Patent Application
20240301690
The present disclosure relates generally to a system and components thereof for fastening structural components in insulated concrete formwork.
Insulated concrete form (ICF) is a system of expanded polystyrene (EPS) rigid insulation blocks separated by plastic webbing. It is used as an integrated concrete form to pour a concrete wall instead of a traditional wood plank or plywood form. ICF blocks come in interlocking sections, so a wall system fits tightly together. Once the blocks are in place, concrete is poured, and finishes like drywall and siding are attached to fastener strips embedded in the insulation.
Installing structural components such as floor joists, floor and roof trusses and beams to an ICF wall can be labour intensive.
The most common approach includes attaching a wood ledger board to the ICF wall and then attaching joist hangers to that ledger board. Structural components (e.g., joists) are then installed in those joist hangers. There are two types of technics using this approach. The first technique includes using anchor bolts, which is probably the oldest and first technique ever utilised to secure a floor system to an ICF structure. This technique requires putting anchor bolts through the ledger every few feet, then cut some square holes in the ICF to line up with the positioning of these anchor bolts, then lift the heavy ledger board in place, level it, and temporarily fasten it to the ICF using screws. The concrete is then poured, and once it is cured, the anchor bolts are tightened. The second technique uses a two bracket system, where the first bracket is a flat surface with 2 wings that is inserted through the ICF wall by creating 2 slots with a saw every few feet. Once concrete is poured, these brackets are secured in place, and then the second bracket is secured on the ledger and lined them up with the brackets on the ICF wall. The ledger is lifted in place, levelled, and 8 specialised screws are used to go through the 2 brackets and ledger board to secure the whole in place.
Another approach includes using a one piece hanger with two round cylinders in the back, that is inserted through the ICF wall prior to the concrete pour, to anchor the structural components directly to the concrete core of the wall without needing a ledger. This system requires a very high level of expertise from the contractor to install and set into position because once the concrete is poured and set, if the hangers are just slightly out of position, the floor system or roof system will be out of level. The flaw with this system is that there is nothing holding the hanger in place during the concrete pour, which sometimes results in the hanger being pushed out by the concrete during the pour. To compensate for this movement, a small wooden ledger (2×4) is installed underneath the hangers and are screwed to the ICF temporarily to hold the hangers in position. These ledger get in the way of the temporary bracing system that is used by installers to ensure the ICF wall remains straight during the concrete pour.
Accordingly, structural connectors for fastening structural components in insulated concrete formwork which address at least some of the aforementioned shortcomings of existing structural connectors remain highly desirable.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter.
As embodied and broadly described herein, the present disclosure relates to a structural connector for use with insulated concrete formwork (ICF), comprising a front surface designed for fastening to the ICF with a connecting piece, wherein the connecting piece is for connecting through the ICF with a secondary structural component; a rear surface designed for receiving a distal end of the connecting piece; and a flange connecting the front surface to the rear surface and defining a longitudinal cavity for receiving a body of the connecting piece; wherein, the structural connector is configured such that upon a concrete pour to form a concrete wall, the structural connector secures the secondary structural component to the ICF and operates as an anchor preventing axial movement of the secondary structural component relative to the ICF.
In some embodiments, the structural connector includes one or more of the following features:
As embodied and broadly described herein, the present disclosure relates to a structural component hanger for use with insulated concrete formworks (ICF), comprising a structural plate having a retention portion at a bottom portion thereof, which is configured to receive a structural component therein; and a pair of flanges extending transversally from opposite sides of the structural plate and configured for embedment in a concrete wall through the ICF, wherein, upon a concrete pour to form the concrete wall, the pair of flanges operates as an anchor preventing axial movement of the structural component hanger relative to the ICF.
In some embodiments, the structural component hanger includes one or more of the following features:
As embodied and broadly described herein, the present disclosure relates to a system for use with insulated concrete formworks (ICF), comprising a joist hanger, a plurality of the structural connectors as described herein, and a plurality of connecting pieces, wherein each connecting piece of the plurality of connecting pieces is for connecting corresponding structural connector of the plurality of the structural connectors to the joist hanger.
In some embodiments, the system further includes the structural component hanger as described herein.
