TIE BAR ASSEMBLY

BACKGROUND

This patent application claims priority to and the benefit of U.S. Provisional Patent Application No. 63,579,326, filed Aug. 29, 2023, the entire contents of which are incorporated herein by reference.

BACKGROUND

For various logistical and technical reasons, concrete floors often include a series of individual cast-in-place concrete slabs. These concrete slabs provide several advantages including relief of internal stresses due to curing, shrinkage, and thermal movement. There are various known issues with such concrete slabs. These issues often involve the joint between concrete slabs, the interface where one concrete slab meets another concrete slab, and the relative vertical movement of adjacent concrete slabs.

More specifically, freshly poured concrete shrinks considerably as it cures and hardens due to the chemical reaction that occurs between the cement and water. As the concrete shrinks, tensile stress accumulates in the concrete resulting in joint openings. The joint openings create discontinuities in the concrete floor surface that can cause the wheels of a vehicle (such as a forklift truck) to impact the edges of the adjacent concrete slabs that form the joint and chip small pieces of concrete from the edge of each concrete slab, particularly if the concrete slabs move too far away from each other. This damage to the edges of concrete slabs is commonly referred to as joint spalling. Joint spalling can interrupt the normal working operations of a facility by slowing down forklift and other truck traffic, and/or causing damage to trucks and the carried products. Joint spalling can also be expensive and time consuming to repair.

It is known to connect adjacent concrete slabs by tie bars such as rebar to reduce the movement of the concrete slabs relative to one another. One technique for forming such adjacent concrete slabs employs a form that supports the tie bars such as illustrated in FIG. 1. The form 30 supports each tie bar 20 such that a portion of each tie bar can be embedded a first one of the concrete slabs and then the form can be removed such that the second portion of the tie bar can be embedded in the second concrete slab. The form 30 is typically constructed from wood. More specifically, before pouring the first concrete slab, holes 36 are drilled in the form 30. The holes 36 extend from a first side 32 of the form 30 through to the second side 34. Tie bars 20 are then driven through each hole 36 so that approximately half of each tie bar 20 is on each side of the form 30. The first concrete slab is poured on the first side 32 of the form 30. After the concrete cures, the form 30 is removed, leaving the first half 22 of the tie bar 20 embedded in the first concrete slab and the second half 24 of the tie bar 20 protruding from the face of the first concrete slab. The second concrete slab is then poured adjacent to the first concrete slab and encapsulates the second half 24 of the tie bar 20, tying the two concrete slabs together.

To ensure proper placement of the tie bars 20 in the concrete slabs, the tie bars 20 must be held firmly in the form 30. If the tie bars 20 are not held firmly, they can shift when the concrete is poured resulting in improper placement. Improperly placed tie bars can create undesirable stresses in the cured concrete. To hold the tie bars firmly, the holes 36 in the form 30 are sized to create a tight fit to the tie bar 20, or even an interference fit. This tight fit creates problems after the first concrete slab cures because the form 30 with the multiple tie bars 20 is difficult to remove. This can increase labor costs and construction time during construction. In certain instances, the form 30 needs to be cut to remove it, rendering the form no longer useable and requiring additional labor and material.

Accordingly, there is a need for improved tie bar assemblies.

SUMMARY

Various embodiments of the present disclosure provide a tie bar assembly that solves the above problem. Various embodiments of the present disclosure provide a tie bar assembly including a tie bar sleeve, a tie bar insert, and a tie bar. The tie bar insert is insertable into the tie bar sleeve, and the tie bar is insertable into the tie bar insert. During construction, the tie bar is inserted into and secured in the tie bar insert. The tie bar and the tie bar insert are then inserted into and secured in the tie bar sleeve. This assembly is fastened to the form. After the first slab is poured, the first tie bar and the tie bar sleeve are embedded in the first slab. The form is removed, and the second slab is then poured and encapsulates at least a portion of the remainder of the tie bar sleeve, tie bar insert, and tie bar.

Additional features and advantages of the present disclosure are described in, and will be apparent from, the following Detailed Description and the Figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a known form that supports tie bars and that is configured to position the tie bars in a concrete slab.

