Abstract:
An interconnecting alignment and support system for supporting and maintaining alignment of at least one conduit or pipe is disclosed. The system may be used, for example, during a concrete pour operation or other construction operation. The system comprises a base spacer and, optionally, one or more of an intermediate spacer and/or another base spacer. The base spacer is constructed to be capable of interlocking with another spacer on each side and the top. The intermediate spacer is constructed to be capable of interlocking with another spacer on each side and both the top and bottom. The interlocks on the spacers may be releasably latched when fully interlocked. By interlocking the spacers, a matrix structure for aligning and supporting conduit or pipe may be created. The base spacer is attachable to a surface, so that the alignment and support system may be fixed in place.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority under 35 USC §19(e) to U.S. Provisional Patent Application Ser. No. 60/620,688, titled “Latching Mechanism”, filed on Oct. 22, 2004, which is hereby incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates generally to an alignment and support apparatus for aligning and supporting conduit and the like during a construction operation. More specifically, this invention relates to an interlocking and latching alignment and support apparatus that keeps conduit and the like supported and aligned during a concrete pour operation.  
       BACKGROUND  
       [0003]     Many building structures, such as foundations, floors, ceilings, walls, and the like, include a concrete slab having conduit, pipes and the like embedded therein. Form boards are typically used to provide the desired shape of concrete slab. Concrete is poured into the form, and once set, the form is removed to reveal a concrete slab with conduit, pipes and the like embedded therein. It is very important that the conduits and/or pipes do not move during the concrete pouring operation so that the conduit or pipes remain in a known location according to the building plans.  
         [0004]     For this reason, various apparatus and methods are employed in the construction art to support a desired configuration of pipes until the concrete (e.g. for a foundation) is poured and has had sufficient time to set or harden, thereby saving space by embedding the pipe work and the like in the concrete. Traditionally, for example, the outside bases of conduit spacers are fixed to the ground with, for example, rebar, with the remaining pieces of conduit not being attached. This allows the sections attached to the base section to move during concrete pouring which disassembles the horizontal connections.  
         [0005]     For example, lengths of rebar are driven into the ground and sections of pipe are taped to the rebar to provide structural support to the conduit configuration. Because the rebar and tape are typically removed prior to the pouring of concrete so that footers may be dug, the conduits or pipes will often sag prior to the concrete pour operation, and unless repositioned will result in a plumbing or wiring configuration that is permanently crooked when later embedded in cured concrete.  
         [0006]     Sagging or displacement often results in a poor pipe work configuration that causes pipe leaks, water pressure problems, and drainage issues all of which are best avoided by maintaining proper support and alignment of pipe work and the like both prior to and during a concrete pour operation. Sagging or displacement during pour often results in a poor or undesirable electrical conduit configuration, with conduit located incorrectly relative to building specifications. Other problems may result from displaced, incorrectly located, or sagging conduits and pipes.  
       SUMMARY  
       [0007]     Thus, an exemplary aspect of this invention includes interlocks with latches that allow the assembly to act as one rigid body preventing the bank of components from moving and/or collapsing upon itself. Through the use of an easily latched and unlatched interlock mechanism, the spacers can be assembled and/or disassembled to provide a sturdy, rigid structure.  
         [0008]     An exemplary aspect of the invention relates to a latch concept for conduit spacers. In particular, an exemplary embodiment of the invention relates to an integral latch that restricts the conduit spacers from moving vertically with respect to each other. If the conduit spacers do not include a vertically restraining latch, the conduit spacers could float during, for example, pouring of concrete.  
