Abstract:
Extruded brackets for use in pre-cast panel forming systems are provided. The brackets generally have first and second mounting faces, at least one support face, and miter cut edges defined by a first and second miter plane. The brackets may have more than one support face. Additionally, a pre-cast panel forming system is provided. The system generally has at least one pre-cast panel form and at least one bracket for attachment to the at least one panel form. 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 brackets for use in pre-cast panel forming systems.  
           [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 forms are generally secured to the casting surface with brackets prior to the pouring of the concrete.  
           [0003]    The present inventor has recognized a need for a bracket that may be used with a variety of pre-cast systems, including tilt-up panel forming systems. An additional need exists for such a bracket that can be easily attached, removed, and reused.  
         SUMMARY  
         [0004]    This need is met by the present invention that provides brackets 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, a bracket for supporting a pre-cast panel form is provided. The bracket comprises first and second mounting faces and a first support face extending between the mounting faces. The first and second mounting faces meet to define a longitudinal vertex of the bracket. The first support face defines first and second lateral edges and first and second longitudinal edges and extends from each of the mounting faces along the longitudinal edges, and the longitudinal edges of the first support face are generally parallel to and displaced from the longitudinal vertex. The first and second mounting faces define top edges and first and second inwardly canted lateral edges. A first miter plane is defined by the first inwardly canted lateral edge of the first mounting face, the first inwardly canted lateral edge of the second mounting face, and the first lateral edge of the first support face. A second miter plane is defined by the second inwardly canted lateral edge of the first mounting face, the second inwardly canted lateral edge of the second mounting face, and the second lateral edge of the first support face. Generally, the first and second miter planes are orthogonal. The first longitudinal edge is typically displaced from the longitudinal vertex a distance equal to a distance the second longitudinal edge is displaced from the longitudinal vertex. The bracket is generally formed from extruded plastic.  
           [0006]    The bracket typically has several nailing areas. The first mounting face may include at least one nailing area defined by the first and second inwardly canted lateral edges of the first mounting face, the top edge of the first mounting face, and the first longitudinal edge of the first support face. The second mounting faces may include at least one nailing area defined by the first and second inwardly canted lateral edges of the second mounting face, the top edge of the second mounting face, and the second longitudinal edge of the first support face. Additionally, the first mounting face may include at least one nailing area defined by the longitudinal vertex, the first longitudinal edge of the first support face, and portions of the first and second inwardly canted lateral edges of the first mounting face. The second mounting face may include at least one nailing area defined by the longitudinal vertex, the second longitudinal edge of the first support face, and portions of the first and second inwardly canted lateral edges of the second mounting face.  
           [0007]    The bracket may also have at least one additional support face. A second support face may extend between the longitudinal vertex and the first support face. The second support face defines first and second lateral edges and first and second longitudinal edges and extends from the longitudinal vertex along the first longitudinal edge and the first support face along said second longitudinal edge. Typically, the first lateral edge of the second support face extends to the first miter plane, and the second lateral edge of the second support face extends to the second miter plane.  
           [0008]    Alternatively, the bracket may have a second support face extending between the mounting faces. The second support face defines first and second lateral edges and first and second longitudinal edges and extends from each of the mounting faces along the longitudinal edges. The longitudinal edges of the second support face are generally parallel to and displaced from the longitudinal vertex. The first lateral edge extends to the first miter plane, and the second lateral edge extends to the second miter plane. The displacement of the second support face from the longitudinal vertex is a distance less than the displacement of the first support face from the longitudinal vertex. The bracket may also have a third support face extending between the longitudinal vertex and the second support face. The third support face defines first and second lateral edges and first and second longitudinal edges and extends from the longitudinal vertex along the first longitudinal edge and the second support face along the second longitudinal edge. The first lateral edge extends to the first miter plane, and the second lateral edge extends to the second miter plane. Alternatively, the third support face may extend between the first support face and the second support face. The third support face defines first and second lateral edges and first and second longitudinal edges and extends from the first support face the first longitudinal edge and the second support face along the second longitudinal edge. The first lateral edge extends to the first miter plane, and the second lateral edge extends to the second miter plane.  