All features of exemplary embodiments which are described in this disclosure and are not mutually exclusive can be combined with one another. Elements of one embodiment can be utilized in the other embodiments without further mention. Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying Figures.
A detailed description of specific exemplary embodiments is provided herein below with reference to the accompanying drawings in which:
In the drawings, exemplary embodiments are illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purpose of illustrating certain embodiments and are an aid for understanding. They are not intended to be a definition of the limits of the invention.
The present technology is explained in greater detail below. This description is not intended to be a detailed catalog of all the different ways in which the technology may be implemented, or all the features that may be added to the instant technology. For example, features illustrated with respect to one embodiment may be incorporated into other embodiments, and features illustrated with respect to a particular embodiment may be deleted from that embodiment. In addition, numerous variations and additions to the various embodiments suggested herein will be apparent to those skilled in the art considering the instant disclosure which variations and additions do not depart from the present technology. Hence, the following description is intended to illustrate some embodiments of the technology, and not to exhaustively specify all permutations, combinations, and variations thereof.
The present inventor has designed a structural connector, a structural component hanger, and a system including both for fastening structural components in insulated concrete formwork (ICF). Such structural connector, structural component hanger, and system may afford one or more technical advantages.
For example, the structural connector, structural component hanger, and system of the present disclosure may affect the efficiency, structural integrity, and speed at which building structural components can be constructed. Particularly, for installing structural components such as floor joists, floor and roof trusses and beams to an ICF wall.
For example, the structural connector, structural component hanger, and system of the present disclosure may be less labour intensive to use relatively to other structural connector, structural component hanger, and systems which often require several skilled construction personnel to install whereas the structural connector, structural component hanger, and system of the present disclosure can be conveniently installed by reduced construction crew, even in some cases can be installed by a single person.
Various components of the structural connector, structural component hanger, and system of the present disclosure will now be described with respect to the accompanying Figures.
With respect to
The structural connector 100 includes a front surface 110 designed for contacting the ICF wall via at least an external surface 120 thereof. For example, the external surface 120 thereof may be substantially planar to ensure intimate contact with the ICF wall upon use. The front surface 110 may be made from any suitable material capable of withstanding contact with concrete over extended periods. For example, the front surface 110 may be made with galvanized steel. The front surface 110 is configured for fastening to the ICF with a suitable attachment mechanism. In some embodiments, a suitable attachment mechanism may be any suitable threaded fasteners, magnets, vacuums and/or interference fittings. For example, the suitable attachment mechanism may be a connecting piece 250 as best shown in
In use, the connecting piece 250 is for connecting the structural connector 100 through the ICF with the secondary structural component. For example, the secondary structural component can be a L bracket, a ledger bracket or a joist hanger.
In some embodiments, the connecting piece 250 may be made from any suitable material capable of withstanding contact with concrete over extended periods. For example, the connecting piece 250 may be made from zinc coated steel. The connecting piece 250 may have any suitable length to accommodate several ICF block walls thickness. For example, the connecting piece 250 may have a length of about 6¼″ (about 160 mm), about 7″ (about 180 mm), and 7¾″ (about 200 mm) to accommodate an ICF block thickness of about 2½″, about 2⅝″, about 3¼″ and about 4″. The reader will readily understand that any other suitable length may be used in specific applications.
In some embodiments, the secondary structural component is a joist hanger 200, as shown in
In some embodiments, the joist can be secured to the joist retention member 202 by, for example, bolting, screwing, or nailing the vertical support members 220 to the joist through joist securing aperture(s) 212. Each vertical support member 220 may include a plurality of joist securing apertures 212. It should be appreciated that in some embodiments the joist can be coupled to or otherwise associated with the joist retention member 202 using any attachment mechanism, as that term is understood and defined herein, and at one or more additional, or alternative, points than at a defined joist securing aperture(s) 212.
The joist hanger 200 further includes flanges 230 extending transversally from respective vertical support members 220. For example, at a substantially orthogonal angle. The flanges 230 can be elongated to a desired length. The flanges 230 are designed to contact the surface of the external wall of the ICF and include a plurality of apertures 240 disposed on a face thereof. The connecting piece 250 can be inserted through a respective one of the plurality of apertures 240 to fasten the joist hanger 200 to the ICF wall.
