Abstract:
A corner bracket for modular foam forms for poured concrete walls includes an outer, horizontal strap with generally vertical strips attached thereto or molded therewith for encapsulation in the outside and optionally the inside foam panels of such a form.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This international application is derived from, claims priority to and incorporates by reference U.S. provisional application Ser. No. 60/644,241, filed Jan. 14, 2005, entitled INSULATED FOAM PANEL FORMS 
    
    
     BACKGROUND OF THE INVENTION 
     In a principal aspect the present invention relates to a device termed a strut, connector, tie, bracket member or bracket, and which is used in combination with spaced, insulating foam, form panels, to thereby provide a mold or form for concrete and cement wall construction. In particular, the bracket is associated with formation of insulating foam, corner forms. 
     The use of modular insulating foam forms for concrete or cement wall construction is disclosed in various prior art patents and use of such forms is commonly practiced in the construction industry. Among the prior art patents depicting such forms and their use are the following: 
     
       
         
               
               
               
               
             
           
               
                   
               
               
                 U.S. Pat. No. 
                 Patentee 
                 Date of Patent 
                 Title 
               
               
                   
               
             
             
               
                 4,884,382 
                 Horobin 
                 Dec. 5, 1989 
                 Modular Building-Block 
               
               
                   
                   
                   
                 Form 
               
               
                 5,060,446 
                 Beliveau 
                 Oct. 29, 1991 
                 Insulating Wall Panel 
               
               
                 5,390,459 
                 Mensen 
                 Feb. 21, 1995 
                 Concrete Form Walls 
               
               
                 5,896,714 
                 Cymbala 
                 Apr. 27, 1999 
                 Insulating Concrete 
               
               
                   
                 et al. 
                   
                 Form System 
               
               
                 6,230,462 
                 Beliveau 
                 May 15, 2001 
                 Concrete Wall Form and 
               
               
                   
                   
                   
                 Connectors Therefor 
               
               
                 6,820,384 B1 
                 Pfeiffer 
                 Nov. 23, 2004 
                 Prefabricated Foam Block 
               
               
                   
                   
                   
                 Concrete Forms and Ties 
               
               
                   
                   
                   
                 Molded Therein 
               
               
                   
               
             
          
         
       
     
     Modular foam forms generally comprise first and second, parallel, spaced, modular sized, plastic foam or polystyrene foam wall panels. The spaced foam wall panels are connected by cross members termed brackets. Brackets are typically made from molded, rigid plastic materials. The brackets are often referred to as struts, ties or connectors. The foamed wall panel forms are made in modular sizes and assembled in building block fashion to define a form for a building or foundation wall. Reinforcing bars (rebars) are typically placed on the ties or brackets that connect or join the foam panels defining the concrete form so that when concrete or cement is poured into the space between the foam panels, the rebars will effectively reinforce the wall. Various designs of the panels and the connectors or brackets which join or tie the panels together are depicted in the prior art. The design of panels and the design of the brackets or connectors or ties is highly varied. 
     A particularly challenging design problem associated with foam panel forms is related to the corners of such forms. Appropriately positioning of foam material in combination with ties or brackets in a manner which enables and facilitates the construction of the corners of a building wall is particularly vexing. Prior art patents suggest various corner wall form constructions including the following: 
     
       
         
               
               
               
               
             
           
               
                   
               
               
                 U.S. Pat. No. 
                 Patentee 
                 Date of Patent 
                 Title 
               
               
                   
               
             
             
               
                 4,765,109 
                 Boeshart 
                 Aug. 23, 1988 
                 Adjustable Tie 
               
               
                 4,916,879 
                 Boeshart 
                 Apr. 17, 1990 
                 Corner Tie 
               
               
                 5,658,483 
                 Boeshart 
                 Aug. 19, 1997 
                 Corner Joint Tie 
               
               
                 5,782,050 
                 Boeshart 
                 Jul. 21, 1998 
                 Two-Piece Corner Tie 
               
               
                 6,224,031 
                 Kohrs 
                 May 1, 2001 
                 Intervertebral Implant 
               
               
                   
                   
                   
                 with Reduced Contact 
               
               
                   
                   
                   
