Abstract:
An assembly for receiving poured concrete including a nonmetallic form which surrounds an inner cavity and is capable of supporting poured concrete. In one particular embodiment, the assembly is composed of individual segments which are joined together to produce a rigid concrete form. The assembly is utilized as an upstanding island for location and placement of fuel dispensers.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    The present invention relates to a concrete form, and in particular, a non-metallic concrete form capable of supporting poured concrete.  
           [0003]    2. Description of the Related Art  
           [0004]    Concrete is used for creating concrete structures such as paved surfaces, patio slabs, sidewalks, curbs, and service station dispenser islands or bases. Liquid concrete is poured into the void or inner cavity created by the concrete forms. These forms may either be permanent or temporary. Permanent forms remain attached to the solidified concrete with the exterior surface of the permanent form creating an edge surface. Temporary forms, in contrast, are removed after the concrete solidifies to reveal a concrete edge.  
           [0005]    Permanent-type forms have traditionally been composed of formed or stamped steel. The steel is shaped to create the desired structure&#39;s shape. The permanent-type form is typically painted to protect the form from being exposed to the environment.  
           [0006]    Temporary forms are removed from solidified concrete to expose a concrete edge. Normally, the concrete edge is painted to seal the concrete from exposure to environment elements, such as rain, snow, salt, as well as petroleum spills, such as fuel and oil.  
           [0007]    One problem with the current concrete forms is the lack of a non-metallic form which is capable of supporting the weight and pressure of poured concrete without the need for additional support. Traditional metallic and non-metallic forms require lateral support. The lateral support spans the form&#39;s inner cavity and provides rigidity to the concrete form. Without this support, the form would not be able to withstand or support the weight and pressure of the poured concrete. Having to provide support to the concrete form increases the cost of materials, shipping, and installing the concrete form. Together, these costs combine to increase the cost of producing a concrete structure.  
           [0008]    Another problem with current methods of producing formed concrete, is the necessity to paint the exterior surface of a permanent-type form or the exposed concrete edge after a temporary form has been removed from the solidified concrete. It is necessary to paint and repaint the exterior surface of a permanent-type form in order to protect the form&#39;s exterior surface from exposure to the environment. Without painting or another method of sealing the form&#39;s surface, the exterior surface of a permanent-type concrete form would be subject to corrosion and wear due to rain, snow, salt, and petroleum spills. Likewise, an unpainted or unsealed concrete edge will be subject to similar wear. Long term exposure to the environment may result in deterioration of the permanent-type form or the concrete edge.  
           [0009]    An additional problem with current methods of producing formed concrete is the cost and time required to maintain a permanent-type form&#39;s exterior surface or a concrete edge. Permanent-type concrete forms are subject to dents or scratches caused by automobiles, snowplows, and other equipment. In addition, the permanent-type form&#39;s exterior surface will show wear due to sunlight fading and petroleum spills. Similarly, the painted concrete edge will show signs of wear. As a result, the concrete edge must be repainted periodically.  
           [0010]    Yet another problem with current concrete forms is the inability to easily shape or bend the forms to create a desired concrete structure. Current concrete forms are produced as a rigid form with a defined shape created at the manufacturer. After the concrete form is manufactured, the form&#39;s shape can not be easily modified. As a result, multiple forms of varying lengths and shapes may be required to meet one&#39;s desired concrete form needs.  
         SUMMARY OF THE INVENTION  
         [0011]    According to the present invention, a non-metallic form is used as a support for poured concrete. In addition, the nonmetallic form may be integrated within the poured concrete such that the exterior surface of the non-metallic form acts as a permanent edge around the poured concrete. The non-metallic form is capable of supporting the weight and pressure of poured concrete without additional lateral support.  
           [0012]    The invention, in one form thereof, is an assembly for receiving poured concrete. The assembly includes a non-metallic form which surrounds an inner cavity. The non-metallic form is capable of supporting poured concrete. In one particular embodiment, the non-metallic form contains at least one protuberance extending into the inner cavity. In an alternate embodiment, the protuberance contains at least one syncline notch.  