In some embodiments, each aperture of the plurality of apertures 240 can be sized and shaped to receive, for example, the shank portion 260 of the connecting piece 250 but to not permit the head 280 thereof to pass there through. For example, the connecting piece 250 may have any suitable diameter which is convenient to fit within one of the plurality of apertures 240. For example, the connecting piece 250 may have a diameter of about 12 mm and each aperture of the plurality of apertures 240 may accordingly have a diameter larger thereto.
Referring back to
In some embodiments, the rear surface 130 may include an integral structure 150 defining an aperture 160B for receiving the distal end 270D of the connecting piece 250. The integral structure 150 may conveniently include female threaded section mating with threaded portion 270 of the connecting piece 250, such that upon installation, the connecting piece 250 can be secured to the rear surface 130. Other configurations for installing and securing the connecting piece 250 to the rear surface 130 are possible, such as using a mating nut with the structural connector 100.
In some embodiments, the rear surface 130 is conveniently in a spaced apart opposing relationship with the front surface 110. Advantageously, the front surface 110 may define an aperture 160A for receiving a body of the connecting piece 250. The aperture may include at least a portion thereof which is aligned along a longitudinal axis y, where the longitudinal axis y intersects with both apertures 160A, 160B. For example, the connecting piece 250 can have an elongated body 255 that extends along a longitudinal axis x, which conveniently allows the elongated body 255 to insert through the apertures 160A, 160B disposed along the longitudinal axis y.
In some embodiments, the rear surface 130 may be made from any suitable material capable of withstanding contact with concrete over extended periods. For example, the rear surface 130 may be made with galvanized steel.
The structural connector 100 further includes a flange 170 connecting the front surface 110 to the rear surface 130. Advantageously, the flange 170 defines a longitudinal cavity 180 for receiving a body of the connecting piece 250, such as at least a portion of the shank portion 260.
In some embodiments, the structural connector 100 is made of a single part, which has been folded.
In some embodiments, the structural connector 100 is made of separate sheets that are affixed one to another using known techniques in the art, such as soldering.
In some embodiments, the structural connector 100 has any suitable thickness size for the desired applications. For example, the structural connector 100 may have a thickness size of about 2 mm.
In use, the structural connector 100 is configured such that upon pouring the concrete to form the concrete wall between adjacent ICF walls, the structural connector 100 secures the secondary structural component to the ICF and operates as an anchor preventing axial movement of the secondary structural component relative to the ICF. In other words, the structural connector 100 prevents the secondary structural component from pulling out of the ICF wall upon concrete pouring.
With reference to
In one or more implementation, the user may install the system 400 for use with an ICF with relative ease. For example, the system 400 may be advantageously installed without requiring the presence of a ledger support (e.g., 2″×4″) across the ICF wall at the bottom thereof or with the use of a screw through the bottom of the joist hanger to hold it in place while pouring the concrete. Such advantageous feature allows the user to save on constructions steps and also facilitates the bracing of the walls, which is required before the concrete pour. It is best practice to place the braces on the inside since the ground/floor is flat. With the 2″×4″ ledger support in the way, the user will typically have to place the bracing outside, which can often be a challenge, or cut 4″ in the 2″×4″ ledger support every six feet to accommodate the brace. The system 400 thus clearly provides a technical advantage over existing systems.
With the system 400, the plurality of structural connectors 100 is configured such that upon a concrete pour to form the concrete wall, the plurality of structural connectors 100 secures the secondary structural component (e.g., joist hanger 200) to the ICF and operates as an anchor preventing axial movement of the secondary structural component relative to the ICF. Once concrete is poured and cured, the system is ready to receive the structural components, e.g., floor joists, floor and roof trusses and beams.
With respect to
For example, the structural component can be a ledger.