                 Area and Method 
               
               
                 6,293,067 
                 Meendering 
                 Sep. 25, 2001 
                 Tie for Forms for Poured 
               
               
                   
                   
                   
                 Concrete 
               
               
                 6,352,237 
                 Cizek 
                 Mar. 5, 2002 
                 Combination Bottle 
               
               
                   
                   
                   
                 Hook and Wrench 
               
               
                 6,691,481 
                 Schmidt 
                 Feb. 17, 2004 
                 Corner Form for Modular 
               
               
                   
                   
                   
                 Insulating Concrete Form 
               
               
                   
                   
                   
                 System 
               
               
                   
               
             
          
         
       
     
     The present invention is directed to improved designs of molded plastic brackets, ties or connectors which are especially useful in combination with spaced foam panels to define corner forms. 
     SUMMARY OF THE INVENTION 
     Briefly, the present invention comprises a corner bracket or tie which includes a first generally horizontal assembly member having an intermediate or generally, but angled central, corner section with a projecting wing extension extending laterally in generally opposite directions from each side of the intermediate or central, corner section. An integral bracing element typically connects the wing extensions to fix and maintain a desired corner angle between the projecting wing extensions. The wing extensions thus may define and include an angle, for example, of 90°, 60°, 45° or some other included angle that defines or conforms to the angle of the corner wall form incorporating the bracket. In addition to the horizontal assembly member, there is included at least one vertical plate member which is attached to or is attachable to the horizontal assembly member and which is designed to be embedded or included within at least one of the foam panels forming a corner wall form. The vertical plate member or members are thus embedded in the corner foam panel in a manner which positions them for cooperation with fasteners that are used to attach various materials such as siding, wallboard, etc, to the corner foam panels. Such attachment is particularly desirable at corners of such foam forms, and the present invention is especially useful because it provides a design which positions generally vertical plate members adjacent or at the corners of an insulated foam wall form. The vertical plate members are analogous to furring strips. 
     The corner brackets or ties of the invention are generally at least partially encapsulated into opposed, spaced foam panels which intersect or are molded to define a corner, modular, foam panel form. One embodiment of the bracket is designed for combination with an outside foam corner panel and a spaced inside foam corner panel, and is constructed to be at least partially embedded in both the inside and outside foam panels. Another embodiment of the corner bracket is designed to be at least partially embedded in an outside corner foam panel and to project into the space between an outside corner foam panel and a spaced, inside corner foam panel. 
     The ties or brackets of the invention thus function to position generally vertical plate members at or adjacent the outside corner insulated foam panel and further optional function to connect an outside corner insulating foam panel to an inside corner foam panel. Also in a preferred embodiment, the corner bracket is comprised of separate elements including (1) a horizontal assembly which defines, or is compatible with, the desired angular relationship of the insulating corner foam panels, and (2) separate, generally vertical plate members which may be slidably inserted into the horizontal corner assembly. 
     As another feature of the invention, the vertical plate members may be molded as a single vertical element, or multiple, spaced vertical elements joined by cross members. The cross member or members may be rigid or may include an adjustable (living hinge) feature. Two or more vertical elements may be provided for combination with a single horizontal corner assembly. The vertical elements may be slidably positioned through vertical slots in the horizontal corner assembly and retained by a bayonet connection or stops in the form of lugs. 
     Thus, it is an object of the invention to provide a multiple variety of corner bracket constructions that may be used in combination with a pair of spaced, insulated foam panels to construct an insulated concrete wall corner form. 
     Another object is to provide a bracket for a corner form which includes one or more vertical plate members or strips adjacent the insulated, outside foam panel. 