FIG. 2A is a rear perspective view of an assembled tie bar assembly of one example embodiment of the present disclosure, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 2B is an enlarged rear perspective view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 3A is a front perspective view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 3B is an enlarged fragmentary front perspective view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 3C is an enlarged fragmentary cross-sectional view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 4 is a fragmentary left side view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 5 is a fragmentary right side view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 6 is a fragmentary top view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 7 is a fragmentary bottom view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 8 is a front end view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 9 is a rear end view of the assembled tie bar assembly of FIG. 2A, showing the tie bar sleeve thereof, the tie bar insert thereof, and the tie bar thereof.

FIG. 10 is a rear perspective view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 11 is a front perspective view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 12 is a left side view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 13 is a right side view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 14 is a top side view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 15 is a bottom side view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 16 is a front end view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 17 is a rear end view of the tie bar sleeve of the tie bar assembly of FIG. 2A.

FIG. 18 is a front perspective view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 19 is a rear perspective view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 20 is a left side view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 21 is a right side view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 22 is a top side view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 23 is a bottom side view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 24 is a front end view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 25 is a rear end view of the tie bar insert of the tie bar assembly of FIG. 2A.

FIG. 26 is a fragmentary rear perspective view showing the tie bar assembly of FIG. 2A attached to a concrete form.

FIG. 27 is a fragmentary front perspective view showing the tie bar assembly of FIG. 2A attached to a concrete form.

FIG. 28 is a left side view showing the tie bar assembly of FIG. 2A attached to a concrete form.

FIG. 29 is a right side view showing the tie bar assembly of FIG. 2A attached to a concrete form.

FIG. 30 is a top side view showing the tie bar assembly of FIG. 2A attached to a concrete form.

FIG. 31 is a bottom side view showing the tie bar assembly of FIG. 2A attached to a concrete form.

FIG. 32 is front fragmentary view of the tie bar assembly attached to a concrete form.

FIG. 33 is rear fragmentary view showing the tie bar assembly attached to a concrete form.

FIG. 34 is a front perspective view showing the tie bar assembly of FIG. 2A attached to a concrete form and embedded in a first concrete slab.

FIG. 35 is front perspective view showing the tie bar assembly of FIG. 2A embedded in a first concrete slab and the second tie bar extending from the concrete slab ready for pouring the second concrete slab.

FIG. 36 is front perspective view showing the tie bar assembly of FIG. 2A embedded in the first and second concrete slabs.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

While the systems, devices, and methods described herein can be embodied in various forms, the drawings show, and the specification describes certain exemplary and non-limiting embodiments. Not all components shown in the drawings and described in the specification can be required, and certain implementations can include additional, different, or fewer components. Variations in the arrangement and type of the components; the shapes, sizes, and materials of the components; and the manners of connections of the components can be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any directions referred to in the specification reflect the orientations of the components shown in the corresponding drawings and do not limit the scope of the present disclosure. Further, terms that refer to mounting methods, such as mounted, connected, etc., are not intended to be limited to direct mounting methods but should be interpreted broadly to include indirect and operably mounted, connected, and like mounting methods. This specification is intended to be taken as a whole and interpreted in accordance with the principles of the present disclosure and as understood by one of ordinary skill in the art.

FIGS. 2 to 25 illustrate a tie bar assembly 100 of one example embodiment of the present disclosure.

The tie bar assembly 100 includes: (1) a tie bar sleeve 200; (2) a tie bar insert 400; and (3) a tie bar 600. The tie bar insert 400 is insertable in and connectable to the tie bar sleeve 200, and the tie bar 600 is insertable in and connectable to the tie bar insert 400. Generally, the tie bar assembly 100 is configured to be positioned partially in a first concrete slab, and the portion of the tie bar assembly 100 not positioned in the first concrete slab is configured to be positioned in the adjacent second concrete slab.

In other example embodiments that are not shown, the tie bar sleeve 200 and tie bar insert 400 are combined into a single component configured to securely hold the tie bar 600.

In other example embodiments that are not shown, the tie bar sleeve 200 and/or the tie bar insert 400 are each formed from multiple components, or their functions can be performed by multiple components.

FIGS. 26 to 33 generally and partially illustrate one method of employing the tie bar assembly 100 in a first cast-in-place slab (such as a first concrete slab 80) and a second cast-in-place slab (such as a second concrete slab 90). The present disclosure provides that multiple tie bar assemblies 100 of the present disclosure can be employed in adjacent concrete slabs to co-act to limit the movement of the adjacent concrete slabs relative to each other.

