BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
FIG. 1 is an exploded view of the rebar support chair and support plate supporting rebar.
FIG. 2 is a perspective view of the rebar support chair;
FIG. 3 is a bottom view of the rebar support chair;
FIG. 4 is bottom perspective view of the rebar support chair;
FIG. 5 is a cross section view along line A-A of FIG. 1;
FIG. 6 is a side view of the rebar support chair;
FIG. 7 is a perspective view of a support plate;
FIG. 8 is a side view of the support plate, upright pegs and support another embodiment of the invention having a noise generating assembly disposed in the weighted body; and
FIG. 9 is a top view of the support plate;
FIG. 10 is an exploded view of two support chairs stacked together.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Referring to FIGS. 1-10, a stackable rebar support chair, noted by the numeral 10 is provided for supporting rebar above a surface such as dirt, rocks, sand, and the like. Referring to FIG. 1, the stackable rebar support chair 10 includes a chair support 12 and a support plate 30 made of a generally rigid material such as plastic or metal. However, any type of material capable of supporting rebar and other construction materials can be utilized. In one example embodiment, the chair support 12 and the support plate 30 can be detachably coupled together for supporting rebar on soft surfaces such as sand. However, the support chair 12 can also be used without the support plate 30 to support rebar or other construction materials above harder surfaces such as rock, cement or concrete.
Referring now to FIG. 2, the support chair 12 includes a base 14 that is oriented generally horizontal to the surface or ground. The base includes an upper surface 15 and a lower surface 16 oriented generally parallel to each other. The base 14 can include at least one hole 18 extending through the upper 15 and lower 16 surfaces to define at least one cross support 19. The at least one hole 18 permits the free flow of concrete or cement around the support chair 12. The free flow of concrete or cement prevents shear plans from developing and impacting the quality of the hardened concrete or cement. As illustrated in the Figures, multiple holes can be formed in the base 14 to define multiple cross supports. The size and shape of the holes can vary depending upon the amount of free flowing concrete desired.
Referring to FIGS. 1, 2, and 4-6, the base 14 includes multiple upstanding posts 20 extending from its upper surface 15 and multiple downwardly extending legs 21 extending from its lower surface 16. Respective upstanding posts 20 and legs 21 are generally axially aligned to each other and generally perpendicular to the base 14 such that the base 14 is suspended above the ground surface between the upstanding posts 20 and legs 21. In one example embodiment, the upstanding posts 20 and legs 21 are positioned at corners of the base 14. However, the upstanding posts 20 and the legs 21 can be positioned anywhere on the base 14, thus allowing for multiple configurations.
As particularly illustrated in FIGS. 1, 2 and 5, the upstanding posts 20 each include a socket 22 extending therein for receiving a corresponding leg 21 when one support chair 12 is stacked upon another support chair 12. Each of the downwardly extending legs 21 generally have a smaller diameter than the upstanding posts 20 to permit relatively easy insertion into the sockets 22 of the upstanding posts 20. In example embodiments of the invention, the ends of each of the legs 21 can be generally pointed, tapered or blunt.
Referring to FIGS. 1, 2, and 5-6, each of the upstanding posts 20 includes at least one centering support bracket or gusset 24. Each of the centering support brackets 24 extends between and is coupled to the upper surface 15 of the base 14 and an upstanding post 20. Referring particularly to FIG. 6, a pair of centering support brackets 24 forms a V-shape, which is designed to permit gravity assisted positioning of the rebar to a central position on the base 14. By positioning the rebar over the central portion of the base 14, it permits the automatic proper weight distribution over the support chair 12.
Referring to the example embodiment of FIGS. 1 and 2, there can be a plurality of centering support brackets 24 such that there is a centering bracket support system 23 to facilitate centering the rebar and supporting the posts. The centering bracket support system 32 can include a first centering support bracket 24a and a second centering support bracket 24b extending between each of the upstanding posts 20 and the upper surface 15 of the base 14 to provide increased structural rigidity to the upstanding posts 20 posts and automatic positioning of the rebar. The first centering support bracket 24a can extend in a first direction proximate a peripheral edge of the base 14. The second centering support bracket 24b can extend in a second direction proximate the peripheral edge of the base 14. In one embodiment, the first centering support bracket 24a and the second centering support bracket 24b are positioned generally orthogonal to each other.
