Abstract:
Structures for securing foam panels in position with respect to each other in order to form a mold for the pouring of concrete, such as in the case of the pouring of a building foundation or building wall are disclosed. A first type of member which has pairs of facing flanges for engaging facing walls at opposite ends on the member. This first type of member comprises an upper and a lower section. The upper and the lower section are connected to each other by at least one frangible bridge, which may be broken to accommodate the need for a shorter member at the top and bottom of the mold. A corner brace, having two pairs of facing flange members located in its upper section, and two pairs of facing flange members located in its lower section, is adapted to engage the four panel corners which meet at the corner of the poured cement mold where the top of one row of panels meets the bottom of the next row of panels.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of copending U.S. patent application Ser. No. 09/368,747 of Charles SEVERINO, filed Aug. 5, 1999 and entitled “INSULATED CONCRETE FORMING SYSTEM.” The disclosure of the aforementioned United States patent application is hereby incorporated herein by reference thereto. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     (Not applicable.) 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an insulated concrete forming system, more particularly to a system of supports that maintains forms in a desired spacial relationship between which concrete is poured. 
     2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98 
     Typical wall-forming systems employ “blocks”, which work as a pair of panels spaced apart by a system of “ties” and are stacked to form a wall of the desired height. The panels can be made of wood or some other material. More effective systems utilize panels of lighter weight materials such as polystyrene. The ties which hold the panels in the predetermined spatial relationship have typically been dowels of fixed length inserted from the outside of the panels through the form and perpendicular to the plane of the panels. These dowels have usually been expensive steel rods which are costly to transport. In an effort to reduce the cost of transportation such ties have been manufactured from lightweight plastics. However, such plastic ties, while they do address certain cost issues, are not without problems. 
     Another problem with the plastic tie of the prior art is that ties placed at the top and/or bottom of the form protrude above or below the form and have to be cut. Alternatively, no ties may be used or a half tie could be placed at the top or bottom of the form, thus eliminating the need for cutting any tie at the top of the form. However, this involves manufacture transport and stocking of the ties. The absence of ties at the top and bottom of the form, however, results in structural instability and reduced strength of the form and can pose a safety threat to workers while concrete is being poured. 
     A further problem with the tie of the prior art is that they are flimsy and composed of two or more parts. Ties which are very narrow and thin do not lend much to the structural integrity of the concrete form, and ties which are composed of a plurality of pieces may separate and weaken the form while concrete is being poured into it. 
     It is therefore a general object of the present invention to provide an improved tie of a single length and height which can be used to form panel walls of varying heights, while providing for the strength and stability of forms stabilized by top and bottom tie without the need for specialized top and bottom ties or foam panels with dedicated middle or top and bottom elements. 
     It is also an object of the present invention to provide a tie which can be used to hold the uppermost and bottommost portions of the panels together in order to maintain the structural integrity of the form while concrete is being poured into it. 
     It is a further object of the invention to provide a tie formed from a single piece of plastic to eliminate the chance of a tie separating while it is being subjected to the stresses of concrete being poured into the form. 
     SUMMARY OF THE INVENTION 
     The present invention is drawn to a device for interlocking form panels. It contemplates an elongated member that is substantially planar and having first and second sections connected by frangible bridges. First and second sections each have first and second ends. First and second flange members are attached to the ends and diverge from the elongated member. These flange members are also substantially planar, parallel to each other and protrude perpendicularly out of the plane of the elongated member an equal distance from the first and second sides of the elongated member. 
     A first pair of guide rib member is attached to the elongated member at a point near the first end of the elongated member, is in a parallel planar relationship with the first diverging flange member, and protrudes perpendicularly from the first side of the elongated member. The first pair of guide rib member is attached at a point from the first diverging flange member so as to define a distance that is substantially equal to the thickness of a form panel. 
     A second pair of guide rib members is attached to the elongated member at a point near the second end of the elongated member, is in a parallel planar relationship with the second diverging flange member, and protrudes perpendicularly from the second side of the elongated member. This pair of guide rib members is attached at a point from the second diverging flange member so as to define a distance that is substantially equal to the thickness of a form panel. 