         [0009]     The components illustrated herein can be scaled to any size as well as made from any material or combination of materials including, but not limited to, plastics, composites, metals, and alloys. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0010]      FIG. 1  is a front elevation view of an exemplary embodiment of a base spacer in accordance with the present invention;  
         [0011]      FIG. 2  is a side elevation view of a receiving interlock side of the base spacer of  FIG. 1 ;  
         [0012]      FIG. 3  is a side elevation view of a positive interlock side of the base spacer of  FIG. 1 ;  
         [0013]      FIG. 4  is a front elevation view showing two exemplary base spacers that have been interlocked side-by-side with each other;  
         [0014]      FIG. 5  is a top view of the base spacer of  FIG. 1 ;  
         [0015]      FIG. 6  is an expanded partial view of the side interlock joint shown in  FIG. 4  showing an exemplary interlock latching mechanism in detail;  
         [0016]      FIG. 7  is a bottom view of the base spacer of  FIG. 1 ;  
         [0017]      FIG. 8  is a front elevation view of an exemplary embodiment of an intermediate spacer in accordance with the present invention;  
         [0018]      FIG. 9  is a side elevation view of a positive interlock side of the intermediate spacer of  FIG. 8 ;  
         [0019]      FIG. 10  is a side elevation view of a receiving interlock side of the intermediate spacer of  FIG. 8 ;  
         [0020]      FIG. 11  is a front elevation view showing two base spacers interlocked in an opposing arrangement; and  
         [0021]      FIG. 12  is a front elevation view showing two base spacers interlocked on opposite ends of an intermediate spacer. 
     
    
       [0022]     Like reference symbols in the various drawings indicate like elements.  
       DETAILED DESCRIPTION  
       [0023]     The terms “conduit” and “pipe” are used interchangeably in this specification. Further, it should be appreciated that the present invention may be used to support and align other elongate articles beyond conduits, pipes and the like. The terms “device”, “apparatus”, and “spacer” are used interchangeable herein.  
         [0024]     The terms “top”, “bottom”, and “sides” are used in the specification to describe the various views of the figures. It should be appreciated that in actual use, an embodiment of the invention may be rotated either horizontally or vertically in order to assemble a support and alignment structure. And, as a result of such rotation, the descriptive terms may not literally apply to a particular construction. In other words, the various terms of “top”, “bottom”, “base” and the like are relative and are used here to describe the figures for illustration purposes and are not intended to limit the embodiments shown to any particular orientation.  
         [0025]     Referring to  FIG. 1 , the exemplary base spacer  10  comprises a body  12  having a middle portion  14 , a positive interlock side  16 , a receiving interlock side  18 , a bottom  20  and a top  22 . The base spacer body  12  also has a front  24  and a back  26  (shown in  FIGS. 2 and 3 ).  
         [0026]     The middle portion  14  of the base spacer body  12  is disposed between the two sides ( 16  and  18 ) and the top  22  and bottom  20 . The middle portion  14  may be formed as a solid member or as a member that is partially open. The middle portion  14  may optionally be formed with one or more stiffening ribs  28  that may increase the load bearing capacity of the base spacer  10  and may serve to reduce twisting or flexing by the base spacer  10 .  
         [0027]     Referring to  FIGS. 1 and 3 , the exemplary positive interlock side  16  includes a positive side projection  30  extending outwardly from the side of the base spacer body  12 . The positive side projection  30  is adapted to slidably engage the receiving interlock side  18  of another base spacer. The positive side projection  30  is widest at the outermost side and tapers inwardly to become narrower nearest the base spacer body (this tapering can be best seen in  FIG. 5 , which is a top view of the base spacer of  FIG. 1 ). The positive side projection  30  is nearly the same height as the side of the base spacer. In an alternative exemplary embodiment, the positive side projection  30  comprises a plurality of vertically spaced segments, instead of a continuous single piece. The base spacer includes a latch member  32  disposed near the bottom of the positive interlock side  16  and extending outwardly at a substantially ninety degree angle from the positive interlock side  16 . The latch member  32  may be integral with the positive side projection, or may be a separate member not integral with the positive side projection. Other latch member angles could be used.  
         [0028]     The middle portion  12  of the base spacer body is recessed slightly from the side and from the bottom of the positive side projection  30 , and extending toward the top of the spacer to approximately one-quarter of the way up from the bottom of the positive side projection  30 . This recess provides a gap  34  between the positive side projection  30  and the middle portion  14  of the base spacer body  12 . The positive side projection  30  is also narrower over the gap  34  than at the rest of the projection, as can be seen in the positive side elevation view of  FIG. 3  at the portion of the positive side projection  30  indicated by reference number  36 .  
         [0029]     Referring to  FIG. 1 , the gap  34  between the positive side projection  30  and the middle portion  14  of the base spacer  10  permits the positive side projection  30  to flex inwardly as the positive side projection  30  engages the receiving side  18  of another spacer. This inward flex accommodates the latch member  32  which extends outwardly. Once the base spacer  10  is fully interlocked side-by-side with another spacer, the latch member  32 , under tension from being inwardly flexed, will extend outwardly into a recess  38  on the receiving side of the other spacer and form a latching mechanism between the two spacers. Two base spacers that have been interlocked side-by-side are shown in  FIG. 4 , described below.  
         [0030]     Referring to  FIGS. 1 and 2 , the exemplary receiving side  18  of the base spacer includes a plurality of projections  40  for receiving and engaging the positive interlock side projection  30  of another base spacer. Together with the positive side projection  30 , the plurality of receiving side projections  40  form a partially open dovetail-like interlocking joint when assembled. The plurality of receiving side projections  40  are disposed and distributed along the receiving side  18  from top to bottom. A number of the projections are disposed toward the front of the base spacer ( 42  in  FIG. 2 ) and a number of the projections are disposed toward the rear of the base spacer ( 44  in  FIG. 2 ). It should be appreciated that while a specific number of projections are illustrated, any number of projection(s) can be used.  
         [0031]     Referring to  FIG. 2 , the front and rear projections ( 42  and  44 ) oppose each other to form a channel in which the positive side projection of another spacer ( 46 , dashed line) can slide into engage. The front and rear receiving side projections ( 42  and  44 ) taper from narrow at the outside to wider on the inside near the base spacer body. This tapering gives the receiving side channel an opposite shape from the positive side projection and allows the positive side projection to engage and interlock with the receiving side of another base spacer.  FIG. 2  shows the arrangement of receiving side projections on the base spacer of  FIG. 1 . A positive side projection is shown in  FIG. 2  by a dashed line and indicates where a positive side projection would be located when fully interlocked and in place.  
         [0032]     Two base spacers are engaged in a top to bottom, or opposed interlocking manner when the positive side projection is slid in place and is fully interlocked when the latch  32  of the positive side projection  30  reaches the bottom of the receiving side  18  and engages the recess  38  provided thereon. Again, a fully interlocked and latched arrangement of two base spacers is shown in  FIG. 4 . The latching mechanism is shown in greater detail in  FIG. 6 .  
         [0033]     Referring to  FIG. 1 , the top  22  of the base spacer  10  includes a conduit recess  48  for receiving a conduit, pipe or in general any elongate article and/or the recessed portion may be left empty. For example, the conduit recess  48  may be formed as a concave semicircle such that a conduit may be placed on top of the base spacer and will rest in the recess. The conduit recess  48  may be formed having a different size or radius depending on the contemplated use of the invention and the size of the conduit or pipe to be aligned and supported. Further, the conduit recess  48  may be formed having a shape to conform to a cross-sectional shape of a conduit, pipe or other elongate article that has a cross-sectional shape other than semicircular. In an exemplary embodiment not shown, a plurality of recesses could be formed permitting a single spacer to support multiple conduits.  
         [0034]     Still referring to  FIG. 1 , the top  22  of the exemplary base spacer  10  includes two vertical interlock members each disposed on the top of the base spacer near a side. A positive vertical interlock member  50  is disposed on the top near the positive interlock side  16  and extends in an upward vertical direction from the base spacer body  12 , the positive vertical interlock member  50  for inserting and interlocking with a receiving vertical interlock member  52  of another base spacer. The positive vertical interlock member  50  includes a series of angled protrusions  54  on each side.  
         [0035]     A receiving vertical interlock member  52  is disposed on the top near the receiving interlock side  18  and includes a recess  56  extending in a downward vertical direction into the base spacer body  12 , the recess  56  for receiving a positive vertical interlock member  50  of another base spacer. The recess  56  is lined on each side with a series of angled protrusions  58 , followed a section  60  having no angled protrusions. The receiving vertical interlock member includes a tab  61  extending away from the recess  56 .  
         [0036]     When two base spacers are interlocked in a vertically opposed manner, with one base spacer on the bottom and one base spacer on the top (as shown in  FIG. 11 ), the two spacers are oriented such that the positive vertical interlock member  50  of the bottom base spacer is aligned with the receiving vertical interlock member  52  of the top base spacer. And, the receiving vertical interlock member  52  of the bottom base spacer is aligned with the positive vertical interlock member  50  of the top base spacer.  
         [0037]     As mentioned above, both the receiving and the positive vertical interlock members ( 52  and  50 ) include a series of angled protrusions ( 58  and  54 ) extending from both side surfaces of both interlock members. These angled protrusions ( 58  and  54 ) create an interlocking and latching mechanism when a positive vertical interlock member  50  is inserted into a receiving vertical interlock member  52 . As a positive vertical interlock member  50  is inserted into a receiving vertical interlock member  52 , each angled protrusion engages and interlocks with a next angled protrusion, until, when fully assembled, each angled protrusion has engaged and interlocked with an angled protrusion on an opposing vertical interlock member, as shown in  FIG. 11 . The vertical interlocks are easily releasable by inserting a screwdriver, or other suitably thin instrument into the recess  56  and opening the receiving vertical interlock enough so that the angled protrusions on the positive vertical interlock member and the receiving vertical interlock member disengage, thus permitting the vertical interlock members to be released from each other.  
         [0038]     Referring to  FIGS. 2 and 3 , the bottom of the exemplary base spacer body includes a support member  62  that extends from the front  24  and back  26  of the base spacer body  12  in a plane perpendicular to the front  24  and back  26  of the base spacer body  12 . The support member  62  forms a stabilizing platform such that the base spacer  10  may be placed on a flat, level surface and stand upright without being supported by any other apparatus. The support member  62  optionally includes one or more reinforcing ribs  64  disposed on each side and joining the support member  62  and the base spacer body  12 . The reinforcing ribs  64  are adapted to strengthen and stabilize the support member  62  relative to the base space body  12 . The support member  62  may optionally include holes (shown in  FIG. 7 ) extending from a top surface of the support member to a bottom surface of the support member. The holes may be adapted and constructed to allow a fastener to be inserted through the support member  62  and into an underlying surface, such that the base spacer  10  may be secured in place during a construction operation. Even without holes in the support member  62 , a piercing fastener, such as a nail may be used to affix the support member  62  to an underlying surface. The support member  62  may be narrower in a middle portion and wider at the sides, as shown in  FIG. 7 . When a plurality of base spacers, each having holes in their respective support members, is interlocked it may be advantageous to use fasteners in only some of the holes to attach the base spacers to an underlying surface. Because the base spacers are interlocked and latched, the base spacers which do not have fasteners will still remain in place.  
         [0039]      FIG. 4  is a front elevation view showing two exemplary base spacers that have been interlocked side-by-side with each other. Specifically, a first base spacer  400  is interlocked in a side-by-side manner with a second base spacer  402 . Two base spacers are interlocked by sliding the sides together to engage the positive side projection of one base spacer with a receiving side projection of another base spacer. The latching mechanism  404  is shown in greater detail in  FIG. 6  and described below. The latching mechanism is easily releasable by inserting a screwdriver, or other thin instrument, between the positive side projection  30  and the receiving interlock side  18 , at a point near the latch member  32  and moving the latch member toward the recess  34  to disengage the latch member  32  from the recess  38 .  
         [0040]      FIG. 5  is a top view of the exemplary base spacer of  FIG. 1 . In particular, an exemplary support member  62  extends from the front  24  and back  26  of the base spacer body  12  in a plane perpendicular to the front  24  and back  26  of the base spacer body  12 .  
         [0041]      FIG. 6  is an expanded partial view of the side interlock joint shown in  FIG. 4  showing an exemplary interlock latching mechanism in detail. It can be better seen in  FIG. 6  how the latch member  32  of the positive side projection  30  engages the recess  38  on the receiving side  18 . The positive side projection  30  slidably engages the receiving side projections  40  to create a partially open dovetail-like joint.  
         [0042]      FIG. 7  is a bottom view of the exemplary base spacer of  FIG. 1 . In particular, an exemplary embodiment of a support member  62  includes holes  702  for inserting fasteners through the support member  62  and into an underlying surface. The support member  62  also includes a middle portion  704  that is narrower than the two end portions.  
         [0043]      FIG. 8  is a front elevation view of an exemplary embodiment of an intermediate spacer in accordance with the present invention. In particular, an intermediate spacer  80  comprises a body  82  having a middle portion  84 , a positive interlock side  86 , a receiving interlock side  88 , a bottom  90  and a top  92 . The intermediate spacer body  82  also has a front  94  and a back  96  (shown in  FIGS. 9 and 10 ).  
         [0044]     The middle portion  84  of the intermediate spacer body  82  is disposed between the two sides ( 86  and  88 ) and the top  92  and bottom  90 . The middle portion  84  may be formed as a solid member or as a member that is partially open. The middle portion  84  may optionally be formed with one or more stiffening ribs  98  that may increase the load bearing capacity of the intermediate spacer  80  and may serve to reduce twisting or flexing by the intermediate spacer  80 .  
         [0045]     Referring to  FIGS. 8 and 9 , the exemplary positive interlock side  86  includes a positive side projection  100  extending outwardly from the side of the intermediate spacer body  82 . The positive side projection  100  is adapted to slidably engage the receiving interlock side  98  of another intermediate spacer. The positive side projection  100  is widest at the outermost side and tapers inwardly to become narrower nearest the base spacer body (this tapering is similar to that shown for the positive side projection  30  in  FIG. 5 , which is a top view of the base spacer of  FIG. 1 ). The positive side projection  100  is nearly the same height as the side of the intermediate spacer and is optionally tapered at each end.  
         [0046]     Referring to  FIGS. 8 and 10 , the exemplary receiving side  88  of the intermediate spacer includes a plurality of projections  110  for receiving and engaging the positive interlock side projection  1000  of another intermediate spacer. Together with the positive side projection  100 , the plurality of receiving side projections  110  form a partially open dovetail-like interlocking joint when assembled. The plurality of receiving side projections  110  are disposed and distributed along the receiving side  88  from top to bottom. A number of the projections are disposed toward the front of the base spacer ( 112  in  FIG. 10 ) and a number of the projections are disposed toward the rear of the base spacer ( 114  in  FIG. 10 ). It should be appreciated that while a specific number of projections are illustrated, any number of projection(s) can be used.  
         [0047]     Referring to  FIG. 10 , the front and rear projections ( 112  and  114 ) oppose each other to form a channel in which the positive side projection  100  of another spacer can slide in to engage the receiving side  88 . The front and rear receiving side projections ( 112  and  114 ) taper from narrow at the outside to wider on the inside near the intermediate spacer body. This tapering gives the receiving side channel an opposite shape from the positive side projection and allows the positive side projection to engage and interlock with the receiving side of another intermediate spacer.  FIG. 10  shows the arrangement of receiving side projections on the intermediate spacer of  FIG. 8 .  
         [0048]     Referring to  FIG. 8 , the top  92  and bottom  90  of the intermediate spacer  80  includes conduit recesses  118 , each having a radius R, for receiving a conduit, pipe or in general any elongate article and/or the recessed portions may be left empty. For example, the conduit recesses  118  may be formed as a concave semicircle such that a conduit may be placed on top and bottom of the intermediate spacer and will rest in the recesses. The conduit recesses  118  may be formed having a different size or radius depending on the contemplated use of the invention and the size of the conduit or pipe to be aligned and supported. Further, the conduit recesses  118  may be formed having a shape to conform to a cross-sectional shape of a conduit, pipe or other elongate article that has a cross-sectional shape other than semicircular. In an exemplary embodiment not shown, a plurality of recesses could be formed permitting a single spacer to support multiple conduits.  
         [0049]     Still referring to  FIG. 8 , the top  92  and bottom  90  of the exemplary intermediate spacer  80  includes two vertical interlock members disposed on each of the top and bottom of the intermediate spacer near a side. A positive vertical interlock member  120  is disposed on the top near the positive interlock side  86  and extends in an upward vertical direction from the intermediate spacer body  82 . Another positive vertical interlock member  120  is disposed on the bottom near the receiving interlock side  88  and extends in an downward vertical direction from the intermediate spacer body  82 . The positive vertical interlock members  120  for inserting and interlocking with receiving vertical interlock members  122  of other spacers. The positive vertical interlock member  120  includes a series of angled protrusions  124  on each side.  
         [0050]     A receiving vertical interlock member  122  is disposed on the top near the receiving interlock side  88  and includes a recess  126  extending in a downward vertical direction into the intermediate spacer body  82 , the recess  126  for receiving a positive vertical interlock member  120  of another spacer. Another receiving vertical interlock member  122  is disposed on the bottom near the positive interlock side  86  and includes a recess  126  extending in a upward vertical direction into the intermediate spacer body  82 , the recess  126  for receiving a positive vertical interlock member  120  of another spacer. The recesses  126  are lined on each side with a series of angled protrusions  128 , followed a section  130  having no angled protrusions. The receiving vertical interlock member  122  also includes a tab  131  extending away from the recess  126 .  
         [0051]     When two intermediate spacers are interlocked in a vertically opposed manner with another intermediate spacer or a base spacer, for example, with one base spacer on the bottom and one base spacer on the top (as shown in  FIG. 12 ), the two spacers are oriented such that the positive vertical interlock member  120  of one intermediate spacer is aligned with the receiving vertical interlock member  122  of another intermediate spacer (or the receiving vertical interlock member  52  of a base spacer). And, the receiving vertical interlock member  122  of one intermediate spacer is aligned with the positive vertical interlock member  120  of another intermediate spacer (or the positive vertical interlock member  50  of a base spacer).  
         [0052]     As mentioned above, both the receiving and the positive vertical interlock members ( 122  and  120 ) include a series of angled protrusions ( 128  and  124 ) extending from both side surfaces of both interlock members. These angled protrusions ( 128  and  124 ) create an interlocking and latching mechanism when a positive vertical interlock member  120  is inserted into a receiving vertical interlock member  122 . As a positive vertical interlock member  120  is inserted into a receiving vertical interlock member  122 , each angled protrusion engages and interlocks with a next angled protrusion, until, when fully assembled, each angled protrusion has engaged and interlocked with an angled protrusion on an opposing vertical interlock member, as shown in  FIG. 12 . The vertical interlocks are easily releasable by inserting a screwdriver, or other suitably thin instrument into the recess  126  and opening the receiving vertical interlock enough so that the angled protrusions on the positive vertical interlock member and the receiving vertical interlock member disengage, thus permitting the vertical interlock members to be released from each other.  
         [0053]      FIG. 11  is a front elevation view showing two base spacers interlocked in an opposing arrangement. In particular, a first base spacer  140  is interlocked in a vertically opposed arrangement with another base spacer  142 . The description of the vertical interlocks may be found above in the description of  FIG. 1 . A circular conduit support and alignment opening  144  is created by the interlocked base spacers.  
         [0054]      FIG. 12  is a front elevation view showing two base spacers interlocked on opposite ends of an intermediate spacer. In particular, a first base spacer  150  is vertically interlocked with an intermediate spacer  152 , which is in turn vertically interlocked with another base spacer  154 . This configuration of an intermediate spacer and two base spacers creates a first conduit opening  156  and a second conduit opening  158 .  
         [0055]     It should be appreciated that base spacers and intermediate spacers of the present invention may be arranged in various configurations according to a contemplated uses of the invention.  
         [0056]     Base spacers and/or intermediate spacers of the present invention can be made of any suitable material such as a plastic, metal, alone or in combination, or formed of a composite material. For example, the spacers shown in  FIGS. 1 and 8  can be made of molded plastic in one piece by an injection molding process. Alternatively, the spacers may be individually made of a metal such as lightweight aluminum, copper or steel, or made of, for example, ABS plastic (ABS, acrylonitrile-butadiene-styrene) or PVC (polyvinylchloride), or other plastic. If made of metal, the spacers may be formed by pressing, stamping, casting, or other technique suitable to form spacers in accordance with the present invention. If made of metal, the spacers may be covered in a suitable coating to prevent unwanted interactions between the spacers and metal pipes or conduits made of a dissimilar metal. Alternatively, the spacers may be made principally of a metal but with some parts made of plastic. Suitable plastics include (but are not limited to): reinforced molded plastic, PVC and ABS, for example.  
         [0057]     As is apparent from the above description and the figures referenced therein, there is provided an interconnecting alignment and support system with latching mechanism in accordance with the present invention. While this invention has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be, or are, apparent to those of ordinary skill in the applicable arts. Accordingly, applicant intends to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of this invention.