The centering bracket support system 23 can also include a third centering support bracket 24c that can also extend between each of the upstanding posts 20 and a cross support 19 to provide increased structural rigidity to the upstanding posts 20 and automatic centering of the rebar. In this embodiment, a length of the third centering support bracket 24c can be greater than a length of the first centering support bracket 24a and the second centering support bracket 24b. However, any configuration of length, size, or position of the upstanding posts 20, legs 21, base 14, cross supports 19 and centering support brackets 24, 24a, 24b, or 24c are considered to be within the spirit and scope of the invention and within the knowledge of the inventor and one skilled in the art.
Referring to FIGS. 3 and 4, ribs 26 can extend from the lower surface 16 of the base 14 to provide additional support when the rebar is positioned thereon. The ribs 26 can be positioned on the cross supports 19 or on the cross supports 19 and portions of the base 14 extending around a perimeter of the base 14. In one example embodiment, as illustrated in FIGS. 3 and 4, each of the ribs 26 is connected to and extends between a leg 21 and a central post 27 that extends from the lower surface 16 of the base 14. The use of the centering support brackets 24 and the ribs 26 provide increased structural rigidity to the upstanding posts 20, legs and base 14 such that installers are able to walk on installed support chairs 12 and rebar without fear of shifting the rebar or breaking the support chairs 12.
Referring to FIGS. 7-9, the support plate 30 includes a generally planar panel 32 having a configuration of a rectangle or square. In one embodiment of the invention, the panel 32 will have the same footprint or area as the base 14 such that when the two are connected together the base 14 is position generally parallel over the panel 32. The panel 32 can be constructed with the same generally rigid material as the support chair 12. The thickness of the panel 32 can vary depending upon the amount of support needed during use.
The panel 32 can include a plurality of pegs 34 extending from its upper surface 35 for receiving and support the legs 21. Each of the pegs 34 includes a bore 36 extending therein having a size and shaped to receive each of the legs 21. The legs 21 and the upstanding posts 20 or the legs 20 and the pegs 34 can be loosely fitted together to ensure easy assembly and disassembly or they can be tightly fitted together to ensure that they will not become disconnected during use. In another embodiment, the legs 20 and the pegs 34 can be fixed together such that the support chair 12 and the support plate 30 are one unit.
Referring to FIGS. 7-9, each of the pegs 34 can include a support bracket or gusset 38 extending between and coupled to the pegs 34 and the upper surface 35 of the panel 32 to provide structural rigidity to the legs 21 when they are connected to the support plate 30. Each pair of support brackets 38 extending from each peg 34 includes long axes that intersect in a center of the pegs 34 such that a pair of corresponding support brackets 38 of each peg 34 is generally oriented orthogonally to each other. Additionally, as particularly illustrated in FIGS. 7 and 9, the support brackets 38 of the pegs 34 are disposed proximate a lateral or peripheral edge of the panel 32 such that each support bracket 38 of the pegs 34 lies in a plane generally parallel to a plane of one of the perimeter edges of the panel 32.
In use, the installer decides if the support chair 12 needs to be connected to the support plate 30. If needed, the installer inserts the legs 21 of the support chair 12 into the bores 36 of each of the pegs 34 on the support plate 30. Once the support chair 12 and the support plate 30 are connected the installer lines them in the form where the concrete will be poured. Once in position, the installer lays rebar or other construction material on to the support chairs 12. The V-shape formed by the support brackets 24 extending between each of the upstanding posts 20 and the upper surface 15 of the base 14 cause each rebar to automatically find a center of the support chair 12 between the posts 20 and the legs 21. The installer can also install rebar on the support chairs 12 such that they cross each other or such that a long axis of each of the rebar intersect each other at a center of the support chair 12.
In some uses, where a thicker layer of concrete is needed, there is a need to have multiple layers of rebar. During this use the installer inserts the legs 21 of additional support chairs 12 into the sockets 22 of the upstanding posts 20. The installer is then able to lay pieces of rebar on top of the new layer of support chairs 12. These steps can be repeated until the desired number of rebar in place. Once all of the support chairs 12 and the rebar are in place, the installer is able to pour the concrete. The concrete then flows around the support chairs 12, through the holes 18, between the upstanding posts 20 and the legs 21, and over the support plate 30, thereby ensuring that they are fixed in place. The orientation and number of support brackets 24 and 28 extending between the upstanding posts 20 and the base 14 and between the pegs 34 and the panel 32 ensure that the lower support chairs 12 do not buckle or break under the weight of the rebar and concrete.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
Patent Application
20080028718
