Abstract:
A deck connector that may be cast into a structural concrete element for use in joining adjacent ones of the concrete elements to each other by the use of weld plates that are movably disposed within a weld plate housing forming an element of each of the deck connectors.

Description:
PRIORITY CLAIM 
     Applicants claim the benefit of their prior Provisional Application, Ser. No. 60/727,175, filed Oct. 14, 2005, and titled IMPROVED DECK CONNECTOR. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an improved construction for deck connectors. The connectors of this invention basically comprise a metal piece that is cast into the edge of a concrete slab or tee, and a void is provided and defined by a box disposed behind the connector in the slab and communicating with a slot formed through the face of the connector. A plate dowel is movably disposed within the box, through the slot formed in the connector whereby adjacent concrete structural members may be joined by welding opposed plate dowels. 
     2. Description of the Prior Art 
     In the construction industry the use of flange connectors for the purpose of connecting adjacent concrete slabs and wall panels is certainly well-known. One early example of such prior art devices is provided in U.S. Pat. No. 3,958,954, to Ehlenbeck. According to the teaching of that patent, the connector is embedded along the edges of concrete members, and is formed of sheet metal that includes an elongated central portion which is exposed for the purpose of welding adjacent connectors on opposed panels. 
     Yet another form of such a connector is taught in U.S. Pat. No. 5,402,616, to Klein. Still another teaching in the patent literature is provided by U.S. Pat. No. 6,185,897, to Johnson, et al. All three of the prior art devices identified in the above patents provide a substantially flat metal surface exposed on the edge of the concrete element and a pair of angularly-extending legs into the concrete element, those legs extending back into the concrete from the exposed planar weldment face. The actual connection between adjacent slabs and connectors is performed by either welding the exposed faces to each other, or, more commonly, inserting a bar or slug between the faces and accomplishing the welding connection. 
     The prior art also teaches that the use of plate dowels between such concrete structures may be advantageous in that such plate dowels may be inserted into a pocket so that the slabs may move horizontally to minimize the size and number of restraint cracks. However, the prior art neither discloses nor suggests any structure whereby the utility of a plate dowel may be combined with state-of-the-art connectors. 
     It is therefore clear that an improved deck connector, suitable for use in combination with a form of plate dowel, would represent a significant improvement in the construction of various structures utilizing precast/prestressed slabs and wall panels. Of course, for purposes of economy and utility, any such improved connector must be suitable for installation as the slabs are formed and easily accessible as the structure is erected. For purposes of safety, the connections formed using the improved connector must satisfy all applicable codes and standards. 
     SUMMARY OF THE INVENTION 
     The present invention relates to an improved deck connector of the type used in the construction industry for joining adjacent concrete structures in an edge-to-edge or edge-to-vertical relationship. The improved connector basically comprises a bent metal anchor that is embedded into the concrete structural element as it is formed. The connector further comprises a plastic box or housing that receives a metal weld plate, preferably having a pull tab attached thereto. The invention further comprises a void former that is held over the exposed surface of the metal connector as the concrete element is formed. The void former is preferably held in place by magnets and is removed for use, as more fully set forth hereinafter. 
     The invention accordingly comprises the features of construction, combination of elements, and arrangement of part which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: 
         FIG. 1  is a front elevation view of the bent metal anchoring device, with the flat metal weld plate indicated in broken lines. 
         FIG. 2  is a top plan view illustrating placement of the improved connector within a concrete slab and including reinforcing mesh and anchor bars. 
         FIG. 3  is a right side view of the improved deck connector of this invention. 
         FIG. 4  is a side view of a preferred embodiment for the metal weld plate. 
         FIG. 5  is a top plan view of the weld plate of  FIG. 4 , and shows the addition of a pull tab. 
         FIG. 6  is as top plan view of the top half of the weld plate box or housing, depicting internal ridges in broken lines. 
         FIG. 7  is an inside plan view of the bottom half of the weld plate box or housing. 
         FIG. 8  is a front elevation of the void former. 
         FIG. 9  is a rear elevation of the void former. 
     
    
    
