Patent Application
20050034384
1. Field of the Invention
This invention relates to window buck panels and more particularly relates to preventing concrete from intruding into the space defined by assembled window buck panels.
2. Description of the Related Art
Concrete is well-known and widely used for various construction projects. Among concrete's many advantages, is concrete's transformation from a fluid state to a solid state. The concrete may be formed and mixed in a fluid state, poured it into a form, and allowed to cure into a hard and very strong object. In construction, concrete is generally used to form footings and foundation walls.
The forms for a foundation wall are generally modular and may be secured together to define various shapes of walls. The fluid concrete is poured between the forms, which may be spaced approximately six inches or more, an allowed to cure to form a wall that is the same shape as the space between the forms. As the forms for a foundation wall are set in place and secured as may be necessary, a buck system may be placed and secured between the forms in order to form a cavity or recess in the concrete wall that will be constructed. The buck system is intended to retain the fluid concrete outside of the desired recess and, after the concrete is cured and the forms are removed, define an opening such as a window or doorway through the concrete wall.
With the window buck panel 102 secured between the concrete forms 104, a fluid concrete 108 is poured into and fills a void between the concrete forms 104. The window buck panel 102, in conjunction with additional panels, such as side and top panels, defines the window opening 103 within the concrete 108 as it cures and solidifies.
With the fluid concrete 108 between the forms 104, the window bucks panel 102 and additional panels substantially prevent the concrete 108 from entering the window opening 103. The weight of the concrete 108, however, typically generates significant pressure, indicated by the arrows 110, on the bottom of the window buck panel 102. The concrete 108 may also exert lateral pressure on the concrete forms 104. These forces may move the window buck panel 102 and/or the concrete forms 104, creating a gap 112 between one or both of the forms 104 and the window buck panel 102.
The forces drive the fluid concrete 108 through the gap 112 and create an undesirable concrete formation 114 within the window opening 103. The concrete formation 114 within the window opening 103 must be removed prior to installation of a window frame or interior building finishes, including wall framing and finishes, as well as other materials. The movement of the interior concrete form 104 also creates an undesirable variation in the wall thickness. Additionally, more concrete 108 may be required to form the wall due to the concrete 108 that escapes into the window opening 103.
From the foregoing discussion, it should be apparent that a need exists for an apparatus, system, and method that compensate for the formation of a gap between the buck system and the concrete forms. Beneficially, such an apparatus, system, and method would block the fluid concrete from entering the window or doorway cavity defined by the buck system and retain the concrete outside of the cavity despite any lateral movement of the concrete forms away from the buck system.
The present invention has been developed in response to the present state of the art, and in particular, the need to prevent the intrusion of concrete into the cavity defined by assembled window buck panels. Accordingly, the present invention has been developed to provide an apparatus, system and method for defining a window cavity in poured concrete walls that overcome many or all of the above-discussed shortcomings in the art.
The apparatus for preventing the intrusion of concrete into the cavity defined by assembled window buck panels includes a window buck panel configured to contact a concrete form under pressure when the window buck panel is installed between concrete forms and to flex outward, thus maintaining tight contact with the form, when the form alters shape due to the weight of the concrete.
In one embodiment of the apparatus a rounded protrusion running the length of the panel body is associated with a flexture groove that allows the protrusion to move laterally in response to pressure from the concrete forms. In a further embodiment of the apparatus the concrete retention flange is attached to a leg extending from the window buck body. In another embodiment of the apparatus, the concrete retention flange comprises a substantially flat member projecting horizontally from the leg of the window buck panel.
In another embodiment of the apparatus the leg is further configured to flex inward under pressure from the concrete form. In another embodiment of the apparatus, the leg includes a rounded protrusion configured to bend the leg under pressure from the concrete forms. In a further embodiment of the apparatus, the leg may be configured to flex at the point of attachment to the window buck panel body, or at any point along the length of the leg. In a further embodiment of the apparatus, the leg may bow. In another embodiment of the apparatus, the leg is wider at the distal end and tapers inward toward the proximate end and is thus configured to assume the concrete retention function of the flange.
In a further embodiment of the apparatus the leg is positioned at an outward angle to the window buck panel, bringing the leg into contact under pressure when the window buck is installed between concrete forms. In a further embodiment of the apparatus the window buck panel includes securing flanges configured to become embedded in the cured concrete and hold the window buck in place.
A system of the present invention is also presented for preventing the intrusion of concrete into the space defined by the assembled window buck. They system may be embodied in a plurality of concrete forms configured to contain concrete during a curing period of the concrete: at least one buck panel defining a cavity between the concrete forms; and a concrete retention barrier attached to one of the at least one of the buck panels, the concrete retention barrier configured to contact at least one of the plurality of concrete forms under pressure and to prevent concrete intrusion into the cavity.
The system may be further embodied in a concrete obstruction barrier that is attached to the lateral edge of a window buck panel and configured to deform under contact pressure from a concrete form when installed. In a further embodiment the concrete obstruction barrier is configured to rebound toward its original form as contact pressure decreases, thereby maintaining contact with the concrete form. In a further embodiment the concrete retention barrier may comprise a shape selected from at least one of a flange, a rounded protrusion, a tapered leg, and an angled leg.