     A frangible bridge separates the top half of the elongated member from the bottom half of the elongated member and is positioned along the longitudinal axis of the elongated member. The top half of the elongated member is coplanar with the bottom half of the elongated member. 
     Another embodiment of the tie contemplates a third pair of guide rib members protruding horizontally out of the second side of the elongated member and configured, positioned, and dimensioned so as to be in a parallel planar relationship with the first pair of diverging flange members and to define a distance between the first pair of diverging flange members and the third pair of guide rib members that is equal to the thickness of a form panel. This embodiment also contemplates a fourth pair of guide rib members protruding perpendicularly out of the first side of the elongated member at points equal and distal from the second pair of diverging flange members and being configured, positioned, and dimensioned so as to be in a parallel planar relationship with the second pair of diverging flange members and to define a distance between the second pair of diverging flange members and the fourth pair of guide rib members that is equal to the thickness of a form panel. 
     Still another embodiment of the invention contemplates a clip for holding rebar in place protruding perpendicularly outward from the first section of the elongated member in a coplanar configuration with the elongated member at a point intermediate the first and second pairs of diverging flange members. A second clip for holding rebar in place similarly protrudes perpendicularly outward from the second section of the elongated member. A plurality of clips for holding rebar may be used. 
     Yet another embodiment of the invention contemplates a void or a plurality of voids formed in the elongated member through which concrete can flow. 
     The invention can be fabricated from a variety of plastic materials, a lightweight metal, or other suitable material. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a planar view of the inventive tie having two pairs of guide ribs, a plurality of clips for holding cement reinforcing metal bars or “rebar” in place, with provision for separating the top half of the tie from the bottom half; 
     FIG. 2 is a planar view of the tie system showing two ties as they are positioned between form panels prior to the pouring of concrete into the form; 
     FIG. 3 is a planar view of the tie system showing two ties as they are positioned between form panels and at the top edge of the form panels prior to the pouring of concrete into the form; 
     FIG. 4 is a planar view of the tie system showing two ties at the interface of two form panels; 
     FIG. 5 is a side view of the tie showing two pairs of guide ribs, and a plurality of clips for holding rebar in place; 
     FIG. 6 is an end view of the tie along line  3 — 3  of FIG. 5; 
     FIG. 7 is a planar view of the tie showing four pairs of guide ribs and a plurality of clips for holding rebar in place; and 
     FIG. 8 is a top view of a tie having four pairs of guide ribs as it would be employed in a form panel system; 
     FIG. 9 is an isometric view of the inventive corner brace for employment of the method of the present invention; 
     FIG. 10 is a plan view of the inventive corner brace illustrated in FIG. 9 along line  10 — 10  of FIG. 9; 
     FIG. 11 is a plan view of the inventive corner brace illustrated in FIG. 9 along line  11 — 11  of FIG. 10; 
     FIG. 12 is a plan view of the inventive corner brace illustrated in FIG. 9 along line  12 — 12  of FIG. 10; 
     FIG. 13 is a top plan view of the inventive corner brace illustrated in FIG. 9; 
     FIG. 14 is a cross-sectional view of the inventive corner brace illustrated in FIG. 9 along line  14 — 14  of FIG. 13; 
     FIG. 15 is a plan view of the view of the inventive corner brace illustrated in FIG. 9 along line  15 — 15  of FIG. 9; and 
     FIG. 16 is an isometric view of a form for forming a concrete wall corner using the inventive corner brace in accordance with the method of the present invention. 
     FIG. 17 is a top plan view of the inventive corner brace illustrated in FIG. 9 depicting a feature of the invention; 
     FIG. 18 is a cross-sectional view of the inventive corner brace illustrated in FIG. 9 depicting a feature of the invention; 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, a tie  10  constructed in accordance with the present invention is illustrated. Tie  10  is constructed out of a flexible polymer, a plastic, or a lightweight metal such as aluminum. In accordance with the preferred embodiment of the invention, tie  10  is injection molded from a tough resilient plastic, such as polystyrene. 