           [0009]    In another embodiment, the bracket may have a second support face extending between the first mounting face the first support face and a third support face extending between the second mounting face and the first support face. The second support face defines first and second lateral edges and first and second longitudinal edges and extends from the first mounting face along the first longitudinal edge and the first support face along the second longitudinal edge. The third support face defines first and second lateral edges and first and second longitudinal edges and extends from the second mounting face along the first longitudinal edge and the first support face along the second longitudinal edge. Typically, the first lateral edge of the second support face extends to the first miter plane, and the second lateral edge of the second support face extends to the second miter plane. Additionally, the first lateral edge of the third support face may extend the first miter plane and the second lateral edge the third support face may extend to the second miter plane.  
           [0010]    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 height; and at least one bracket for attachment to the at least one panel form. The bracket comprises first and second mounting faces, and a first support face extending between the mounting faces. The first and second mounting faces meet to define a longitudinal vertex of the bracket. The first support face defines first and second lateral edges and first and second longitudinal edges and extends from each of the mounting faces along the longitudinal edges, and the longitudinal edges of the first support face are generally parallel to and displaced from the longitudinal vertex. Each of the first and second mounting faces define top edges and first and second inwardly canted lateral edges. A first miter plane is defined by the first inwardly canted lateral edge of the first mounting face, the first inwardly canted lateral edge of the second mounting face, and the first lateral edge of the first support face. A second miter plane is defined by the second inwardly canted lateral edge of the first mounting face, the second inwardly canted lateral edge of the second mounting face, and the second lateral edge of the first support face. The height of the first and second mounting face is less the height of the at least one pre-cast panel form. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0011]    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:  
         [0012]    [0012]FIG. 1 is a three dimensional view of a bracket according to the present invention.  
         [0013]    [0013]FIG. 2 is a side view of the bracket illustrated in FIG. 1.  
         [0014]    [0014]FIG. 3 is an illustration of an assembled configuration utilizing a bracket and a pre-cast form according to the present invention.  
         [0015]    FIGS.  4 - 7  illustrates additional embodiments of a bracket according to the present invention.  
         [0016]    [0016]FIG. 8 is a front view of the bracket illustrated in FIG. 4. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0017]    The present invention is directed toward a bracket for use with pre-cast panel forms. The bracket secures the forms to the casting slab prior to the formation of the pre-cast panel.  
         [0018]    Referring to FIGS. 1 and 2, a first embodiment of a bracket or support  1  is illustrated. The bracket  1  has a first mounting face  2 , a second mounting face  4 , and a first support face  6 . The bracket  1  is typically formed from a plastic material (e.g., polyvinyl chloride (PVC), low or high-density polyethylene or polypropylene, acrylics, polycarbonates, thermoplastic elastomers). Generally, the bracket  1  is a one-piece bracket. The first mounting face  2  and the second mounting face  4  meet to define a longitudinal vertex  8  of the bracket. The first mounting face  2  and the second mounting face  4  are generally perpendicular to each other and form the mounting surface of the bracket. The first mounting face  2  has a top edge  18  and first and second inwardly canted lateral edges  14   a ,  14   b . Therefore, the first mounting face  2  has a quadrilateral shape formed by the longitudinal vertex  8 , the first and second inwardly canted lateral edges  14   a ,  14   b , and the top edge  18 . The inwardly canted lateral edges  14   a ,  14   b  slope inward from the longitudinal vertex  8  to the top edge  18 . Therefore, an interior angle of less than 90° is formed between the first inwardly canted lateral edge  14   a  and the longitudinal vertex  8 . Similarly, an interior angle of less than 90° is formed between the second inwardly canted lateral edge  14   b  and the longitudinal vertex. Generally the interior angles formed between the first and second inwardly canted lateral edges  14   a ,  14   b  and the longitudinal vertex  8  will be about 45°. Generally, the bracket  1  will be about four to eight inches wide (10.16 cm to 20.32 cm) from one end of the longitudinal vertex  8  to the other.  