In some embodiments, the structural component hanger 500 includes a structural plate 510 having a retention member 520 at a bottom portion thereof, which is configured to receive a structural component therein. For example, the retention member 520 is sized and shaped to accommodate the ledger therein. The retention member 520 includes an opening 505 that is defined on two sides by vertical support member 540 and bottom portion 510B of the structural plate 510, and on a bottom side by ledger support platform 530. When a ledger is associated with the ledger retention member 520, it is placed within and rests on and/or is supported by the ledger support platform 530 and bounded on its sides by the vertical support member 540 and bottom portion 510B of the structural plate 510. In some embodiments, the bottom portion 510B may have flanges 550 extending laterally from each side wall of structural plate 510 to increase contact surface between the ledger and the bottom portion 510B. The ledger support platform 530 can be sized to accommodate any sized ledger, for example a ledger up to 2″ wide.
In some embodiments, the structural component hanger 500 further includes a pair of flanges 560 extending transversally from opposite sides of the structural plate 510. For example, at a substantially orthogonal angle. The pair of flanges 560 are configured for embedment in a concrete wall through the ICF. Upon a concrete pour to form the concrete wall, the pair of flanges 560 operates as an anchor preventing axial movement of the structural component hanger 500 relative to the ICF.
For example, the pair of flanges 560 may advantageously be positioned in a spaced apart opposite relationship. The pair of flanges 560 may include at least one aperture 570 disposed on a face thereof. In some embodiment, the corresponding aperture 570 disposed on the face of one flange of the pair of flanges 560 may be positioned in a spaced apart opposite relationship to the corresponding aperture 570 disposed on the face of the other one flange of the pair of flanges 560. In other words, while observing the structural component hanger 500 from the side, the apertures 570 would align such that the user can see through both at the same time.
In some embodiment, the apertures 570 may have any suitable size and shape, which allow concrete flow there-through during the concrete pour.
In some embodiment, the pair of flanges 560 may have any suitable size and shape for embedding in a concrete wall. For example, the pair of flanges 560 may have a substantially rectangular shape. For example, the pair of flanges 560 may be designed to fit in 2½″ to 4″ ICF walls.
In some embodiments, the structural component hanger 500 is made of a single part, which has been folded.
In some embodiments, the structural component hanger 500 is made of separate sheets that are affixed one to another using known techniques in the art, such as soldering.
In some embodiments, the structural component hanger 500 has any suitable thickness size for the desired applications. For example, the structural component hanger 500 may have a thickness size of about 2 mm.
With respect to
Other examples of implementations will become apparent to the reader in view of the teachings of the present description and as such, will not be further described here.
Various aspects of the present disclosure, including devices, systems, and methods may be illustrated with reference to one or more embodiments or implementations, which are exemplary in nature. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments disclosed herein.
As used herein, directional terms, such as “top,” “bottom,” “left,” “right,” “up,” “down,” “upper,” “lower,” “proximal,” “distal” and the like are used herein solely to indicate relative directions and are not otherwise intended to limit the scope of the disclosure and/or claimed invention.
Note that titles or subtitles may be used throughout the present disclosure for convenience of a reader, but in no way these should limit the scope of the invention. Moreover, certain theories may be proposed and disclosed herein; however, in no way they, whether they are right or wrong, should limit the scope of the invention so long as the invention is practiced according to the present disclosure without regard for any particular theory or scheme of action.
All references cited throughout the specification are hereby incorporated by reference in their entirety for all purposes.
Reference throughout the specification to “some embodiments”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the invention is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described inventive features may be combined in any suitable manner in the various embodiments.
It will be understood by those of skill in the art that throughout the present specification, the term “a” used before a term encompasses embodiments containing one or more to what the term refers. It will also be understood by those of skill in the art that throughout the present specification, the term “comprising”, which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, un-recited elements or method steps.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In the case of conflict, the present document, including definitions will control.
As used in the present disclosure, the terms “around”, “about” or “approximately” shall generally mean within the error margin generally accepted in the art. Hence, numerical quantities given herein generally include such error margin such that the terms “around”, “about” or “approximately” can be inferred if not expressly stated.
Although various embodiments of the disclosure have been described and illustrated, it will be apparent to those skilled in the art considering the present description that numerous modifications and variations can be made. The scope of the invention is defined more particularly in the appended claims.
This application claims the benefit of Provisional U.S. Patent Application No. 63/450,774, filed Mar. 8, 2023, the entire disclosure of which are hereby incorporated by reference herein in their respective entireties.
| Number | Date | Country | |
|---|---|---|---|
| 63450774 | Mar 2023 | US |
