Abstract:
Elongate bodies for use in providing architectural and structural features in pre-cast panels are provided. The elongate bodies may comprise a cross-section comprising a set portion, a hinged portion, and a hinge. The set portion and the hinged portion are configured to define an engagement. The hinge couples the set portion and the hinged portion such that the hinged portion is movable about the hinge to an engaged state and disengaged state. Methods of using the elongate bodies to form pre-cast panels are provided, and pre-cast panel forming systems are provided. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that is will not be used to interpret or limit the scope or meaning of the claims.

Description:
BACKGROUND  
         [0001]    The present invention relates generally to the formation of pre-cast panels, and more particularly to elongate bodies for providing architectural and structural features in pre-cast panels.  
           [0002]    Pre-cast construction of concrete wall panels for tilt-up and other types of construction is well known in the art. In the tilt-up approach, forms, also known as form liners, are placed on a flat casting surface in the shape and dimension of the desired panel and filled with concrete. When the concrete cures, the forms may be removed, and the panel tilted up into a preferred, typically vertical, orientation, where it can be joined to structural frames or other panels. The panels may have architectural features such as reveal bands or structural features formed therein by providing an elongate body that is attached to the casting surface inside the form.  
           [0003]    The present inventor has recognized a need for elongate bodies that may be used with a variety of pre-cast systems to provide panels having architectural or structural features. An additional need exists for such bodies that can be easily attached, removed, and reused.  
         SUMMARY  
         [0004]    This need is met by the present invention that provides elongate bodies for use with pre-cast panel forming systems. As used herein, pre-cast panel forming systems include any panel forming system that allows panels to be formed from a cast material that upon curing hardens, thereby allowing the panel to be subsequently placed in a desired location within a building structure.  
           [0005]    In accordance with one embodiment, an elongate body comprising a cross-section comprising a set portion, a hinged portion, and a hinge is provided. The set portion comprises a first member defining a base plane, at least a portion of which is configured to engage a panel forming surface. The set portion and the hinged portion are configured to define an engagement. The hinge couples the set portion and the hinged portion such that the hinged portion is movable about the hinge to an engaged state and disengaged state of the engagement, and one of the set portion and the hinged portion define a first beveled edge extending away from the base plane. The elongate body may comprise an extruded member, and the elongate body may comprise a substantially uniform extruded cross-section extending along substantially the entire length of the elongate body. In an engaged state, the first beveled edge may intersect the base plane.  
           [0006]    In accordance with another embodiment, the elongate body may also have, in an engaged state, the hinged portion defining a face plane opposite the base plane, the first beveled edge defined by the set portion, the first beveled edge defined by the set portion extending away from the base plane toward the face plane, and the hinged portion further comprising a second beveled edge extending away from the base plane toward the face plane. The first and second beveled edges may comprise inwardly canted edges, and the first and second beveled edges may intersect the base plane. The hinge may be located proximate to the face plane. The hinged portion may further comprise a second member along the face plane between the first and second beveled edges.  
           [0007]    In accordance with yet another embodiment, the elongate body may also have, in an engaged state, the set portion further comprising a first sidewall extending away from the first member of the set portion and a second sidewall extending away from the first member of the set portion, the first beveled edge defined by the set portion, the first beveled edge defined by the set portion extending away from the base plane to a portion of the first sidewall of the set portion displaced from the base plane, the hinged portion further comprising a second member extending from a portion of the first sidewall of the set portion displaced from the base plane to a portion of the second sidewall of the set portion displaced from the base plane and a second beveled edge extending away from the base plane to a portion of the second sidewall of the set portion displaced from the base plane.  
           [0008]    The hinge may be located proximate to the second member of the hinged portion or adjacent to the first sidewall along the second member of the hinged portion. The engagement may comprise an inwardly extending portion and an outwardly extending portion. The inwardly extending portion may extends from a portion of the second sidewall displaced from the base plane, and the outwardly extending portion of the engagement may extend from the second member such that the inwardly and outwardly extending portions are capable of being engaged. The inwardly extending portion may extend from a portion of the second beveled edge displaced from the base plane, and the outwardly extending portion may extend from the second member such that the inwardly and outwardly extending portions are capable of being engaged.  