     Tie  10  comprises a first upper section  12  and a second lower section  14 . First section  12  and second section  14  have first ends  16  and second ends  18 . First section  12  and second section  14  are joined by narrow frangible bridges  50 . Frangible bridges  50  can be broken or cut allowing first section  12  to be separated from second section  14 . 
     Generally, ties  10  are placed and may be used to form a form for pouring cement, as illustrated in FIG.  2 . As can be seen in the figure, a form is formed by a pair of spaced and facing panels  60  (usually made of expanded modified polystyrene). During use, concrete reinforcing bars  61  are placed in clips  26  in the ties  10 , and concrete is poured between the panels  60 . After the concrete hardens, the form panels  60  may be removed, leaving behind a concrete wall. Alternately, form panels  60  may be left on the concrete wall to serve as insulation or a base for another type of finish. If the form panels  60  are removed, protruding portions  63  of ties  10  can be broken off and removed befor finishing the concrete wall. 
     As can be understood from FIG. 3, in addition, in accordance with the preferred embodiment, a particularly advantageous mode of use is achieved with respect to the bottom and top of the mold. In particular, first section  12  or second section  14  can be inserted into a top or bottom transverse slot  58  of form panel  60  in such a manner so as to not protrude above the top or below the bottom edge of form panel  60 . Such an arrangement showing the use of a half-tie at the top of a mold is illustrated in FIG.  3 . 
     First sections  12  and second sections  14  are configured to receive, support, and maintained in a spaced configuration a pair of form boards  60 . On the first ends  16  of both first section  12  and second section  14  are disposed a first pair of diverging flange members  20 . Diverging flange members  20  are positioned, configured, and dimensioned to project perpendicularly outward from the planes of first section  12  and second section  14 . A second pair of diverging flange members  22  is disposed on the second ends  18  of both first section  12  and second section  14  and project similarly outward from the planes of first section  12  and second section  14 . Diverging flange members  20  and  22  provide better support to form panels  60  against the stresses incurred by the pouring of wet concrete. 
     First ends  16  of first section  12  and second section  14  have disposed on them a first pair of guide rib members  30  at points distal from the diverging flange members  20 . The distance between the first pair of guide rib members  30  and diverging flange members  20  defines the thickness of form panel  60 . Guide rib members  30  perpendicularly protrude from one side of first section  12  and second section  14  outward and in such a manner so as to be in a parallel planar relationship with diverging flange members  20 . 
     Second ends  18  of first section  12  and second section  14  have disposed on them a second pair of guide rib members  32  at points distal from the diverging flange members  22 . The distance between the second pair of guide rib members  32  and diverging flange members  22  also defines the thickness of form panel  60 . Second pair of guide rib members  32  protrudes from the opposite side from which first pair of guide rib members  30  protrude. Second pair of guide rib members  32  protrudes from first section  12  and second section  14 , perpendicularly outward and in such a manner so as to be in a parallel planar relationship with diverging flange members  22 . 
     Clips  26  for holding rebar in place protrude from the top edge of first section  12  and bottom edge of second section  14 . Clips  26  are molded as part of both first section  12  and second section  14  if tie  10  is plastic. Alternately, clips  26  are cast as part of both first section  12  and second section  14 , if tie  10  is made of metal. Clips  26  consist of two curved prongs which protrude away from the first section  12  and second section  14  in an arcing fashion. The arcing prongs are situated and configured in such a manner that the concave portions of each arcing prong face each other. Furthermore, the arcing prongs conform substantially to the radius of the cross section of the rebar. Arcing prongs are constructed so as to be flexible. The prongs can be spread apart when rebar is forced part way between them and can clip around and hold rebar firmly when the rebar is forced all the way between them. A plurality of clips  26  can be molded or cast into each first section  12  and second section  14 . 