A method of the present invention is also presented for preventing the intrusion of poured concrete into the space defined by assembled window buck panels. The method in the disclosed embodiments substantially includes the steps necessary to carry out the functions presented above with respect to the operation of the described apparatus and system. In one embodiment the method includes the steps of: forming a window buck system and thereby partially defining a window cavity, the window buck system comprising least one concrete retention barrier and one or more window buck panels; orienting the window buck system between a plurality of concrete forms and thereby fully defining the window cavity; and securing the window buck system between a plurality of concrete forms and displacing the at least one concrete retention barrier under pressure from the plurality of concrete forms.
Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention. These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of several embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
In one embodiment, the interior and exterior legs 208, 210 may be integrally formed with the body of the window buck panel 202, or alternatively may be attached to the panel 202. In either of these embodiments, the legs 208, 210 include a point of attachment 212 (proximal end) that defines the intersection where the interior and exterior surfaces 204, 206 meet the interior and exterior legs 208, 210, respectively. In the preferred embodiment, the interior leg 208 includes a concrete retention flange 214. In the depicted embodiment, the concrete retention flange 214 is shown at the distal end of the interior leg 208. The concrete retention flange 214 preferably runs the length of the window buck panel 202 and extends laterally away from body of the window buck panel 202 and through the interior plane 205.
The interior leg 208 may flex or bend at the point of attachment 212 due to external forces, such as the direct contact pressure exerted by one of the concrete forms 104. Alternatively, the interior leg 208 may flex or bend between the point of attachment 212 and the concrete retention flange 214. The interior leg 208 preferably flexes under pressure produced when one of the concrete forms 104 contacts the concrete retention flange 214.
The concrete retention flange 214 is located, in one embodiment, at the distal end of the interior leg 208. Alternatively, the concrete retention flange 214 may be located anywhere along the interior leg 208 or the interior surface 204, so long as the placement allows suitable displacement concrete retention flange 214 when in contact with one of the concrete forms 104. The contact pressure between one of the concrete forms 104 and the concrete retention flange 214 prevents concrete 108 from creating and entering a gap 112 (see
In another embodiment, the concrete retention flange 214 may be located on the exterior leg 210 or on the exterior surface 206 of the window buck panel 202. In a further embodiment, the window buck panel 202 may include one or more flanges 214 on each of the interior and exterior surfaces 204, 206 and legs 208, 210.
The concrete retention flange 214 is designed and located to provide increased contact pressure between the window buck panel 202 and the concrete forms 104 so as to resist concrete 108 intrusion into the defined window opening 103. The concrete retention flange 214 also may be referred to as a concrete retention barrier.
The position and configuration of the concrete retention flange 214 may vary. For example, the concrete retention flange 214 may be a substantially flat, horizontally projecting member. Alternatively, the concrete retention flange 214 may comprise a tapered interior leg 208 or exterior leg 210 that is wider at the lower end. The concrete retention flange 214 may further comprise a rounded protrusion, such as a nub suitably sized and positioned to bend the interior or exterior leg 208, 210 to increase the contact pressure and prevent concrete 108 intrusion.
In another embodiment, the interior and/or exterior surfaces 204, 206 may include a curved wall having a concave or convex cross-section. Alternatively, the interior and/or exterior legs 208, 210 may flare outwardly, away from the body of the window buck 202 panel by being connected to the respective surfaces 204, 206 at an appropriate angle that is substantially vertical. In the case of one or more flared legs 208, 210, the window buck panel 202 may or may not include a horizontally projecting member, such as the concrete retention flange 214. One skilled in the art will also recognize the potential cost, production, and installation benefits of a combination of one or more of the above implementations of the concrete retention flange 214.
The depicted window buck panel 202 has an interior leg 204 and a horizontally projecting concrete retention flange 214. The illustrated interior leg 204 and concrete retention flange 214 have been moved laterally due to the lateral pressure of the concrete forms 104. In the depicted embodiment, the interior leg 204 is hinged at the point of connection 212 (proximal end of the interior leg 204). In an alternate embodiment, the interior leg 204 may hinge or bend at multiple locations along the length of the interior leg 204. In a further embodiment, the interior leg may bow across the entire interior leg 204 or along one or more portions of the interior leg 204.
In the depicted embodiment, one of the concrete forms 104 on the interior side of the window buck panel 202 has been forced outward due to the lateral force, indicated by the arrows 110, generated by the weight of the fluid concrete 108. As the concrete form 104 is forced laterally outward, a gap 112 may be formed between the interior surface 204 and the concrete form 104. As the gap 112 is created, the interior leg 208 and concrete retention flange 214 returns to a détente position, maintaining a barrier between the concrete form 104 and concrete retention flange 214 that prevents the fluid concrete 108 from entering the window opening 103. In an alternative embodiment, the concrete form 104 may only partially be forced outward, allowing the interior leg 208 and concrete retention flange 214 to only partially return to a détente position, but still maintaining an adequate barrier to prevent the fluid concrete 108 from entering the window opening 103.
Once the window buck panel 202 is installed in the cured concrete 108 and the concrete forms 104 are removed, a window frame 224 may be attached to the window buck panel 202 within the window opening 103.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
This application claims the benefit of U.S. Provisional Application No. 60/471,273, filed May 16, 2003.
| Number | Date | Country | |
|---|---|---|---|
| 60471273 | May 2003 | US |