           [0009]    In accordance with a further embodiment, the elongate body may also have, in an engaged state, the set portion further comprising a first sidewall extending away from the first member of the set portion, the first beveled edge defined by the set portion, and the first beveled edge extending away from the base plane to a portion of the first sidewall of the set portion displaced from the base plane. The hinged portion may further comprise a second member extending away from a portion of the first sidewall of the set portion displaced from the base plane, a second sidewall extending from the second member of the hinged portion to the first member of the set portion, and a second beveled edge extending away from the base plane to a portion of the second sidewall of the hinged portion displaced from said base plane. The hinge may be located proximate to the second member of the hinged portion or adjacent to the first sidewall of the set portion along the second member of the hinged portion.  
           [0010]    The engagement may comprise an inwardly extending portion and an outwardly extending portion. The outwardly extending portion may extend from a portion of the second sidewall proximate to the base plane, and the inwardly extending portion may extend from the first member of the set portion such that the inwardly and outwardly extending portions are capable of being engaged. The inwardly extending portion may extend from a portion of the second sidewall proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.  
           [0011]    In accordance with another embodiment, the elongate body may also have, in an engaged state, the hinged portion further comprising a first sidewall extending away from the first member, the first beveled edge defined by the hinged portion, and the first beveled edge extending from the first member to a portion of the first sidewall displaced from the base plane. The hinge may be located proximate to said first member of said set portion.  
           [0012]    The engagement may comprise an inwardly extending portion and an outwardly extending portion, and the hinge may be located proximate to the first member along the first sidewall. The inwardly extending portion may extend from a portion of the first beveled edge proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.  
           [0013]    The hinge may be located proximate to the first member along the first beveled edge of the hinged portion, and the engagement may comprise an inwardly extending portion and an outwardly extending portion. The inwardly extending portion may extend from a portion of the first sidewall proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.  
           [0014]    In accordance with another embodiment, the elongate body may also have, in an engaged state, the set portion further comprising a first sidewall extending away from the first member, the first beveled edge defined by the hinged portion, and the first beveled edge extending from the first member to a portion of the first sidewall opposite the base plane. The hinge may be located adjacent to the first sidewall of the set portion. The hinge may be located adjacent to a portion of the first sidewall opposite the base plane along the first beveled edge, and the engagement may comprise an inwardly extending portion and an outwardly extending portion. The inwardly extending portion may extend from the first beveled edge proximate to the base plane, and the outwardly extending portion may extend from the first member such that the inwardly and outwardly extending portions are capable of being engaged.  
           [0015]    In accordance with another embodiment, a method of manufacturing a pre-cast panel is provided. The method comprises configuring an elongate body comprising a cross-section comprising a set portion, a hinged portion, and a hinge wherein: the set portion comprises a first member defining a base plane, at least a portion of which is configured to engage a panel forming surface; the set portion and the hinged portion are configured to define an engagement; the hinge couples the set portion and the hinged portion such that the hinged portion is movable about the hinge to an engaged state and disengaged state of the engagement; and one of the set portion and the hinged portion define a first beveled edge extending away from the base plane. The method comprises placing the elongate body on the panel forming surface, pouring pre-cast material at least around the elongate body while said pre-cast material is in an uncured state, curing said pre-cast material, removing the elongate body from the panel forming surface. The method may further comprise securing the elongate body to the panel forming surface prior to pouring the pre-cast material. The elongate body may be secured to the panel forming surface with the engagement disengaged, and the engagement may be subsequently engaged.  
           [0016]    In accordance with another embodiment, a pre-cast panel forming system is provided. The system comprises at least one pre-cast panel form having a length and at least one elongate body for use with the said at least one pre-cast panel form. The elongate body comprises a cross-section comprising a set portion, a hinged portion, and a hinge. The set portion comprises a first member defining a base plane, at least a portion of which is configured to engage a panel forming surface. The set portion and the hinged portion are configured to define an engagement, and the hinge couples the set portion and the hinged portion such that the hinged portion is movable about the hinge to an engaged state and disengaged state of the engagement. One of the set portion and the hinged portion define a first beveled edge extending away from the base plane, and the elongate body has a length configured to be less than the length of the at least one pre-cast panel form. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0017]    The following detailed description of the preferred embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:  
         [0018]    FIGS.  1 A- 1 D are cross-sectional views of elongate bodies in accordance with one aspect of the present invention.  
         [0019]    FIGS.  2 A- 2 C are cross-sectional views of elongate bodies in accordance with another aspect of the present invention.  
         [0020]    [0020]FIG. 3 is a cross-sectional view of an elongate body in a disengaged state in accordance with the present invention.  