         [0019]    Similarly, the second mounting face has a top edge  20  and first and second inwardly canted lateral edges  16   a ,  16   b . Therefore, the second mounting face  4  has a quadrilateral shape formed by the longitudinal vertex  8 , the first and second inwardly canted lateral edges  16   a ,  16   b , and the top edge  20 . The inwardly canted lateral edges  16   a ,  16   b  slope inward from the longitudinal vertex  8  to the top edge  20 . Therefore, an interior angle of less than 90° is formed between the first inwardly canted lateral edge  16   a  and the longitudinal vertex  8 . Similarly, an interior angle of less than 90° is formed between the second inwardly canted lateral edge  16   b  and the longitudinal vertex  8 . Generally the interior angles formed between the first and second inwardly canted lateral edges  16   a ,  16   b  and the longitudinal vertex  8  will be about 45°.  
         [0020]    Referring to FIGS. 1 and 2, the bracket  1  also has a first support face  6  extending between the first mounting face  2  and the second mounting face  4 . The first support face  6  has first and second lateral edges  10   a ,  10   b  and first and second longitudinal edges  12   a ,  12   b . The first support face extends from the first mounting face  2  and the second mounting face  4  along the longitudinal edges  12   a ,  12   b . The longitudinal edges  12   a ,  12   b  are generally parallel to the longitudinal vertex  8 , and the longitudinal edges  12   a ,  12   b  are displaced from the longitudinal vertex  8 . Typically, the first longitudinal edge  12   a  is displaced from the longitudinal vertex  8  by a distance equal to a distance the second longitudinal edge  12   b  is displaced from the longitudinal vertex  8 .  
         [0021]    The bracket  1  may be formed through a conventional extrusion process, and, as such define an extrudable cross-section. For the purposes of defining and describing the present invention, it is noted that a structural member defines an extrudable cross-sectional profile if respective cross sections of the member, taken along a length or width-wise axis of the member, each define substantially identical dimensions. In which case, the member defining the extrudable profile may be produced by an extrusion process where a semi-soft plastic is forced through the orifice of an extrusion die to produce a continuously formed piece having a cross-sectional shape defined by the orifice or other shaping members down line of the orifice. It is contemplated that a structural member having an extrudable cross-sectional profile may also include portions along its axis that are subject to post extrusion cutting, drilling, bending, deforming, etc.  
         [0022]    Referring to FIG. 1, it is noted that the bracket  1  may be extruded along an extrusion axis E. Extrusion axis E lies along longitudinal vertex  8 , and longitudinal vertex defines a longitudinal dimension of the bracket. Specifically, the bracket  1  may define an extrudable cross-sectional profile spaced along an extrusion axis E. Referring to FIGS. 1 and 2, it is noted that the end portions of the bracket  1  are provided with miter-cuts to form miter-cut edges that extend all the way across the extrudable cross-sectional profile. The cross-sectional profile of the bracket  1  has a shape that is generally that of a right triangle along a portion the longitudinal dimension defined between the miter cut edges of the end portions. The first support face  6  defines the hypotenuse of the right triangle while the first and second mounting faces  2 ,  4  define the other two sides. The hypotenuse of the right triangle may be recessed from the edges defined by the first and second mounting faces  2 ,  4 .  
