to reinforce the resulting form structure as the interior of the form structure is subsequently filled with concrete.
The form structure is removed after drying of the poured concrete. In order to reduce waste and save on cost of subsequent construction projects, the forms are saved for future use. In order to remove the forms from the dried concrete, the connecting piece is disengaged from abutting forms. This disengagement is typically done in the fastest manner possible which involves tearing the connecting piece off of the forms. As can be imagined, the forms are susceptible to being damaged when the connecting piece is forcibly removed. The forms thus become damaged over time which leads to the forms being discarded and hence results in an increase in the cost of construction.
Connectors for use in attaching sequential forms that do not involve driving nails into the forms are known. These types of connectors are generally made of metal and have resilient members that give when the ends of sequential forms are forced into the connector. The resilient members apply a holding force to the forms in order to retain the forms in a desired position. Although these types of connectors work well for their intended purpose, they are not capable of holding forms together that slope upwards over the crown of a hill or slope downwards across a valley. These types of connectors hold forms in such a way that offers no versatility in angling the forms upwards or downwards when sloped form structures are needed. As such, there remains room for variation and improvement within the art.
Various features and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned from practice of the invention.
One aspect of the present invention provides for a form connector for use in connecting adjacent forms. The form connector includes a frame in the shape of a channel. The frame has a top wall and a pair of side walls extending therefrom. The lengths of the top wall and side walls extend between opposite ends of the frame. The opposite ends of the frame are open for receipt of forms The frame has a bottom that is open along the length of the side walls between the opposite ends of the frame. A leg is also included that extends from one of the side walls. The leg has a surface configured for engaging a form. This surface is closer to the bottom of the frame than to the top wall of the frame. The surface of the leg has a length that is less than the length of the side walls between opposite ends of the frame.
An additional aspect of the present invention resides in a form connector as immediately discussed that also has a second leg. The second leg extends from one of the side walls of the frame. The second leg has a second surface configured for engaging a form. The second surface is closer to the bottom of the frame than to the top wall of the frame. The second surface has a length that is less than the length of the side walls between the opposite ends of the frame.
Another aspect of the present invention is provided in a form connector as discussed above in which the leg extends from a position between the ends of the frame. The leg is offset a distance from each of the ends of the frame along the length of the side wall.
A further aspect of the present invention is found in a form connector as previously discussed in which the side walls and top wall define an interior. Adjacent forms are capable of being disposed in the interior. The interior is configured so that adjacent forms are capable of contacting one another.
The present invention also provides for a form connector as discussed prior in which the frame and the leg define an empty space that has a height that is the distance between the bottom of the frame and the surface of the leg that is configured for engaging the form. The empty space extends along the length of the side walls the distance from one of the ends of the frame to the other end of the frame.
Also provided in accordance with another aspect of the present invention is a form connector that has a frame with a pair of side walls that extend from a frame. The frame defines an interior that is configured for receiving a pair of adjacent forms. The frame has a bottom that is at least partially open. A leg is present and is connected to the frame. The frame and leg are configured to allow the pair of adjacent forms to touch one another. The frame and leg are configured to allow the pair of adjacent forms to be arranged so that the top surfaces of the pair of adjacent forms are not parallel to one another when received by the interior of the frame.
An additional aspect of the present invention resides in a form connector as immediately discussed that also has a second leg. The second leg is connected to the frame. The first leg and second leg are spaced from one another and define a space therebetween.
Another aspect of the present invention exists in a form connector as immediately mentioned in which each of the legs has a surface that faces the bottom of the frame and are configured for engaging at least one of the forms. The lengths of the side walls of the frame extend from an open end of the frame to an opposite open end of the frame. Both of the legs are located at positions along the length of one of the side walls so that both are offset a distance from each of the ends of the frame along the length of the side wall.
An additional aspect of the present invention is found in a form connector as previously mentioned in which the leg has a surface configured for engaging a form. The frame and leg define an empty space that has a height that is the distance between the bottom of the frame and the surface of the leg configured for engaging the form. The empty space extends along the length of the side walls the distance from an open end of the frame to an opposite open end of the frame.