     A further object is to provide a corner bracket and foam panel wall construction form which is rugged, reasonably priced, and easy to incorporate with insulated wall panel forms. 
     These and other objects, advantages and features are set forth in the following description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       In the detailed description which follows, reference will be made to the drawing comprised of the following figures: 
         FIG. 1  is an isometric view of an insulated wall form comprised of modular elements including straight wall panel forms and corner forms; 
         FIG. 2  is a top plan view of the wall forms of the type depicted in  FIG. 1 ; 
         FIG. 3  is an isometric view of a corner bracket assembly or corner bracket for a corner wall form; 
         FIG. 4  is another isometric view of the corner bracket of  FIG. 3  which may be employed in the creation of a modular, insulated corner wall form of the type depicted in  FIG. 1 ; 
         FIG. 5  is a cross sectional view of the corner bracket depicted in  FIG. 3  taken substantially along the line  5 - 5 ; 
         FIG. 6  is an isometric view of the horizontal assembly member or plate which is included as an element of the bracket of  FIG. 3 ; 
         FIG. 7  is a side view of the corner bracket depicted in  FIG. 5  viewed in the direction of the arrow in  FIG. 5 ; 
         FIG. 8  is a top plan view of the corner bracket depicted in  FIG. 5  as incorporated in spaced foam panels to provide a modular corner wall form; 
         FIG. 9  is an isometric view of an alternative construction of a corner bracket designed for a 45° corner wall form; 
         FIG. 10  is a top plan view depicting the corner bracket of  FIG. 9  as incorporated in spaced foam panels to provide a modular, insulated corner wall form; 
         FIG. 11  is an isometric view of the construction of  FIG. 10 . 
         FIG. 12  is an isometric view of a corner bracket construction including two connected vertical plate members or strips; 
         FIG. 13  is an isometric view of a corner bracket incorporating a connected vertical strip in combination with single vertical strips or plate members; 
         FIG. 14  is an isometric view of a corner bracket incorporating more than two connected vertical strips or plate members; and 
         FIG. 15  is an isometric view of a corner bracket for a right angle corner, including first and second vertical plate members. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1 and 2 , there is depicted an assembled array of modular, foam panel forms which are utilized, in combination, to provide a form for casting or pouring of a concrete building wall, for example. The prior art patents referenced above generally depict the manner of construction and use of such modular foam forms. Briefly, the modular forms  21  are generally comprised of modular sized, first and second panels  20  and  22  which are formed from a plastic foam material such as polystyrene. The panels  20 ,  22  are maintained in spaced, typically parallel, connected relationship one with respect to the other by means of brackets, connectors, struts, ties or the like  24 . The number and spacing of the brackets  24  may be varied. For modular foam forms  21  which are designed for straight line sections of a wall, six to eight connectors or brackets  24  may, for example, comprise cross linking members extending between the generally parallel spaced, insulating panels  20  and  22 . Such parallel or straight modular wall sections or forms, such as section  21 , will thus, in combination, define a straight wall form. Steel reinforcing bars (rebars)  25  may be positioned on the brackets  24 , and concrete or cement may be placed in the region between the foam panels  20  and  22  to encapsulate the reinforcing bars  25  as well as the brackets  24 . The materials forming the panels  20  and  22  provide an insulating feature as well as a form  21 . 
     The present invention relates to the construction of corner forms and brackets such as the right angle corner form  32  in  FIG. 1  for a corner incorporating a corner bracket  30 . Multiple corner forms  32  as well as the straight panel forms  21  may thus be assembled in various combinations to create a complex, large form for pouring of a concrete wall. Obtuse corner forms, such as obtuse corner form  28 , may be constructed having an angular relationship other than 90°. For example, the form  28  defines an obtuse angle corner form including an angular inside insulating foam panel  33  and an outside insulating foam panel  38 . Panels  33 ,  35  are joined by straight ties or connectors  24  and a molded plastic corner bracket  102  as described hereinafter. Acute angle as well as right angle forms may be made in the practice of the invention. 
       FIGS. 3 ,  4 ,  5 ,  6 ,  7  and  8  relate particularly to the corner bracket  30  which is constructed and designed for use in the formation of a 90° angle or right angle corner form  32 .  FIGS. 9 ,  10  and  11  illustrate an alternative corner bracket construction utilized to provide or with a 135° angle corner form. The invention is not limited to any particular angular relationship of the panel walls of a modular corner foam form, however, and thus the brackets described may be designed to be used for a wide variety of angular corner relationships. 