         [0021]    [0021]FIG. 4 is a cross-sectional view of an elongate body in a casting operation in accordance with the present invention.  
         [0022]    [0022]FIG. 5 is a partial top view of a pre-cast panel forming system in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]    The present invention is directed toward elongate bodies for use with pre-cast panel forming systems. The elongate bodies may be used to provide architectural or structural features in pre-cast panels.  
         [0024]    Referring to FIGS.  1 A- 1 D and  2 A- 2 C, several embodiments of an elongate body  10  are illustrated in cross-section in an engaged state. The body  10  has a set portion  12 , a hinged portion  14 , and a hinge  16 . The elongate body  10  of the present invention may be manufactured in an extrusion process and, as such, may comprise an extruded cross-section extending along its entire length. The elongate body may be formed from any plastic material but is preferably formed from extricable plastic materials because the design of the present invention is well-suited for manufacture by an extrusion process. Preferred materials include polyvinyl chloride (PVC), low or high-density polyethylene or polypropylene, acrylics, polycarbonates, and thermoplastic elastomers. As will be appreciated by those familiar with the art of extrusion, an extruded member defines a substantially uniform extruded cross-section that extends along substantially the entire length of the member.  
         [0025]    Referring to FIGS.  1 A- 1 D, several embodiments of the elongate body  10  are illustrated. The set portion  12  has a first member  18 , and first member  18  defines a base plane  20 . At least a portion of the first member  18  is configured to engage a panel forming surface. The hinge  16  couples set portion  12  and hinged portion  14 . The set portion  12  and hinged portion  14  are configured to define an engagement  24 , and the hinged portion  14  is movable about the hinge  16  to an engaged state and disengaged state of the engagement. The set portion  12  may define a first beveled edge  22  extending away from the base plane  20 , and the first beveled edge  22  may intersect the base plane  20 .  
         [0026]    The hinged portion  14  may define a face plane  28  opposite the base plane  20 , and the first beveled edge  22  defined by the set portion may extend away from the base plane  20  toward the face plane  28 . The hinged portion  14  may have a second beveled edge  34  extending away from the base plane  20  toward the face plane  28 . The first and second beveled edges  22 ,  34  may be inwardly canted edges as shown in FIGS.  1 A- 1 D, and the first and second beveled edges  22 ,  34  may intersect the base plane  20 .  
         [0027]    The hinged portion  14  may have a second member  26  that extends along the face plane  20 . The set portion  12  may have a first sidewall  30  extending away from said first member  18 . The first beveled edge  22  may extend to a portion of the first sidewall  30  displaced from the base plane  20 .  
         [0028]    The hinge  16  may be formed in any suitable manner. For example, the hinge  16  may comprise relatively pliant portions of the extruded cross section and the set portion  12  and hinged portion  14  may define relatively rigid portions of the cross section. In this manner, hinge  16  comprises a living hinge formed with the set portion  12  and the hinged portion  14 . For the purposes of defining and describing the present invention, it is noted that a living hinge may be bent multiple times without breakage or fracture of the hinge material. Living hinges may be formed from soft, flexible thermoplastic elastomers that exhibit high endurance to flexural fatigue. Although the hinge  16  is shown along the second member  26  adjacent to the first sidewall  30 , it will be understood by those having skill in the art at that hinge  16  may be formed in any suitable position that allows the hinged portion  14  to be moved into an engaged and disengaged state of the engagement  24 . For example, the hinge  16  may be proximate to the face plane  28 .  
         [0029]    Referring to FIGS. 1A and 1B, the set portion  12  may also have a second sidewall  32  extending away from the first member  18 . The second beveled edge  34  may extend to a portion of the second sidewall  32  displaced from the base plane  20 . The engagement  24  may have inwardly extending portions and outwardly extending portions, and the inwardly and outwardly extending portions may be formed in a variety of positions. An inwardly extending portion extends generally towards a central axis of elongate body  10 , and an outwardly extending portion extends generally away from a central axis of elongate body  10 .  
         [0030]    For example, as shown in FIG. 1A, the inwardly extending portion  36  of the engagement  24  extends from a portion of the second sidewall  32  of the set portion  12  displaced from the base plane  20 , and the inwardly extending portion  36  extends generally towards a central axis of elongate body  10 . The outwardly extending portion  38  of the engagement  24  extends from the second member  26  of the hinged portion  14  such that the inwardly extending portion  36  and the outwardly extending portion  38  are capable of being engaged as shown in FIG. 1A. The outwardly extending portion  38  extends generally away from a central axis of elongate body  10 . Alternatively, as shown in FIG. 1 b,  the inwardly extending portion  40  of the engagement  24  extends from a portion of the second beveled edge  34  of the hinged portion  14  displaced from the base plane  20 . The outwardly extending portion  42  of the engagement  24  extends from the second sidewall  32  at the set portion  12  such that the inwardly extending portion  40  and the outwardly extending portion  42  are capable of being engaged as shown in FIG. 1B.  