The tie bar sleeve 200 is configured to be attached to a conventional form 30 before the first concrete slab 80 is poured such that the tie bar sleeve 200 extends into the first concrete slab 80. In one example embodiment, the tie bar sleeve 200 is maintained in the first concrete slab 80 after the first concrete slab 80 is poured, cured, and hardened such as shown in FIG. 32. In another example embodiment, the tie bar sleeve 200 stays attached to the form 30 when the form 30 is removed, leaving only the tie bar insert 400 and tie bar 600 maintained in the first concrete slab 80 after the first concrete slab 80 is poured, cured, and hardened.

The tie bar sleeve 200 includes: (1) an attachment wall 210; (2) one or more fastener guides 240 and 250 connected to and extending from the attachment wall 210; (3) a receiver 300 connected to and extending from the attachment wall 210; and (4) a locator 380 connected to and extending from the attachment wall 210.

The attachment wall 210 includes a generally flat member 212 having a front surface 214, back surface 216, and one or more edges. In the illustrated embodiment, the attachment wall has a generally hexagonal shape including a top edge 218, a bottom edge 220, a first side tab 222, and a second side tab 224. However, other shapes can be used including, without limitation, rectangular, triangular, circular, ovular, teardrop, and numerous others.

In the illustrated example embodiment, the receiver 300 includes a rear boss 310 and a front boss 350. The receiver 300 defines a tie bar insert opening 322 and a tie bar clearance opening 370.

In the illustrated example embodiment, the first fastener guide 240 is integrally formed in the first side tab 222 of the attachment wall 210. However, other arrangements are possible.

In the illustrated example embodiment, the second fastener guide 250 is integrally formed in the first side tab 222 of the attachment wall 210. However, other arrangements are possible in accordance with the present disclosure.

The fastener guides 240 and 250 respectively define openings 244 and 254 configured to respectively receive fasteners such as nails 40 such as shown in FIG. 2A to attach and hold the tie bar sleeve 200 to a form 30 before and during pouring of the first concrete slab 80 such that: (a) the attachment wall extends in the same or substantially the same plane as the outer vertical side surface 82 of the first concrete slab 80; (b) the first fastener guide 240 extends into the first concrete slab 80; (c) the second fastener guide 250 extends into the first concrete slab 80; and (d) the rear boss 310 is configured to extend into and be retained by the first concrete slab 80. In certain example embodiments, the guides 240 and 250 are configured to hold the fasteners 40 securely before the tie bar sleeve 200 is attached to the form 30. In certain example embodiments, the openings 244 and 254 can be sized such that the guides have a low-clearance fit to the respective fastener 40, an interference fit with the respective fastener 40, or can include ribs (not pictured) to assist in holding the respective fastener 40. In other example embodiments, the tie bar sleeve 200 can be secured to the form 30 using different methods such as but not limited to adhesives, penetrating barbs (similar to wood frame truss connectors), rivets, or other methods.

The locator 380 is configured to locate the tie bar sleeve 200 in a clearance hole 35 in an edge form 30. In the illustrated example embodiment, the locator 380 has a cylindrical shape that extends into the clearance hole 35 and affirmatively locates the tie bar sleeve 200. However, in other example embodiments, the locator can have a different shape or can include several smaller features configured to collectively locate the tie bar sleeve 200.

In the illustrated example embodiment, the rear boss 310 extends from the attachment wall 210 and has a generally rectangular shape, including a top surface 312, a first side surface 314, a bottom surface 316, a second side surface 318 and a rear face surface 320. However, the rear boss 310 could have other shapes, including cylindrical, hexagonal, octagonal, and others. The tie bar insert opening 322 extends from the rear face surface 320 into the interior of the receiver 300 to a stop surface 372. The tie bar insert opening 322 is configured to receive the tie bar insert 400 with the tie bar 600 inserted into it. The tie bar insert opening 322 is configured such that the tie bar sleeve can securely hold the tie bar insert 400 and the tie bar 600 while the first concrete slab 80 is being poured and cured. In certain example embodiments, the tie bar receiving opening 322 can be configured to have a low-clearance fit to the tie bar insert 400, an interference fit with the tie bar insert 400, or can include inwardly extending ribs 374 to assist in holding the tie bar insert 400.