     Referring to  FIGS. 3-8 , the right angle corner bracket embodiment of the invention includes a first generally horizontal assembly member  40 . The assembly member  40  includes a generally intermediate corner or angle defining section or portion  42 , a first lateral wing extension  44  extending from the intermediate section  42  in one direction and a second lateral wing extension  46  extending from the intermediate section  42  in a generally distinct direction. The included angle between the wing extensions  44  and  46  is approximately 90°. The bracket assembly member  40  further includes a rigid cross brace member  48  connected with a second rigid cross brace member  50 . The cross brace members  48  and  50  join together at a juncture  52 . A bisecting reinforcing brace  54  extends generally from the apex of the intermediate section  42  and generally bisects the angle between the wing extensions  44  and  46 . The brace  54  extends outwardly from the intermediate section a distance which enables insertion of distal end  56  of the brace  54  into an inside foam panel wall such as depicted in  FIG. 8  as the foam panel wall  60 . Thus, referring to  FIG. 8 , an outer right angle foam panel wall  62  encapsulates the wing extensions  44  and  46  with the brace  54  extending through the space between the panels  60  and  62  to be encapsulated and included within the inside molded corner foam panel  60  during the molding operation of the corner foam form  32 . Straight ties  24  may also be molded into the corner forms extending between parallel sections of the panels  60 ,  62 . Note the straight ties  24  include generally vertical strips or plate members  79 . These plate members  79  act as furring strips for attachment of siding, etc. to the panels. 
     The wing extensions  44  and  46  each include first and second vertical tracks or slots  64  and  66 ;  68  and  70  respectively on the inside face of the wing extensions  44  and  46 . These slots  64 ,  66 ,  68  and  70  receive bayonet shaped, generally vertical, plate members or strips which slide into the slots  64 ,  66 ,  68  and  70  as depicted, for example, in  FIG. 7  as well as in  FIGS. 3 and 4 . Thus, the 90° corner bracket further includes a series of plate members  72 ,  74 ,  76  and  78  which are arrayed in a generally vertical parallel manner with respect to one another and with respect to the horizontal assembly member  40 . Each of the plate members  72 ,  74 ,  76  and  78  has a T-shaped cross section in a preferred embodiment and is slidably received respectively the compatibly shaped slots  64 ,  66 ,  68  and  70  as previously described. The bayonet shaped plate members  72 ,  74 ,  76  and  78  include a stop panel or tab  80  which limits the sliding movement into the respective slots and further include detent projections such as the detent projection  84  in  FIG. 7  which limits the movement of a plate member  74  once it is inserted into an appropriate slot  66 , by way of example. In this manner, the plate members, such as the plate member  74 , are held in a generally fixed or locked position once inserted into their respective slots, such as slot  66 . Other means such as clamps, etc. may be utilized in place of the described slots or tracks to function to connect and hold plates in position for the corner bracket. 
     In the preferred embodiment, the pairs of vertical plate members  72  and  74  are interconnected one with respect to the other through a molded, flexible horizontal bridge or connecting hinge section  90  and  92 . That is, the generally rigid plate members  72 ,  74 , are made from a molded plastic material and are designed to be connected one to the other by means of a flexible linkage or hinge  90  and  92 . Once inserted, the plate members  72  and  74  will remain rigidly in place mounted on the wing extension  44 . A detent or wedge projection  84  may be provided on one or both sides of the plate member, for example, the plate member  72 . Plates such as the plate  76  may include projecting stops or studs  81  as depicted, for example, in  FIG. 3 . In other words, various means may be utilized to generally lock the vertical plates  72 ,  74 ,  76 ,  78  in position in the assembled combination with the generally horizontal assembly member  40  of the corner bracket. 
       FIG. 8  also illustrates the manner in which a 90° corner bracket is encapsulated within foam panels  60 ,  62  defining the inside face and outside face of a modular corner mold form wherein the foam panel walls  60 ,  62  are defined by integrally molded right angle foam walls. Note that the horizontal assembly members are typically encapsulated within the foam material as are the vertical brackets or vertical plate members  72  and  74 . With the construction of the invention, the vertical plate members  72  and  74  may be positioned closely adjacent a corner; such as a corner  75  of a mold form. Positioning the vertical plate members, as described, enables the attachment of wall board by fasteners, for example, tightly to the region adjacent the corner of the mold form. 