     FIG. 2 is a planar view of two ties  10  inserted into slots  58  in two form panels. Ties  10  are positioned in a row of slots  58  evenly spaced in the top and bottom edges of form panels  60  on one side and in a corresponding row of equally spaced slots  58  in form panels  60  on the opposite side. Form panels  60  are typically constructed of polystyrene or a similar deformable material. Alternately, form panels  60  may also be constructed of wood. It is contemplated that the in the case of form panels  60  being made of wood, the panels  60  may be reused. 
     The height of the ties  10  is approximately twice the depth of the slots  58  of form panels  60 , so that half of each of the ties fits into a slot  58  in the form panel  60  below while the other half fits into a slot  58  in the form panel  60  above, thereby causing ties  10  to straddle the interfaces between horizontal edges of upper and lower form panels  60 , as illustrated in FIG.  4 . 
     Second section  14  is inserted into the slots  58  of form panels in such a manner so as one form panel is held between diverging flange member  20  and guide rib  30  on second section  14  of tie  10 . Likewise, another form panel is held between diverging flange member  22  and guide rib  32  on second section  14  of tie  10 . Once two form panels  60  are adequately linked together at their tops using a number of ties  10  that correspond to the number of slots  58  in the forms panels  60 , additional form panels  60  may be placed on top of the linked form panels  60  and held together by the first sections  12  of ties  10 . In this manner, the form panels can be stacked to a height that meets the specification of the concrete wall to be built. 
     FIG. 5 is a side view of tie  10 . Separating the first section  12  from the second section  14  in order to use half of the tie  10  at the top or bottom of a form panel involves cutting frangible bridges  50 . 
     FIG. 6 shows an end view illustration of tie  10  along the line  3 — 3  of FIG.  5 . Second pair of guide rib members  32  is shown on the second end of tie  10 . Frangible bridge  50  is also illustrated. 
     In FIG. 1, only two pairs of guide rib members are shown. Each are located on opposing sides of tie  10 . However, referring now to FIG. 7, another embodiment of the tie is disclosed. Tie  110  has two additional pairs of guide rib members attached to first section  112  and second section  114  of tie  110 . A third pair of guide rib members  134  is disposed on the first end of tie  110  at points distal from diverging flange members  120  and opposite the first pair of guide rib members  130 . 
     Third pair of guide rib members  134  protrudes from first section  112  and second section  114  perpendicularly outward from the plane of tie  110  and in the opposite direction from first pair of guide rib members  130 . In a similar manner fourth pair of guide rib members  136  is situated on the second end of tie  110  distal from diverging flange member  122  and protrudes perpendicularly outward from the plane of tie  110  and in the opposite direction from second pair of guide rib members  132 . 
     The distance between the first pair of guide rib members  130  and diverging flange member  120 , as well as the distance between third pair of guide rib members  134  and diverging flange member  120 , defines the thickness of a form panel situated on the first end  116  of tie  110  and placed so as to form one side of a wall. Likewise, the distance between the second pair of guide rib members  132  and diverging flange member  122 , as well as the distance between fourth pair of guide rib members  136  and diverging flange member  122 , defines the thickness of a form panel situated on the second end  118  of tie  110  and forms the second side of a wall. The volume defined between the two form panels, which is partially occupied by the tie  110 , is where concrete is poured to form the wall. 
     FIG. 8 is an illustration of the top view of tie  110  of FIG. 7 as it would be employed in a wall form system. Guide ribs  130  and  134  serve to hold form panel  60  against diverging flange members  120 , while guide ribs  132  and  136  serve to hold form panel  20  against diverging flange members  122 . 
     The system described above gives an unprecedented degree of stability during the pouring of concrete. However, yet additional stability can be achieved through the additional use of corner braces of the type illustrated in FIGS. 9 through 15 to construct a form such as that illustrated in FIG.  16 . 