Another aspect of the present invention resides in a form connector as discussed above in which the side walls each have surfaces configured for engaging a pair of forms. Also, the surfaces of the side walls are rigid.
Another aspect of the present invention is provided for in a form connector discussed prior in which the leg is L-shaped.
The present invention also provides for a form connector for use in connecting adjacent forms that has a frame in the shape of a channel. The frame has a top wall and a pair of side walls extending therefrom. The lengths of the top wall and side walls extend between opposite ends of the frame. The opposite ends of the frame are open for receipt of forms therethrough. The frame has a bottom that is open along the length of the side walls between the opposite ends of the frame. The side walls have rigid surfaces configured for engaging forms. A pair of L-shaped legs are included and extend from the same side wall of the frame. Both of the legs have a surface configured for engaging a form. The aforementioned surfaces of the legs are closer to the bottom of the frame than to the top wall of the frame. The surfaces of the legs are located the same distance from the bottom of the frame. The legs are located at positions along the length of the side wall so that the legs are offset a distance from each of the ends of the frame along the length of the side wall. The pair of legs are spaced from one another along the length of the side wall to define a space therebetween. The frame and legs define an empty space that has a height that is the distance between the bottom of the frame and the surfaces of the legs. The empty space extends along the length of the side walls the distance from the open end of the frame to the opposite open end of the frame.
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended Figs. in which:
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention.
Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.
It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.
The present invention provides for a form connector 10 used to connect adjacent forms 12 and 14 when building a form structure 66 in constructing walkways, driveways and other concrete structures. The form connector 10 allows adjacent forms 12 and 14 to be arranged next to one another so that their top surfaces 54 and 56 are not parallel to one another. This feature may be advantageous when the forms 12 and 14 are located on a surface that is inclined that has one or more peaks and valleys.
The top wall 18 has a surface 58 that faces the interior 50 of frame 16. In addition, side walls 20 and 22 also have surfaces 60 and 62 that face the interior 50 of frame 16. The side walls 20 and 22 can be arranged so that surfaces 60 and 62 are parallel to one another and are each oriented at a 90° angle to surface 58 of top wall 18. Although the surfaces 60 and 62 can be set at any distance to one another, they are spaced at ⅞th of an inch in the embodiment shown. Other arrangements are possible in which the side walls 20 and 22 are angled with respect to top wall 18 so that surfaces 60 and 62 are oriented at an angle up to 110° to surface 58. In further exemplary embodiments, the side walls 20 and 22 are oriented at different angles to the top wall 18 so that surfaces 60 and 62 are likewise oriented at different angles to surface 58. Top wall 18 may be integrally formed with side walls 20 and 22 or may be a separate component that is attached thereto through means such as welding or mechanical fasteners. In accordance with one method of production, a flat metal sheet of 16 gauge steel is twice bent in order to form the top wall 18 and side walls 20 and 22.
A first leg 34 extends from the bottom of side wall 20. The first leg 34 is an L-shaped member as shown in
Top wall 18 of frame 16 has a length 28. Additionally, side walls 20 and 22 have lengths 30 and 31 that are the same as length 28 in the exemplary embodiment shown. However, it is to be understood that other embodiments exist in which length 28 is greater or less than the lengths 30 and 31 of side walls 20 and 22. Further embodiments are also possible in which the length 30 of side wall 20 is different than the length 31 of side wall 22. In accordance with one exemplary embodiment, the lengths 28, 30 and 31 are all 8 inches. However, in other embodiments the lengths 28, 30 and 31 may be up to 24 inches. The first leg 34 is located along the length 30 of side wall 20 so as to be a distance 46 from the end 24. In a similar manner, second leg 40 is located along the length 30 of side wall 20 a distance 48 from end 26. Distances 46 and 48 may be the same as one another or may be different in various exemplary embodiments. In accordance with one exemplary embodiment of the present invention, distance 46 is ½ inch and distance 48 is ½ inch. However, it is to be understood that other embodiments are possible in which distances 46 and 48 are up to 3 inches. Side walls 20 and 22 each have a height that is generally oriented at 90° to their lengths 30 and 31. The heights of side walls 20 and 22 are 2.75 inches in the embodiment shown but may be up to 12 inches in other embodiments.