In the illustrated example embodiment, the front boss 350 extends from the attachment wall 210 and has a generally rectangular shape, including a top surface 352, a first side surface 354, a bottom surface 356, a second side surface 358 and a front face surface 360. However, the front boss 350 could have other shapes, including cylindrical, hexagonal, octagonal, and others. The tie bar clearance opening 370 extends from the from face surface 360 into the interior of the receiver 300 to the stop surface 372. The tie bar clearance opening 370 is configured for the tie bar 600 to pass through without interference.

The tie bar insert 400 is configured to receive the tie bar 600 and hold it securely when the tie bar insert 400 is inserted into the tie bar sleeve 200 and while the first concrete slab 80 is being poured and cured.

The tie bar insert 400 is generally configured with a shape complementary to, although not necessarily the same as, the tie bar receiving opening 322. In the illustrated example embodiment, the tie bar insert 400 has a generally rectangular shape, including a top wall 402, a first side wall 404, a bottom wall 406, a second side wall 408, a rear face 410, and a front face 412. However, the tie bar insert 400 could have other shapes, including cylindrical, hexagonal, octagonal, and others. The tie bar insert 400 defines a tie bar receiving opening 450. The tie bar receiving opening 450 is configured to receive the tie bar 600 such that the tie bar sleeve 200 can hold the tie bar 600 securely when the tie bar insert 400 is inserted into the tie bar sleeve 200 and while the first concrete slab 80 is being poured and cured. In certain example embodiments, the tie bar receiving opening 450 can be configured to have a low-clearance fit to the tie bar 600, an interference fit with the tie bar 600, or can include inwardly extending ribs 460 to assist in holding the tie bar 600.

The tie bar sleeve 200 is symmetrical from top to bottom and from side to side, and thus is configured to be used in multiple orientations (i.e., right side up, upside down, or on either side). This facilitates ease of manufacture, ease of use, and reduction of needed inventory. This also facilitates reduction of errors in positioning during installation. Since the form 30 is more easily removed than in the present art, as described below, forms can be reused. If the fastener holes in the form become too worn for further reuse, the tie bar sleeve 200 can be attached to the form in a different orientation.

The tie bar sleeve 200 and tie bar insert 400 are made from a suitable plastic (such as a High Impact Polystyrene (HIPS)) in this example embodiment, but can be made from other suitable materials.

The tie bar sleeve 200 and tie bar insert 400 are each monolithically formed as single molded units, in this example embodiment, but can be made from multiple connected parts in other embodiments.

The tie bar sleeve 200 includes multiple tapered outer surfaces 280 and large radiused corners 282 or connections that cause air bubbles to be propelled towards the edges of pocket. This enables air adjacent to those members to flow uninterrupted along the outer surfaces of those members and to escape from being trapped under or adjacent to those members. These radiused edges and apexes also minimize perimeter point loads.

It should be appreciated from the above that various embodiments of the present disclosure provide a tie bar assembly for a first concrete slab and a second concrete slab, the tie bar assembly comprising: a tie bar sleeve; and a tie bar insert insertable in the tie bar sleeve, the tie bar insert configured to receive a tie bar, wherein a portion of the tie bar sleeve, the tie bar insert, and the tie bar are configured to be positioned in the first concrete slab, and wherein at least a portion of a remainder of the tie bar sleeve, the tie bar insert, and the tie bar are configured to be positioned in the second concrete slab. In various such embodiments, the tie bar sleeve includes a receiver configured to receive the tie bar insert. In various such embodiments, the receiver incudes a front boss and a rear boss. In various such embodiments, the receiver defines a tie bar insert receiving opening. In various such embodiments, the tie bar sleeve is configured to secure the tie bar insert within the tie bar receiving opening. In various such embodiments, the tie bar insert is configured to secure the tie bar within the tie bar receiving opening. In various such embodiments, the tie bar sleeve includes inwardly extending ribs configured to secure the tie bar insert within the tie bar insert receiving opening. In various such embodiments, the tie bar insert includes inwardly extending ribs configured to secure the tie bar within the tie bar receiving opening. In various such embodiments, the tie bar assembly includes the tie bar.

It should further be appreciated from the above that various embodiments of the present disclosure provide a tie bar sleeve for a first concrete slab and a second concrete slab, the tie bar sleeve comprising: an attaching wall configured to be attached to a concrete form; and a receiver configured to receive a tie bar insert insertable into the tie bar sleeve. In various such embodiments, the receiver incudes a front boss and a rear boss. In various such embodiments, the receiver defines a tie bar insert receiving opening. In various such embodiments, the tie bar sleeve is configured to secure the tie bar insert within the tie bar insert receiving opening. In various such embodiments, the tie bar sleeve includes inwardly extending ribs configured to secure the tie bar insert within the tie bar insert receiving opening. In various such embodiments, the attaching wall includes a locator configured to locate the tie bar sleeve relative to a hole in the concrete form.