         [0023]    A first and second miter plane may define the miter-cut edges. A first miter plane is shown in FIG. 1 as being defined by reference lines  100   a ,  102   a , and  104   a . Line  100   a  is defined along the first inwardly canted lateral edge  14   a  of the first mounting face. Line  102   a  is defined along the first inwardly canted lateral edge  16   a  of the second mounting face  4 . Line  104   a  is defined along the first lateral edge  10   a  of the first support face  6 ,  2 . A second miter plane is shown in FIG. 1 as being defined by reference lines  100   b ,  102   b , and  104   b . Line  100   b  is defined along the second inwardly canted lateral edge  14   b  of the first mounting face  2 . Line  102   b  is defined along the second inwardly canted lateral edge  14   b  of the first mounting face  2 . Line  104   b  is defined along the second lateral edge  10   b  of the first support face  6 . The first miter plane and the second miter plane may be orthogonal to each other or may be oriented to define any other suitable angle of intersection.  
         [0024]    Referring to FIGS. 1, 2, and  3 , the bracket  1  typically includes several nailing areas through which nails or other fasteners may be driven to attach the bracket  1  to the pre-cast form  42  and the panel forming slab  40 . The bracket typically has nailing areas  22  and  24  that are located near the top edges  18 ,  20  of the first and second mounting faces  2 ,  4 . Nailing area  22  is defined by the first and second inwardly canted lateral edges  14   a ,  14   b  of the first mounting face  2 , the top edge  18  of the first mounting face  2 , and the first longitudinal edge  12   a  of the first support face  6 . Typically, the distance between the first longitudinal edge  12   a  of the first support face  6  and the top edge  18  of the first mounting face  2  will be about ⅝ to ¼ inch (1.60 cm to 0.64 cm). Similarly, nailing area  24  is defined by the first and second inwardly canted lateral edges  16   a ,  16   b  of the second mounting face  4 , the top edge  20  of the second mounting face  4 , and the second longitudinal edge  12   b  of the first support face  6 . The distance between the second longitudinal edge  12   b  of the first support face  6  and the top edge  18  of the second mounting face  4  will generally be about ⅝-¼ inch.  
         [0025]    The bracket additionally has nailing areas  26  and  28  that are located near the inwardly canted lateral edges  14   a ,  14   b ,  16   a ,  16   b  of the first and second mounting faces  2 ,  4 . Nailing area  26  is defined by the longitudinal vertex  8 , the first longitudinal edge  12   a  of the first support face  6 , and portions of the first and second inwardly canted lateral edges  14   a ,  14   b  of the first mounting face  2 . Nailing area  28  is defined by the longitudinal vertex, the second longitudinal edge  12   a  of the first support face  6 , and portions of the first and second inwardly canted lateral edges  16   a ,  16   b  of the second mounting face  4 . Nailing areas  26  and  28  are located on the first and second mounting faces  2 ,  4  in the areas below the first and second miter planes  100   a ,  100   b . Nailing areas  26  and  28  are easily accessible for nailing during installation of the brackets because they are exposed beneath the first and second miter planes.  
         [0026]    Referring to FIGS. 1 and 3, the bracket  1  is used to attach the pre-cast panel form  42  to the casting surface  40  in an upright configuration. The pre-cast panel form  42  is generally made from dimensional lumber or other wooden products. The pre-cast panel form  42  may also be made from a variety of plastic materials such as an extruded plastic. The pre-cast panel form  42  is placed on the casting slab  40  and bracket  1  is attached to the pre-cast panel form  42  and the casting slab  40  to hold the form  42  in place prior to the formation of a pre-cast panel. The first mounting face  2  of the bracket  1  is attached to the form  42 , and the second mounting face  4  is attached to the casting slab  40 . However, the second mounting face  4  could be attached to the form  42 , and the first mounting face  2  could be attached to the casting slab  40 . By attaching the form  42  to the slab  40  with the bracket  1 , the form  42  may be oriented securely perpendicular to the casting slab  40  or may be oriented to define any other suitable angle. The height of the first and second mounting faces  2 ,  4  is generally less than the height of the pre-cast panel form  42 . Typically, the first and second mounting faces will be about six inches tall. Several forms  42  and brackets  1  are generally used to form a pre-cast panel. The bracket  1  is attached to the slab  40  and the form  42  by utilizing fasteners such as nails. The fasteners are typically placed through nailing areas  22 ,  24 ,  26 , and  28 . However, not all of the nailing areas must be utilized. After the formation of the panel, the pre-cast form  42  and the bracket  1  are removed. The bracket  1  may be reused during the formation of another pre-cast panel.  