As shown, a space 52 is defined between the first leg 34 and the second leg 40. Space 52 may extend a distance of 3 inches in a direction parallel to the length 30 of side wall 20. In other configurations, the length of space 52 in the direction parallel to length 30 is up to 6 inches. Space 52 can be completely open so that nothing is present across the width of space 52 which extends from opposite ends of legs 34 and 40 in a direction perpendicular to the length 30 of side wall 20.
First leg 34 has a first surface 36 that is oriented so as to face the bottom 32 of frame 16. As shown, first surface 36 is planar in shape but can be variously shaped in other embodiments. The first surface 36 has a length 38 that extends in a direction generally parallel to the direction of length 30 of side wall 20. In accordance with one embodiment of the invention, length 38 is 2 inches. Other embodiments are possible in which length 38 is up to 6 inches. The second leg 40 has a second surface 42 that is likewise oriented in facing relationship with bottom 32 of frame 16. Although shown as being planar in shape, the second surface 42 can alternatively be contoured. The second surface 42 has a length 44 that extends generally parallel to the length 30 of side wall 20. As with length 38, length 44 is 2 inches in the exemplary embodiment shown but may be up to 6 inches in other embodiments. Although shown as being the same, the lengths 38 and 44 of surfaces 36 and 42 may be different in accordance with various exemplary embodiments. For example, length 38 may be 1 inch and length 44 may be 4 inches in one configuration of the form connector 10. The legs 34 and 40 are L-shaped in the embodiment shown so that the surfaces 36 and 42 are oriented at a right angle to the vertically extending portions of the legs 34 and 40 contiguous with the side wall 20. Other embodiments are possible in which the surfaces 36 and 42 are not oriented at 90° but are instead oriented at various angles to the upwardly extending portions of legs 34 and 40. The width or depth of surfaces 36 and 42, which extend at a generally 90° angle to the direction of length 30 of side wall 20, may be 1 inch in certain exemplary embodiments. The width or depth of surfaces 36 and 42 may be from ¼ inch to 6 inches in accordance with other exemplary embodiments. It is to be understood that although shown in relation to planar surfaces 36 and 42, lengths 38 and 44 can be associated with variously shaped surfaces 36 and 42. In this regard, surfaces 36 and 42 can be convex, concave, sinusoidal, or shaped otherwise. Here, the lengths 38 and 44 are still present and represent the lengths of the surfaces 36 and 42 in the direction generally parallel to the length 30 of side wall 20.
The form connector 10 defines an empty space 64. Empty space 64 has a height that extends from the bottom 32 of frame 16 to the surfaces 36 and 42 of the legs 34 and 40. In accordance with one exemplary embodiment, the height of empty space 64 is 1 inch. However, other embodiments are possible in which the height of empty space 64 is from ¼ inch to 6 inches. The empty space 64 has a length that extends the same distance as the length 30 of side wall 22. The length of empty space 64 is 8 inches in the displayed embodiment but may be from 3 inches to 18 inches in accordance with other exemplary embodiments. Empty space 64 is aligned with both the space 52 between legs 34 and 40 and also with the open bottom 32 of frame 16 so that a surface 58 of top wall 18 is visible as shown in
The ground 68 shown in
The configuration of the form connector 10 may be helpful in allowing forms 12 and 14 to be connected to one another when the ground 68 is not level.
The form connector 10 can also be used to connect forms 12 and 14 that themselves do not contact one another.
As mentioned, the forms 12 and 14 can be made of pieces of 1×4 lumber. Extended pieces of such lumber are capable of curving over their lengths.
A series of forms may be connected to one another with several form connectors 10 to construct a form structure 66 to be used over ground 68 with a varying topography.
Although various components of the form connector 10 were described herein as having certain dimensions, it is to be understood that the aforementioned dimensions were only for sake of example and are not limiting to the present invention. The present invention includes various form connectors 10 that may or may not have components with the previously discussed dimensions.
While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.