         [0031]    Referring to FIGS. 1C and 1D, the hinged portion  14  may also have a second sidewall  33  extending away from the first member  18 . The second beveled edge  34  may extend to a portion of the second sidewall  33  displaced from the base plane  20 . The engagement  24  may have an inwardly extending portion and an outwardly extending portion, and inwardly and outwardly extending portion may be formed in a variety of positions.  
         [0032]    For example, referring to FIG. 1C, the engagement  24  may have an inwardly extending portion  44  extending from a portion of the second sidewall  33  of the hinged portion  14  proximate to the base plane  20 . The engagement  24  may have an outwardly extending portion  46  extending from the first member  18  of the set portion  12  such that the inwardly extending portion  44  and the outwardly extending portion  46  are capable of being engaged as shown in FIG. 1C. Alternatively, referring to FIG. 1D, the engagement  24  may have an outwardly extending portion  50  extending from a portion of the second sidewall  33  of the hinged portion  14  proximate to the base plane  20 . The engagement  24  may have an inwardly extending portion  48  extending from the first member  18  of the set portion  12  such that the inwardly extending portion  48  and outwardly extending portion  50  are capable of being engaged as shown in FIG. 1D.  
         [0033]    Referring again to FIG. 1D, the elongate body  10  may have a fastening area or areas  52  provided in the first member  18 . For example, the fastening areas  52  may be grooves formed in the first member  18  in order to allow fasteners such as nails or screws (not shown) to be more easily driven through the first member  18  to secure the elongate body  10  to a panel forming area. It will be understood by those having skill in the art that the fastening areas may be provided in the first member  18  and  18   a  of the elongate bodies shown in FIGS.  1 A- 1 D and  2 A- 2 C.  
         [0034]    Referring to FIG. 3, the elongate body  10  illustrated in FIG. 1A is shown with the engagement  24  in a disengaged state. Thus, the hinged portion  14  is movable about the hinge  16  to an engaged state and disengaged state of the engagement  24 . When the engagement  24  is in a disengaged state, the first member  18  may be exposed in order to allow the first member  18  to be fastened to a panel forming surface. Subsequently, the engagement  24  may be engaged in order to allow the elongate body  10  to be used to form architectural features in pre-cast panels. It will be understood that the elongate bodies illustrated in FIGS.  1 B- 1 D may be similarly engaged and disengaged about the engagement  24 .  
         [0035]    Referring to FIGS.  2 A- 2 C, alternative embodiments of the elongate body  10  are illustrated. The set portion  12  has a first member  18   a,  and the first member  18   a  defines a base plane  20 . At least a portion of the first member  18   a  is configured to engage a panel forming surface. The hinge  16  couples the set portion  12  and the hinged portion  14 . The set portion  12  and the hinged portion  14  are configured to define an engagement  24 , and the hinged portion  14  is movable about the hinge  16  to an engaged and disengaged state of the engagement  24  as described above in conjunction with the embodiments illustrated in FIGS.  1 A- 1 D. The hinged portion  14  may define a first beveled edge  22   a  that extends away from the base plane  20 .  
         [0036]    Referring to FIGS.  2 A- 2 B, the hinged portion  14  may further define a first sidewall  31  extending away from the first member  18   a.  The first beveled edge  22   a  may extend from the first member  18   a  of the set portion  12  to a portion of first sidewall  31  of the hinged portion  14  displaced from the base plane  20 . The hinge  16  may be located proximate to the first member  18   a  of the set portion  12 . For example, as shown in FIG. 2A, the hinge  16  may be located proximate to the first member  18   a  of the set portion  12  along the first sidewall  31  of the hinged portion  14 . Alternatively, as shown in FIG. 2B, the hinge  16  may be located proximate to the first member  18   a  of the set portion  12  along the first beveled edge  22   a  of the hinged portion  14 . It will be understood by those having skill in the art that the exact location of the hinge may be changed so long as the engagement  24  may be engaged and disengaged effectively.  