           [0013]    The invention, in another form thereof, is an assembly for receiving poured concrete to form a base on which a fuel dispenser is disposed. A non-metallic form surrounds an inner cavity. The non-metallic form is capable of containing poured concrete such that when the inner cavity is filled with poured concrete, the concrete composes a base for a fuel dispenser. In alternate embodiments, the non-metallic form is produced by extrusion molded polyethylene, injection molded polyethylene, or rotationally molded polyethylene. In another particular embodiment, an exterior cover is removably affixed to the nonmetallic form.  
           [0014]    The invention, in yet another form thereof, is a method of producing an assembly for receiving concrete. The method includes the step of providing segments of non-metallic form. The segments of non-metallic form are bent as required and fastened together. In alternate embodiments, the non-metallic form is produced by extrusion molded polyethylene, injection molded polyethylene, or rotationally molded polyethylene.  
           [0015]    An advantage of the present invention is the strength of the non-metallic form to support poured concrete without additional support. Unlike some current concrete forms, the present invention does not typically require additional supports spanning the form&#39;s inner cavity to provide rigidity in order to sustain the pressure and weight of poured concrete.  
           [0016]    Another advantage of a specific embodiment of the present invention is the ability of the non-metallic concrete form to self-lock into the concrete. The self-locking is achieved through at least one protuberance that extends from the concrete form into the inner cavity which is then filled with poured concrete. The advantage of self-locking concrete form to the concrete is the ability to control thermal expansion of the concrete form. The self-locking concrete form is held or maintained snug up against the edge of the concrete structure even if the concrete expands or contracts due to thermal effects.  
           [0017]    Another advantage of the present invention is the ability to vary the overall length and shape of the concrete form. In one particular embodiment of the present invention, the non-metallic concrete form is composed of joined segments. By adding or subtracting segments, the overall length of the concrete form can be varied.  
           [0018]    In addition, the segments of non-metallic form are flexible allowing one to shape the non-metallic form as desired. By joining varying lengths of segments and shaping the concrete form, concrete structures of varying dimensions and contours may be produced. By varying the shape and dividing the form in pieces, shipping costs may be lowered.  
           [0019]    Yet another advantage of the present invention is the durability of the exterior surface of the non-metallic concrete form. In one particular embodiment, polyethylene provides a chemically resistant and environmentally resistant exterior surface to the concrete form. Polyethylene, unlike a painted surface, the polyethylene surface will not chip or flake away from the surface of a concrete form.  
           [0020]    Another advantage of the present invention is the ease of maintaining the exterior surface of the non-metallic concrete form. In a particular embodiment, a removable cover, face, or rub rail attaches to the exterior surface of the non-metallic concrete form. When it is necessary to replace a damaged or worn exterior cover, the old cover is removed and a new one is installed in its place. The covers can be manufactured in any color to meet the particular needs of a user; thereby, the color of the exterior face or edge of a concrete structure may be easily changed by simply replacing one cover with a different colored cover.  
           [0021]    An additional advantage of the present invention is the syncline notch design of one particular embodiment. A syncline notch or plurality of notches are made in the protuberance which extends into the form&#39;s inner cavity. The notch or notches permit bending, shaping, and curving of the form. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0022]    The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:  
         [0023]    [0023]FIG. 1 is a elevational view of a fuel dispenser disposed upon a concrete base which incorporates the present invention;  
         [0024]    [0024]FIG. 2 is a perspective view of a non-metallic form segment;  
         [0025]    [0025]FIG. 3 is a top view of a non-metallic form;  
         [0026]    [0026]FIG. 4 is an exploded perspective view of a non-metallic form and exterior cover;  
         [0027]    [0027]FIG. 5 is an exploded perspective view of a non-metallic form with non-metallic band;  
         [0028]    [0028]FIG. 6 is a cross-sectional view of the non-metallic form of FIG. 4;  
         [0029]    [0029]FIG. 7 is a perspective view of the present invention depicting a non-metallic form with syncline shaped notched protuberances;  
         [0030]    [0030]FIG. 8 is a top view of a non-metallic form fastened to a metallic structure;  
         [0031]    [0031]FIG. 9 is a top view of the present invention depicting a non-metallic concrete form with notched extending protuberances;  
         [0032]    [0032]FIG. 10 depicts a perspective view of the present invention; and  
         [0033]    [0033]FIG. 11 is a perspective view of the present invention depicting two curved and two linear segments of non-metallic form adjoined together. 