     Referring first to FIG. 9, a corner brace  210  constructed in accordance with the present invention is illustrated. Comer brace  210  includes a first long side wall  211  and the second long side wall  213 . Corner brace  210  also includes a first short side wall  215  to the second short side wall  217 . Comer brace  210  thus defines a pair of legs  219  and  221 . The structural integrity of the system is maintained by L-shaped crosspiece  223 , which has a plurality of holes  225  disposed in it. 
     Holes  225  are provided for the purpose of reducing the consumption of materials. 
     Elongated thin regions  227  are provided to receive screws. Regions  227  are elongated in order to allow the screws to be fastened at a plurality of positions which are selectable by the user. This is of importance for firmly securing the foam and because, in accordance with the preferred embodiment, it is contemplated that plywood, sheet rock or other material will be fastened to the sides of the concrete wall after it has been cast. The use of elongated screw-receiving regions  227  allows the person to accommodate unpredictability in the positions of the edges of the sheet rock or other similar material. 
     As shown most clearly in FIG. 13, elongated regions  227  are defined between two slanted elongated surfaces  229 . Elongated surfaces  229  are slanted to match the angular slant of the screw used to secure the tie in place. 
     As illustrated most clearly in FIG. 14, the side walls are provided with slanted guide surfaces  231  which extend from the top surfaces  233  to the main body of the side walls. The purpose of guide surfaces  231  is to make it easy to insert stunt fitting panels  260  into the corner brace as illustrated in FIG.  16 . 
     As is illustrated in FIG. 16, a plurality of corner braces  210   a  are positioned on the outside corner of the wall, while a plurality of braces  210   b  are positioned on the inside of the corner to define a concrete wall mold. 
     During use, panels  260  are laid out on the top of the first tier and penetrates from one tier to the next. Panels  260  are kept in position using half of one of the crosspieces illustrated in FIGS. 1 through 8. The same is not illustrated in FIG. 16 for the purpose of clarity of illustration, and, accordingly, slots  258  are visible in this figure. 
     After the first tier has been laid, the crosspiece illustrated in FIGS. 1-8 is mounted in each of the slots  258  and a corner brace  210  is put at each of the corners. The concrete form is then ready to receive another layer of panels  260 , and the crosspieces and corner braces are again put in position until the last layer has been laid and the structure is completed with half crosspieces and corner braces, as illustrated in FIG.  16 . For purposes of illustration, a fuel of the crosspieces  10  have been illustrated in FIG. 16 in phantom lines. 
     After the form has been completed as illustrated in FIG. 16, concrete  235  may be poured in the space defined between the inner and outer corner walls, thus resulting in the formation of a concrete wall corner. 
     After this has been done, sheet rock, plywood or other material is placed against the sides of the mold and galvanized sheet rock screws are used to attach the material to the wall by going through the material and regions  215  and  217 . The resulting structure is economical, has excellent insulated materials because the panels are made of a modified expanded polystyrene material. 
     In accordance with the invention and has been discovered that the use of corner braces on the bottom adjacent the ground is not necessary in view of the friction provided by the ground and the stability provided by the half crosspieces. 
     FIGS. 17 and 18 illustrate another feature of the inventive corner brace. Elongated regions  227  and elongated surfaces  229  provide entrance points for screws that can be utilized quickly and allow screws to enter easily because they are thin, flexible and easily identified and pierced. As illustrated in FIG. 17, screw  237  passes through the thin elongated region  227  and the form panel  260 , and enters side wall  213 . Once screw  237  is through elongated region  227  and the form panel  260 , screw  237  will enter side wall  213  requiring less effort than it would take to put screw  237  through side wall  213  by itself. Using this method to anchor screw  237  adds further strength to the system because of the thickness of the wall on the opposite side of the thin elongated region  227 . Screw  237  may also be anchored in side wall  213  on a slant as illustrated in FIG. 18 to engage the thickest part of the opposite wall of the corner brace  210 . 
     While illustrative embodiments of the invention have been described above, it is understood that various modifications may be made without departing from the spirit and scope of the invention, which is limited and defined only by the appended claims.