         [0037]    The engagement  24  may have an inwardly extending portion and an outwardly extending portion, and inwardly and outwardly extending portion may be formed in a variety of positions. For example, as shown in FIG. 2A, the engagement  24  may have an inwardly extending portion  56  extending from a portion of the first beveled edge  22   a  of the hinged portion  14  proximate to the base plane  20 . The engagement  24  may have an outwardly extending portion  54  extending from the first member  18   a  of the set portion  12  such that the inwardly extending portion  56  and the outwardly extending portion  54  are capable of being engaged as shown in FIG. 2A. Alternatively, as shown in FIG. 2B, the engagement  24  may have inwardly extending portion  58  extending from a portion of the first sidewall  31  of the hinged portion  14  proximate to the base plane  20 . The engagement  24  may have an outwardly extending portion  60  extending from the first member  18   a  of the set portion  12  such that the inwardly extending portion  58  and the outwardly extending portion  60  are capable of being engaged as shown in FIG. 2B.  
         [0038]    Referring to FIG. 2C, the set portion  12  may further define a first sidewall  35  extending away from the first member  18   a.  The first beveled edge  22   a  may extend from the first member  18   a  of the set portion  12  to a portion of first sidewall  35  of the set portion  12  displaced from the base plane  20 . The hinge  16  may be located proximate to the first sidewall  35  of the set portion  12 . The engagement  24  may have an inwardly extending portion and an outwardly extending portion, and inwardly and outwardly extending portion may be formed in a variety of positions. For example, the engagement  24  may have an inwardly extending portion  62  extending from the first beveled edge  22   a  of the hinged portion  14  proximate to the base plane  20 . The engagement may have an outwardly extending portion  64  extending from the first member  18   a  of the set portion  12  such that the inwardly extending portion  62  and outwardly extending portion  64  are capable of being engaged as shown in FIG. 2C.  
         [0039]    [0039]FIG. 4 illustrates an elongate body  10  similar to the embodiments illustrated in FIGS. 1 a - 1   b  in a concrete casting operation. The elongate body  10  is secured to the panel forming surface  70 . The elongate body  10  may be secured to the panel forming surface  70  through conventional means, such as tape, screws, nails, rivets or a soluble glue (not shown). At least a portion of the first member  18  engages the panel forming surface  70 . For example, the elongate body  10  may be opened about the hinge  16  to a disengaged state (not shown) and nailed to the panel forming surface. The engagement  24  is subsequently engaged, and the pre-cast material is poured around at least the elongate body  10  in an uncured state and allowed to cure. Although FIG. 4 illustrates an elongate body similar those in FIGS.  1 A- 1 D, it will be understood by those having skill in the art that the elongate bodies  10  of FIGS.  2 A- 2 C may be similarly utilized.  
         [0040]    Referring to FIGS.  1 A- 1 D and  4 , the intersection of the beveled edges  22 ,  34  with the base plane  20  ensures that a generally downward-projecting load provided by the casting material  72  will force the beveled edges  22 ,  34  to laterally scrape along the panel-forming surface  70 , thus minimizing the amount of pre-cast material  72 , such as concrete, that can seep in underneath elongate body  10 . This seal between the beveled edges  22 ,  34  and the panel forming surface  70  promotes long-life, reusable elongate bodies, as the opportunity for the formation of cured/hardened casting material on the elongate body surfaces is reduced.  
         [0041]    A method of manufacturing pre-cast panels would include configuring an elongate body as described in conjunction with the embodiments herein, placing the elongate body on a panel forming surface, securing the elongate body to the surface through conventional means, such as tape, screws, nails, rivets or a soluble glue, pouring pre-cast material into a panel at least partially defined by the elongate body, curing the poured concrete, and removing the elongate body from the panel forming surface. The elongate body may be secured with the engagement disengaged and the engagement may be subsequently engaged.  
         [0042]    Referring to FIG. 5, a portion of a pre-cast panel form  80  having an elongate body  10  placed therein is illustrated. The pre-cast panel form  80  has a length L 1 . Elongate body  10  is configured to have a length L 2  that is less than the length L 1  of the pre-cast panel form  80 . Thus, the pre-cast panel form  80  and at least one elongate body  10  may form a system for forming pre-cast panels having architectural or structural features to be utilized as described above. It will be understood by those having skill in the art that more than one elongate body  10  may be utilized and that the elongate bodies  10  may be of different lengths. Additionally, the elongate bodies  10  may be configured in any desired configuration.  
         [0043]    It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification.