Abstract:
The present invention is directed to a pre-cast panel form insert used in precast construction. The insert comprises a substantially planar portion defining dimensions suitable to complement dimensions of a pre-cast panel form and a fluid diverting portion. The fluid diverting portion is configured to define a fluid-diverting recess in an edge face of a pre-cast panel bounded by a form including the form insert. The fluid diverting portion is configured such that said fluid diverting recess defines, a circular cross-sectional profile, or a multi-angular cross-sectional profile, that impedes the flow of water along said pre-cast panel edge face when said edge face assumes a substantially horizontal orientation.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of U.S. Provisional Application Ser. No. 60/420,853, filed Oct. 24, 2002. 

   BACKGROUND 
   The present invention relates to the formation of panels, and more particularly to the formation of pre-cast construction panels for use in tilt-up and other pre-cast construction. 
   SUMMARY OF THE INVENTION 
   The present invention provides an insert and a method of making a wall panel that is constructed to allow fluid to drain off the building quickly and efficiently. The wall panels made using an insert according to the present invention, have a recess that diverts the flow of fluid running back or under an overhang. By diverting the flow of fluid in this manner, the fluid does not touch the side of the building, the doors, or the windows as the fluid drains, thereby extending the life of the wall panel and, in turn, the life of the building. 
   According to the present invention, a panel form insert having a fluid diverting portion is provided. When the fluid diverting portion is formed in the panel, the pathway of fluid is diverted and kept from running back or under an overhang. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an illustration of a pre-cast panel form including an insert according to the present invention. 
       FIG. 2  is a cross-sectional view of a panel form insert according to one embodiment of the present invention. 
       FIGS. 3   a – 3   d  are illustrations of panel form insert fluid diverting portions according to various alternative embodiments of the present invention. 
       FIG. 4  is an illustration of a panel form insert according to the present invention having two integral chamfer portions. 
       FIG. 5  is an illustration of a panel form insert according to the present invention having two separate chamfer portions. 
       FIG. 6  is an illustration of a formed panel according to the present invention having a recessed fluid diverting portion and a chamfered edge. 
       FIG. 7  is an illustration of a portion of a panel form insert according to the present invention having a sealing edge and a longitudinal area of weakness. 
   

   DETAILED DESCRIPTION 
   Referring to  FIG. 1 , a panel form  10  is shown. A casting material, e.g. concrete, is introduced into one panel form  10  and cured for use in the construction of commercial and industrial buildings by, for example, the tilt-up method. The panel form  10  comprises a panel frame  2  made of four panel frame members  2   a ,  2   b ,  2   c , and  2   d . The panel frame members  2   a ,  2   b ,  2   c , and  2   d  form a rectangular shaped panel frame in  FIG. 1 , however, it is to be appreciated that any desired shape may be used. The panel frame members  2   a ,  2   b ,  2   c , and  2   d  are placed onto a forming surface  8 . 
   The forming surface can be a concrete slab, a smooth floor, or any surface capable of forming a flat, smooth, horizontal surface. The forming surface  8  is typically poured in place and then coated with a release agent for easier removal of the cured panel. The forming surface  8  can alternatively be referred to as a slab or casting surface. After the casting material is poured within the panel form  10 , the top edges  3  of the panel form are used as a guide for a screed which forms a flat casting material surface. After the casting material is cured, the cured panel is lifted, tilted, or otherwise positioned for use. 
   The panel form  10  can be configured such that an opening  4  is formed in the panel. Within the panel frame  2  is an opening frame  6  formed by three opening frame members  6   a ,  6   b , and  6   c . The opening frame  6  distinguishes an area where the casting material is not to be poured and obstructs the flow the poured casting material into the opening  4 . Therefore, once the wall panel is set, cured, and positioned for use, an open space exists in the wall panel to form a doorway, window, or the like. 
   The panel frame members  2   a ,  2   b ,  2   c , and  2   d  and the opening frame members  6   a ,  6   b , and  6   c  are typically made of wood, plastic, or other suitable materials. Although it is contemplated that a variety of dimensions may be suitable, the panel frame members  2   a ,  2   b ,  2   c , and  2   d  can have a length dimension of at least about six feet (2 meters) with a height dimension of at least about 4 inches (10 cm). The opening frame members  6   a ,  6   b , and  6   c  can have a height dimension of at least about 4 inches (10 cm) and a length dimension of at least about 24 inches (60 cm). The panel frame members  2   a ,  2   b ,  2   c , and  2   d  and the opening frame members  6   a ,  6   b , and  6   c  may be secured to the forming surface  8  by hardware, such as braces, clamps, nails, screws, adhesive, tapes, fasteners, or any other suitable means for securing a member to a forming surface. 
   Referring to  FIGS. 1 and 2 , a panel form insert  30  according to the present invention is positioned along the opening frame member  6   b . The insert  30  is placed over a header portion  20  of the opening frame member  6   b  such that as the casting material is poured onto the forming surface  8 , the casting material will cure with a profile defined by the insert  30 . The insert  30  comprises a substantially planar portion  32  and a fluid diverting portion  34 . The substantially planar portion  32  comprises first and second peripheral edges  32   a  and  32   b  that extend longitudinally from the substantially planar portion  32 . 
   The substantially planar portion  32  of the insert  30  and the fluid diverting portion  34  are elongate along a lengthwise dimension L. Thus, the insert  30  rests lengthwise L over opening frame member  6   b . The insert  30  is shown extending the entire length of the opening frame member  6   b , however, the insert  30  does not have to extend the entire length of the opening frame member  6   b  but can extend any desired length. 
   The fluid diverting portion  34  protrudes from the substantially planar portion  32  such that the substantially planar portion  32  and the fluid diverting portion  34  form a monolithic structure. The fluid diverting portion  34  can be oriented generally parallel to one or both of the peripheral edges  32   a  and  32   b  of the substantially planar portion  32  and can extend along the lengthwise dimension L of the substantial planar portion  32 . The fluid diverting portion  34  can be placed a substantial distance from either the first peripheral edge  32   a , the second peripheral edge  32   b , or the fluid diverting portion  34  may be disposed between the first and second peripheral edges  32   a  and  32   b . The fluid diverting portion  34  may be disposed anywhere along the substantially planar portion  32  such that when the insert  30  is used to make a panel, the fluid diverting recess made in the panel by the fluid diverting portion  34  of the insert  30  prevents fluid, such as water, moving down a vertical face of a panel from reaching a window, door, or other partition in the opening  4  in the panel. The fluid diverting portion  34  extends along the lengthwise direction of the substantially planar portion  32  parallel to the longitudinal peripheral edges  32   a  and  32   b  of the substantially planar portion  32 . The preferred position of the fluid diverting portion  34  relative to the front and back major faces of the panel depends upon the location of the window or door in the opening  4 . 
   In the illustrated embodiment, the fluid diverting portion  34  decreases in cross section size from a maximum cross sectional dimension. Thus, a fluid diverting recess created by the fluid diverting portion  34  in an edge face of a cured panel decreases in cross sectional size from a maximum cross sectional dimension to a minimum cross sectional dimension at the terminal portion of the fluid diverting portion  34 . The cross sectional dimension of the fluid diverting portion is sufficient to substantially impede the flow of fluid across the fluid diverting portion. More specifically, the size and profile of the fluid diverting recess is configured such that the fluid diverting recess will substantially impede fluid from touching a window or door placed in the opening  4  when the panel is in a vertical orientation. 
   Referring to  FIG. 2 , the fluid diverting portion  34  may be a recessed area, meaning that there is an open space  33  between the opening frame  6  member and the insert  30  at the location of the fluid diverting portion  34  of the insert. Alternatively, the fluid diverting portion  34  may be solid such that the fluid diverting portion is flush with the opening frame member  6   b.    
   Referring to  FIGS. 3   a – 3   b , the cross-section of the fluid diverting portion  34  may be a variety of shapes that comprise a curved cross-sectional profile.  FIG. 3   a  shows a fluid diverting portion  34  comprising a semicircular cross-section while  FIG. 3   b  shows the fluid diverting portion  34  comprising an elliptical cross-section. Referring to  FIGS. 3   c  and  3   d , the fluid diverting portion  34  may be characterized by a multi-angular cross sectional profile.  FIG. 3   c  shows a fluid diverting portion  34  comprising a hexagonal cross-section while  FIG. 3   d  shows the fluid diverting portion  34  comprising an octagonal cross-section. It is to be appreciated that these shapes are merely examples of shapes that may form the fluid diverting portion  34  and that the fluid diverting portion  34  is not limited to these specific shapes. 
   The insert  30  may comprise a first chamfer portion  36 . The first chamfer portion  36  is formed by a portion of the insert  30  that extends diagonally outward from the substantially planar portion  32 . In one embodiment, the first chamfer portion  36  extends about 45° from the substantially planar portion  32 . Once the insert  30  is removed from the panel, the panel displays a cut edge. As shown in  FIG. 4 , a second chamfer portion  38  can be integral with the substantially planar portion. Typically, the second chamfer portion  38  extends diagonally about 45° from the substantially planar portion  32 . 
   As shown in  FIG. 5 , the first and second chamfer portions  36  and  38  may be separate from the substantially planar portion  32 . Therefore, the first and second chamfer portions  36  and  38  may be placed between the panel forming surface  8  and the substantially planar portion  32  at the first peripheral edge  32   a . At the second peripheral edge  32   b  of the substantially planar portion  32 , the second chamfer  38  rests over the substantially planar portion  32 . 
   Also shown in  FIGS. 1 and 2 , the insert  30  may also comprise an extension leg  39 . The extension leg  39  extends from the substantially planar portion  32  at an angle of about 90°. The extension leg extends a sufficient distance to provide an insert mounting surface to mount the insert  30  to the forming surface  8 . The extension leg  39  may act as a fastening device for the insert  30  by adhering, coupling, or fastening to the opening member  6   b  and/or the panel forming surface  8  in order to keep the insert  30  in place while the concrete is being poured. 
   The entire insert  30  is a one-piece member which may be extruded of a rigid or semi-rigid plastic material such as polyvinylchloride (PVC), high density polyethylene (HDPC), etc. The insert  30  may be formed by injection molding, or other suitable processes. 
   The substantially planar portion  32  and fluid diverting portion  34  have a rigidity sufficient to resist significant deformation and breakage under panel forming pressure. Therefore, the insert  30  can withstand the pressure of casting material, such as concrete, contacting and forming around the side substantially planar portion from which the fluid diverting portion  34  protrudes. By placing the insert  30  over the header portion  20  of opening frame member  6   b  the casting material will contact the insert  30 . By having the fluid diverting portion  34  protrude from the substantially planar portion  32 , as the casting material hardens around the insert  30 , the casting material will have the indentation of the fluid diverting portion  34 . If a chamfer portion  36  is included on the insert  30 , the panel wall will also display a cut edge. 
   The insert  30  is coupled to a header portion  20  of the opening frame member  6   b  such that it is connected to and extends from the panel forming surface  8  at an angle of about 90°. Once the frame members and the insert  30  are in place, the casting material is poured onto the panel forming surface  8 . The casting material is poured at a depth to that allows for the desired thickness of the wall panel. It is to be appreciated that while the insert  30  is explained as being placed over opening frame member  6   b , the insert  30  can be placed over any member where a fluid diverting portion  34  is desired in a panel wall. The insert  30  may be attached to the panel forming surface  8  by an adhesive, tape, hardware, such as nails, screws, suitable fasteners, or any other suitable means for securing and the insert to the slab. Alternatively, the insert  30  can simply rest upon panel forming surface  8 , secured by the weight of the header portion  20 . The adhesive can be any conventional adhesive suitable for securing a plastic member to a concrete surface. The extension leg  39  may comprise a groove into which hardware can be placed to fasten the insert  30  to the panel forming surface  8 . 
   Referring to  FIG. 6 , once the panel  40  is lifted vertically or otherwise positioned into place, the insert (not shown) can be stripped from the concrete wall panel  40 . A fluid diverting recess  42  is formed in the panel  40  that is the shape of the fluid diverting portion of the insert. The recess  42  acts as a drip edge to help prevent fluid from running back or under an overhang of a vertically-oriented panel. A chamfered edge  46  is also shown, however, it is to be appreciated that a chamfered edge  46  does not have to be included on the panel  40 . The arrows indicate the path of fluid running down the panel  40 . The water follows the chamfered edge  46  of the panel and flows to the recess  42  of the panel  40 . Once the water reaches the recess  42 , all of the water, or a substantial portion of the water, is prevented from reaching the door  45  or any other portion of the overhang  44 . The recess  42  thereby obstructs the path of the water. 
   Referring to  FIG. 7 , another embodiment of the present invention is shown. The fluid diverting portion  34  extends from the second peripheral edge  32   b  of the substantially planar portion  32 . The fluid diverting portion  34  has a beginning point  34   a  and a terminating point  34   b . At the beginning point  34   a , the fluid diverting portion  34  protrudes from said substantially planar portion  32  and extends to a terminating point  34   b . A sealing edge  65  extends from the terminating point  34   b . The sealing edge  65  extends across a plane  60  defined by substantially planar portion  32  such that the sealing edge  65  hangs below said substantially planar portion  32 . In this manner, a secure seal may be established between the sealing edge  65  and the panel forming surface. 
   Referring again to  FIG. 7 , the substantially planar portion  32  may comprise a longitudinal area of weakness  70 . The longitudinal area of weakness  70  is shown disposed between the first peripheral edge  32   a  and the fluid diverting portion  34 . However, the longitudinal area of weakness  70  can be disposed anywhere along the substantially planar portion  32 . The longitudinal area of weakness  70  can be anything that causes a weak area in the substantially planar portion  32 . For example, the longitudinal area of weakness  70  may comprise a reduced thickness portion of the substantially planar portion  32  as shown in  FIG. 8 . The longitudinal area of weakness  70  may comprise a different, more brittle material that is extruded with the substantially planar portion. One example of a longitudinal area of weakness  70  is a score line. By providing a longitudinal area of weakness  70 , the substantially planar portion  32  can be broken off, or a portion of the substantially planar portion  32  can be detached. 
   Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.