     
    
       [0034]    Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.  
       DETAILED DESCRIPTION OF THE INVENTION  
       [0035]    Referring now to the drawings and particularly to FIG. 1, there is shown an assembly  12  for receiving poured concrete which incorporates the present invention. Assembly  12  includes nonmetallic form  14  and exterior cover  16 . Assembly  12 , along with poured concrete (not shown) compose base  18  upon which fuel dispenser  20  is disposed.  
         [0036]    Referring to FIG. 2, non-metallic form  14  surrounds an inner cavity  22 . Protuberance  24  extends into cavity  22 . Protuberance  24  contains an upward angled surface  26  and a downward angled surface  28  (best seen in FIG. 6). When cavity  22  is filled with poured concrete (FIG. 3), concrete fills around surfaces  26 ,  28  and abuts interior form surface  30  to lock non-metallic form  14  into the concrete. Protuberance  24  prevents non-metallic form  14  from pulling away from the poured concrete after it solidifies.  
         [0037]    Anchor  32  is disposed within and is affixed to the corners of non-metallic form  14  and is located approximately half-way up the interior form surface  30 . Anchor  32  secures non-metallic form  14  to the solidified concrete. Anchor  32  contains void  34 , which is filled with poured concrete to further anchor nonmetallic form  14  to the concrete. Together, anchor  32 , with void  34  and protuberance  24 , retards non-metallic form  14  from separating from the poured concrete after the concrete solidifies.  
         [0038]    The locking of non-metallic form  14  to the solidified concrete maintains non-metallic form  14  snug against the concrete. When the concrete is subject to thermal expansion and contraction, non-metallic form  14  will similarly expand and contract due to the locking of form  14  to the concrete.  
         [0039]    Referring now to FIG. 3, in one particular embodiment, nonmetallic form  14  is composed of two segments  36  and  38 . Segments  36 ,  38  are fastened together by bolts  40  inserted through apertures  42  and tightened down on nuts  44 . While depicted in FIG. 3, non-metallic form  14  is composed of two segments  36 ,  38 , non-metallic form  14  may be composed of additional segments. Bolts  40  hold segments  36 ,  38  together and provide rigidity to non-metallic form  14  whereby inner cavity  22  may be filled with poured concrete.  
         [0040]    After segments  36 ,  38  are joined together, liquid concrete is poured into inner cavity  22 . Non-metallic form  14  is sufficiently rigid and strong to support the pressure and weight exerted by the poured concrete on interior surface  30  without supports spanning inner cavity  22 . Once the poured concrete has solidified, the concrete composes base  18  for fuel dispenser  20  (FIG. 1).  
         [0041]    Alternatively, non-metallic form  14  can be used as a form for other concrete structures including but not limited to patio slabs, sidewalks, curbs, and retaining walls.  
         [0042]    [0042]FIG. 6 is a cross-sectional view of the non-metallic form  14 . Projection  46  extends from exterior surface  48  of nonmetallic form  14 . Projection  46  defines a groove  50  and channel  52 .  
         [0043]    Exterior cover  16  is provided and contains upper and lower tabs  54  and  56  (FIG. 4). Tab  54  form fits into channel  52  and tab  56  form fits into groove  50 . The interior surface contour of cover  16  substantially matches the contour of projection  46 . Exterior cover  16  attached over projection  46  by inserting tab  54  into channel  52 , followed by snapping tab  56  into groove  50 . Exterior channel  16  is composed of a flexible material such that it is able to be snapped into place. Exterior cover  16  can be removed from projection  46  by pulling tab  56  away from groove  50 , followed by lifting exterior cover  16  off of non-metallic form  14 .  