         [0027]    Referring to FIGS.  1 - 7 , the bracket  1  may have at least one additional support face. The additional support faces add structural stability to the bracket  1  and allow the bracket to resist twisting and bending when subjected to stress. In one embodiment shown in FIGS.  1 - 3 , a second support face  30  extends between the longitudinal vertex  8  and the first support face  6 . The second support face has lateral edges  30  and first and second longitudinal edges  32   a ,  32   b . The second support face  30  extends from the longitudinal vertex  8  along first longitudinal edge  32   a  to the first support face  6  along said second longitudinal edge  32   b . Generally, the lateral edges  30  extend to the first and second miter planes respectively.  
         [0028]    Referring to FIGS. 4 and 8, the bracket  1  may alternatively have a second support face  50  extending between the first mounting face  2  and the second mounting face  4 . The second support face  50  has lateral edges  52  and first and second longitudinal edges  54   a ,  54   b . The first and second longitudinal edges  54   a ,  54   b  are generally parallel to and displaced from the longitudinal vertex  8 . The displacement of the second support face  50  from the longitudinal vertex  8  is less than the displacement of the first support face  6  from the longitudinal vertex  8 . The lateral edges  52  generally extend to the first and second miter planes respectively.  
         [0029]    Referring to FIG. 5, the bracket  1  may additionally have a third support face  56  extending between the longitudinal vertex  8  and the second support face  50 . The third support face  56  has a first longitudinal edge  58   a, a  second longitudinal edge  58   b , and lateral edges  60 . The third support face  56  extends from the longitudinal vertex  8  the first longitudinal edge  58   a , and the third support face  56  extends from the second support face along the second longitudinal edge  58   b . The lateral edges  60  generally extend to the first and second miter planes respectively.  
         [0030]    Referring to FIG. 6, the bracket  1  may alternatively have a third support face  62  extending between the second support face  50  and the first support face  6 . The third support face  62  has first and second longitudinal edges  64   a ,  64   b  and lateral edges  66 . The third support face  62  extends from the second support face  50  along the first longitudinal edge  64   a . The third support face  62  extends from the first support face  6  along the second longitudinal edge  64   b . The lateral edges  66  extend to the first and second miter planes respectively.  
         [0031]    Referring to FIG. 7, a bracket  1  with alternative second  68  and third  74  support faces is shown. The second support face  68  has lateral edges  72  and first and second longitudinal edges  70   a ,  70   b . The second support face  68  extends between the first mounting face  2  and the first support face  6 . The second support face  68  extends from the first mounting face  2  along the first longitudinal edge  70   a . The second support face  68  extends from the first support face  6  along the second longitudinal edge  70   b . The second support face  68  is shown as having an interior angle of less than 90° with respect to the first mounting face  2 . However, this angle may be adjusted to be greater than, less than, or equal to 90°. The third support face  74  extends between the second mounting face  4  and the first support face  6 . The third support face  74  has first and second longitudinal edges  76   a ,  76   b  and lateral edges  78 . The third support face  74  extends from the second mounting face  4  along the first longitudinal edge  76   a , and the third support face  74  extends from the first support face  6  along the second longitudinal edge  76   b . The third support face  74  is shown as having an interior angle of less than 90° with respect to the second mounting face  4 . However, this angle may be greater than, less than, or equal to 90°. The lateral edges  72  of the second support face  68  and the lateral edges  78  of the third support face  74  generally extend to the first and second miter planes respectively.  
         [0032]    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.