     Similar reference characters refer to similar parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     A preferred embodiment for the improved deck connector of this invention is shown in drawing  FIGS. 1-9 . The invention basically comprises a bent metal anchoring device, generally indicated as  10  in the views of  FIGS. 1-3 . A plastic box or housing, generally indicated as  12  in the views of  FIGS. 2 ,  6  and  7 , is provided rearwardly of the anchoring device  10 , and a flat metal weld plate, generally indicated as  14  in the views of  FIGS. 4 and 5 , is mounted within box  12 . Finally, a void former, generally indicated as  16  in the views of  FIGS. 2 ,  8  and  9 , is removably attachable to the front of anchoring device  10 . 
     Attention is first invited to the view of  FIG. 2 , wherein the improved deck connector of this invention is shown as it might be typically placed within a concrete slab as the slab is formed. Metal anchoring device  10  may be stamped and formed from a sheet of metal stock, preferably steel. The anchoring device  10  includes a substantially planar front face  18  having a rectangular opening  20  formed therein. On each side of front face  18  the metal stock is split to form four legs, defined by upper legs  22  and  24  and lower legs  26  and  28 . As indicated in the views of  FIGS. 1 and 2 , each of the upper legs  22  and  24  are bent rearwardly from front face  18  to define an angle of about 50 degrees with respect to the plane defined by front plate front face  18 . Each of the lower legs  26  and  28  are similarly bent rearwardly, and preferably define an angle of about 95 degrees with respect to the plane defined by front face  18 . In the view of  FIG. 2  one can see that all legs  22 ,  24 ,  26  and  28  are further formed in a wave-like manner. Finally, at the distal end of each of the legs  22 - 28  a leg aperture  30  is formed. 
     Both the angular orientation of legs  22 - 28  and the wave-like bending of each of those legs significantly enhance the security of anchoring device  10  within the concrete slab. Additional security of anchoring device  10  within the concrete may be accomplished by the insertion of reinforcing bars  32  through opposed leg apertures  30  in the upper legs  22  and  24 , and the opposed leg apertures  30  in each of the lower legs  26  and  28 . However, the use of reinforcing bars  32  is considered optional. 
     The plastic box or housing  12  is also shown in the view of  FIG. 2 , and is disposed on the back side of front face  18 . Referring to the views of  FIGS. 6 and 7 , it can be seen that the box  12  is preferably formed from a top half, generally indicated as  34  in the view of  FIG. 6 , and a bottom half generally indicated as  36  in the view of  FIG. 7 . Box  12  is preferably formed from plastic and each of the halves  34  and  36  comprise opposed, mating male tabs  38  and female receivers  40  whereby the halves  34  and  36  may be snapped together. One can also see that each of the halves  34  and  36  include a plurality of ridges  42  formed on the interior thereof. Finally, a box opening  44  is provided, and box opening  44  is in registry with rectangular opening  20  formed in front face  18  of anchoring device  10 . Attention is invited to the fact that box opening  44  is centered on the face of box  12  and is smaller than the horizontal dimension (width) defined by the interior of box  12 . 
     Movably mounted within box  12  is weld plate  14 . As clearly seen in the view of  FIG. 5 , weld plate  14  defines a horizontal dimension (width) at its rear edge  46  that is greater than the horizontal dimension (width) defined by beveled front edge  48 . Rear edge  46  is wider than the corresponding width of box opening  44 , and beveled front edge  48  is slightly less than the corresponding dimension of box opening  44 . Thus, beveled front edge  48  of weld plate  14  may be withdrawn from box  12 , using pull tab  50 , thereby extending outwardly from box  12  and through rectangular opening  20  to position beveled front edge  48  of weld plate  14  for its intended use of connecting to an adjacent anchoring device  10  in an adjacent concrete structure. Pull tab  50  would then simply be removed. 
     The provision of the ridges  42  on the interior of box  12  serves as guides or runners for weld plate  14 . The substantially T-shape of weld plate  14  prevents its removal from anchoring device  10 , while still permitting adjustment of its position with respect to an adjacent anchoring device  10  in a second concrete structure to which attachment is desired. The beveled structure defined by front edge  48  of weld plate  14  further enhances the ease with which a connection can be made. It is to be understood that a welding slug or bar is not required, but may be used. It is also to be understood that, for purposes of economy, the opposed anchoring device in the second concrete structure may be constructed to define a continuous front face, having no rectangular opening  20 , no box or housing  12 , and no weld plate  14 . That second device would, however, include upper legs  22  and  24  and lower legs  26  and  28  as described above. If such a modified anchoring device were used, in the second concrete structure, weld plate  14  as described above could be welded directly to the modified front face of the modified anchoring device. 
     While the preferred method of connecting adjacent anchoring devices is by welding opposed weld plates  14  as described above, or by welding weld plate  14  to the modified face of the modified anchoring device, other means for accomplishing the connection are also contemplated. For example, the front edge of opposed weld plates may be modified to define correspondingly opposed relieved portions, or steps such that opposed modified weld plates would actually overlap each other when withdrawn from their respective boxes  12  for attachment. Physical attachment could then be accomplished by welding, or even by the placement of bolts through apertures formed in the opposed ledges. 
     Referring once again to the view of  FIGS. 2 and 3 , it should be noted that leg apertures  30  are preferably of an oval configuration and that each of the upper legs  22  and  24  are preferably disposed above reinforcing mesh  52  while lower legs  26  and  28  are preferably disposed below reinforcing mesh  52 . 
     According to known forming techniques, it is necessary to “protect” what will be the exposed front face  18  of anchoring device  10  as the concrete is poured and allowed to set. This “protection” is accomplished by the use of void former  16 . Referring to the view of  FIG. 8 , one can see that void former front face  54  comprises opposed, substantially U-shaped ridges  56  thereon. While attachment of void former  16  to anchoring device  10  may be accomplished by any suitable, standard means for removal after the structure has been formed, the preferred attachment is by placing magnets within the area defined by U-shaped ridges  56 . 
     Clearly, then, the improved deck connector of this invention represents a significant advance over the current state of the art. The structure of metal anchoring device  10  enhances the “capture” of the connector within the concrete structure, particularly if reinforcing bars  32  are utilized. Box or housing  12  into which the weld plate  14  is mounted is easily assembled because of its two-part, snap-together structure, and the shape of weld plate  14  literally eliminates the possibility of the plate being lost by falling out during transportation or installation. Furthermore, because weld plate  14  is free to move on the ridges  42  formed within box  12 , the connector of this invention is suitable for use across joints of from about zero (0) to about 1.5 inches in width. Even once the connection has been made, weld plate  14  may still “move” to accommodate expansion and contraction of the joined structure without transferring stress to the concrete. Finally, because the weld plate  14  does not come into contact with either surrounding concrete or anchoring device  10 , heat resulting from the welding operation more easily dissipates and is not directly transferred to the structure. This significantly reduces the likelihood of cracking or splintering during the connection process. While it may be viewed as relatively minor, the addition of the removable pull tab  50  to weld plate  14  significantly enhances the ease with which the weld plate  14  may be withdrawn for connection. Finally, the utility of the improved deck connector of this invention is enhanced by the fact that anchoring device  10  may be formed using known cutting and stamping techniques from flat stock and that box or housing  12  may be formed with extreme economy by plastic molding. 
     It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. 
     Now that the invention has been described,