It should further be appreciated from the above that various embodiments of the present disclosure provide a tie bar insert insertable in a tie bar sleeve for a first concrete slab and a second concrete slab, the tie bar insert comprising: a top wall; a first side wall; a bottom wall; and a second side wall, wherein the top wall, the first side wall, the bottom wall, and the second side wall are insertable into and securable within a receiver of the tie bar sleeve. In various such embodiments, the tie bar insert defines a tie bar receiving opening. In various such embodiments, the tie bar insert is configured to secure the tie bar within the tie bar receiving opening. In various such embodiments, the tie bar insert includes inwardly extending ribs configured to secure the tie bar within the tie bar receiving opening.

It should further be appreciated from the above that various embodiments of the present disclosure provide a tie bar assembly for a first concrete slab and a second concrete slab, the tie bar assembly comprising: a tie bar sleeve configured to receive a tie bar insertable in and connectable to the tie bar sleeve; wherein a portion of the tie bar sleeve and the tie bar are configured to be positioned in the first concrete slab; and wherein at least a portion of a remainder of the tie bar sleeve and the tie bar are configured to be positioned in the second concrete slab.

The present disclosure further provides a method of installing the tie bar assembly 100 in a first cast-in-place concrete slab 80 and a second cast-in-place concrete slab 90.

In one example embodiment, the method can include the steps of: (1) drilling a clearance hole 35 in an edge form 30; (2) placing the edge form 30 on the ground or other suitable substrate; (3) inserting the tie bar 600 in the tie bar insert 400 (if the tie bar 600 and tie bar sleeve 400 are not provided pre-assembled); (4) attaching the tie bar sleeve 200 to the edge form 30 such the tie bar sleeve 200 is located in the clearance hole 35 by the locator 380 and the attachment wall 210 and the rear boss 310 extend into the area where the first concrete slab 80 will be formed; and (5) inserting the tie bar insert 400 and tie bar into the tie bar sleeve 200. The method further includes: (6) pouring the concrete material which forms the first concrete slab 80; (7) allowing the first concrete slab 80 to cure and harden to a certain degree; (8) removing the edge form 30 from the first concrete slab 80 such that the tie bar sleeve 200, the tie bar insert 400, and the tie bar 600 remain within and attached to the first concrete slab 80, and (9) pouring the second concrete slab. It should be appreciated that the removal of the form 30 is substantially easier and quicker than the removal of the edge form described above. Because the tie bar is securely held by the tie bar assembly 100, the form 30 does not require the tight fit described above. Therefore, only the fasteners 40 hold the form 30 to the tie bar sleeve 200. The form 30 can be easily separated from the fasteners 40 using conventional tools (such as a pry bar). Unlike removing the form from long, straight, tightly-fit tie bars as described above, the fasteners 40 are relatively short, so only a few inches (cm) of travel are required to separate them from the form 30.

In another example embodiment, the method can include the steps of: (1) drilling a clearance hole 35 in an edge form 30; (2) placing the edge form 30 on the ground or other suitable substrate; (3) inserting the tie bar 600 in the tie bar insert 400 (if the tie bar 600 and tie bar sleeve 400 are not provided pre-assembled); (4) inserting the tie bar insert 400 and tie bar into the tie bar sleeve 200; (5) attaching the tie bar sleeve 200, tie bar insert 400, and tie bar 600 to the edge form 30 such that the tie bar sleeve 200 is located in the clearance hole 35 by the locator 380 and the attachment wall 210 and the rear boss 310 extend into the area where the first concrete slab 80 will be formed; (6) pouring the concrete material which forms the first concrete slab 80; (7) allowing the first concrete slab 80 to cure and harden to a certain degree; (8) removing the edge form 30 from the first concrete slab 80 such that the tie bar sleeve 200, the tie bar insert 400, and the tie bar 600 remain within and attached to the first concrete slab 80, and (9) pouring the second concrete slab. It should be appreciated that other sequences of the method and/or additional or fewer steps may be performed.

It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

TIE BAR ASSEMBLY

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Abstract

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Provisional Applications (1)