         [0044]    Exterior cover  16  may be any color and it may be composed of any appropriate material, such as polyethylene or rubber. In addition, exterior cover  16  serves as a replaceable rub rail and may be easily replaced if cover  16  becomes damaged or one wishes to change the color of exterior cover  16  no assembly  12 .  
         [0045]    Referring now to FIG. 5, a band  58  fits and attaches into channel  52  when exterior cover  16  is not used. Band  58  fills the void of channel  52  and keeps debris, rain, snow, salt, ice, petroleum, etc. from collecting within channel  52 . Band  58  may be composed of any appropriate material, such a polyethylene or rubber, and may be colored to correspond the color scheme of assembly  12 .  
         [0046]    Referring now to FIGS. 7 and 8, a plurality of alternately rotated upward “L”-shaped protuberances and downward “L”-shaped protuberances  60 ,  62 , respectively, project from interior surface  30  into inner cavity  22 . Upward “L”-shaped protuberance  60  contains horizontal portion  64  which extends relatively perpendicular to inner surface  30 , and vertical upward extending portion  66 , which extends upward, in a direction parallel to interior surface  30 . Downward “L”-shaped projection  62  contains horizontal portion  64  and vertical downward extending portion  68 . As depicted in FIG. 8, non-metallic form  14  is fastened to metal structure  78  by screws  80 . Metal structure  78  may be part of dispenser  20  or a part of a web or lattice framework disposed within inner cavity  22  to be filled with poured concrete.  
         [0047]    As depicted in FIG. 9, assembly  12  is composed of nonmetallic form of  14  with “L-shaped” protuberances  60 ,  62 . Concrete poured into inner cavity  22  fills in and around “L”-shaped protuberances  60 ,  62  and lock non-metallic form  14  to the concrete when the concrete solidifies. Protuberances  60 ,  62  hold non-metallic form  14  snug against concrete and allow non-metallic form  14  to conform to the concrete as the concrete expands and contracts due to thermal expansion and contraction. “L”-shaped protuberances  60 ,  62  contain syncline notches  70 . Syncline notches  70  allows non-metallic form  14  to be bent or shaped. As shown in FIG. 9, a plurality of syncline notches compose curved portion  71  of non-metallic form  14 . When the poured concrete solidifies, the resulting concrete structure is used as a base for a fuel dispenser which is depicted as outline of fuel dispenser  82 .  
         [0048]    Referring now to the embodiment shown in FIG. 10, nonmetallic form  14  is composed of four segments, two linear segments  72 , and two curved segments  74 . Segments  72 ,  74  are fastened together by bolts  40  inserted through apertures  42  and tightened down with nuts  44 . The advantage of this embodiment is the ability to package the present invention in the smallest container possible for shipping and storage.  
         [0049]    Delivery services and freight carriers have package dimension restrictions. For example, currently, a parcel shipped by United Parcel Service (UPS) must have a combined circumference plus height less than 130 inches. The United Stated Postal Service (USPS) currently has a dimension restriction whereby the length plus height cannot exceed 108 inches. Therefore, for shipping purposes, it may be necessary to limit the size of each individual segment such that when packaged together, the segments will fit in a container having a sum dimension of length plus height within the range of 108 inches or less, or having a container with a sum dimension of circumference plus height within the range of 130 inches or less.  
         [0050]    [0050]FIG. 11 shows the embodiment of assembly  12  with linear segments  72  and “C” shaped curved segments  76 . Linear segment  72 , “C” shaped curved segment  76  are fastened together by a plurality of bolts  40 .  
         [0051]    Non-metallic form  14  is composed of polyethylene. The process for producing non-metallic form  14  may be one of either extrusion molded polyethylene, injection molded polyethylene, or rotationally molded polyethylene. In addition, non-metallic form  14  may be composed of numerous segments produced by different molding techniques, which are joined together. Nonmetallic form  14  may be composed of any suitable non-metallic material, but most preferably plastics.  
         [0052]    While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.