     That is, typically the straight ties  24  for connecting opposed panel walls  60  and  62 ; includes a vertical plate member  79  which is generally encapsulated within foam material  62 . The plate  79  thus serves as a means to receive fasteners for attaching wallboard, siding, or the like, to the foam panel  62 . In like fashion the plates  72 ,  74  have a similar function. This resolves a problem of prior art corner constructions that did not include a vertical plate member positioned near a corner, such as a corner  75 . With the present invention, the positioning of a plate member, such as the plate member  72  or the plate member  74  at the corner  75  enhances the ability to construct and attach wallboard or the like to the corner of a foam form wall. 
       FIGS. 9-11  depict an alternative embodiment of the invention designed, by way of example, for use with a 135° corner section, such as the corner section  100  in  FIG. 10 . The corner modular section  100  includes a corner bracket  102  again comprised of a horizontal assembly member  104  having at least one, and in the embodiment depicted two vertical slots  106  and  108 , for receipt of the vertical plate members  110  and  112 , respectively. The vertical plate members  110  and  112  are substantially identical to the vertical plate members  72 ,  74  affixed to a wing extension for the 90° corner construction. However; because the web or connecting portion  114  for the vertical plate members  110  and  112 , as well as the connecting section  116  are flexible the vertical plate members  110  and  112  may be easily inserted and positioned in combination with the horizontal assembly member  102  to bridge the corner angle. 
     The horizontal assembly member  102  of this embodiment includes a foreshortened brace or extension  120  which generally bisects the angle defined by the wing extensions  104  and  107 . The brace  120  extends only partially between the foam corner panels  100  and  101 .  FIG. 11  is an isometric view of the obtuse angle corner construction of  FIG. 10  incorporating a corner bracket as depicted in  FIG. 9 . It will also be observed that the modular corner form foam panels  100 ,  101  includes some straight side connectors or ties such as the connector  130  extending between the panels  100  and  101 . 
       FIGS. 12 ,  13  and  14  illustrate variations of the combination of plate constructions in combination with various horizontal corner assemblies. Thus, a single plate  150  may be utilized, as in  FIG. 13 . Alternatively, two spaced plates  152 ,  154  rigidly connected by a horizontal bridge section  156  with a flexible hinge portion  152  may be used. Alternatively, more than two plates may be connected by a living hinge and/or a rigid hinge, such as hinge  166  in  FIG. 14 . Thus, three or four plates or strips  158 ,  160 ,  162  and  163  are appropriately spaced by a rigid bridge section  164  and a flexible hinge bridge section  166  in  FIG. 14 . 
     Note that the preferred embodiment of the plate construction having two or more vertical plates, two or more horizontal bridging sections, such as sections  164 ,  172  are used to insure stability of the assembly. The vertical rib in  FIG. 9  also enhances structural integrity of the plate construction. 
       FIG. 15  illustrates yet another variation of the plate and bracket construction in combination to provide a corner assembly for a foam panel construction. The corner assembly includes a generally horizontal, molded corner  200  having a first horizontal run  210  and a second horizontal run  212  molded at a right angle thereto and joined thereto by a bracket  214 . The bracket  214  includes a bisecting, planar member  216  extending from the apex defined by the horizontal runs  210  and  212 . The inside of each run  210  and  212  includes a molded slot  218  and  220 , respectively, adapted to receive vertical sliding plate members  222  and  224 , respectively. Thus, as depicted in  FIG. 15 , the vertical plate members  222  and  224  are positioned so as to comprise furring type strips in the plastic or molded forms. 
     Other variations combining the concepts disclosed herein may be utilized. The vertical strips  222  and  224  may, for example, be integrally molded with the corner forms. The length and width of the vertical plates or strips  222  and  224  may be modified or varied. The configuration, or shape, of the vertical strips or plates  222  and  224  may be varied. The cross sectional configuration of the vertical strips may also be varied. 
     Numerous variations of the described embodiments may be adapted to provide a corner bracket having a defined angle and including strips of desired width and height and spacing. Thus, while there has been set forth preferred embodiments of the invention, it is to be understood that the invention is limited only by the following claims and equivalents thereof.