Abstract:
An elongate body for forming profiles in a castable material. The body includes support structure to promote dimensional stability of the body when subjected to loads imposed by the weight of the castable material. In one form, the support structure can be of a hollow, preferably extruded, construction, while in another, the entire body can be of a foamed construction. The elongate body includes a topographic feature in at least one surface such that upon formation of a precast panel that includes profiles formed by the body, the topographic feature creates a relief in portions of the profile. The relief may be in the form of a decorative design or the like. In addition, the elongate body may include enhanced sealing features and a fastening adapter to facilitate improved connection between the body and a surface upon which a precast panel is to be formed.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application is a divisional of co-pending application Ser. No. 10/453,456, filed Jun. 3, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates to a device used for creating a profile in cured concrete and other castable materials.  
         [0003]     In the construction of buildings, especially those used in commercial and industrial applications, precast panels are made from castable material, such as concrete. Precast panels are integral to the tilt-up construction process, and are commonly formed by using a panel-forming surface (such as a concrete building floor) that is coated with a release agent to define a horizontal forming surface for the wall panels. Forms for producing the concrete wall panels are then placed on the panel-forming surface in a predetermined pattern, after which reinforcing steel (such as rebar) may be positioned within the forms. When concrete is poured within the shape defined by the forms, the top edges of the forms are used as a guide for a screed to form one of the flat surfaces of the wall panels. After the concrete wall panels are cured, the forms are removed, and the panels are lifted or tilted by a crane to preferred, typically vertical, positions to form the building walls, where they can be joined to structural frames or other panels. When it is desired to form profiles, such as reveal bands, in the castable material, profile-forming strips (sometimes referred to as rustications) are placed on the panel-forming surface prior to pouring the concrete, thus allowing a shape coincident with the strip to be formed in the concrete. Typically, the strips are treated or sprayed with a concrete release agent prior to panel formation to promote separation and subsequent reuse of the strips.  
       SUMMARY OF THE INVENTION  
       [0004]     The present inventors have recognized that a limitation to prior art rustication devices is that none of them can form a decorative pattern or related design on the surface of the reveal band. Therefore, a need exists for a rustication device that can easily and efficiently place a decorative pattern on the surfaces of wall panels. In addition, the present inventors have found that a need exists for such a rustication device that can be easily secured to the panel-forming surface. The needs are met by the present invention, wherein an improved rustication device is disclosed that has applicability in tilt-up and other construction processes that utilize castable materials.  
         [0005]     According to a first aspect of the invention, an elongate body comprising a support structure, at least one upward-facing surface supported by the support structure, and a topographic feature formed on the upward-facing surface is disclosed. The upward-facing surface defines in the body a height dimension and a width dimension, while the upward facing surface and the topographic feature are configured to form a profile in a castable material. The support structure and the upward facing surface are configured to give the body a structural rigidity such that upon placement of the body onto a panel-forming surface and subsequent placement of the castable material over or around the body, the body is substantially resistant to deformation caused by the castable material. In the present context, the term “substantially” refers to features that, while in theory would be expected to exhibit exact correspondence or behavior, may in practice embody something slightly less than exact. As such, the term denotes the degree by which a quantitative value, measurement or other related representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. As such, “designed-in” deformation is permissible and is understood to not be destructive of the claim requirement. By way of example, one attribute of at least one embodiment of the structure of the present invention elongate body is that sealing edges (described below) are configured to splay under a load caused by the weight of castable material placed on or around the body. This type of deformation, having been designed into the device, would not be inconsistent with the claimed requirement, as such deformation not only does not change the basic function of the device, but is in fact consistent with it. By contrast, undue flexural or edgewise bending or surface undulations produced under the load of the castable material would be the type of deformation the present invention avoids, as such deformation, if allowed, would significantly effect the dimensions or surface properties of the body and the finished reveal band produced by that body.  
         [0006]     Optionally, the topographic feature is a decorative pattern, and more preferably, the decorative pattern is a repeating pattern. In one form, the decorative pattern is integrally formed with the upward-facing surface. As another option, the body further includes at least one downward-facing surface configured to engage the panel-forming surface. In addition, the body includes pair of laterally-spaced sidewalls that extend between the upward-facing and downward-facing surfaces. Furthermore, each of the laterally-spaced sidewalls includes a sloping wall that at least partially defines the profile formed in the castable material. In another option, at least a portion of the downward-facing surface terminates in a sealing edge. This allows the body to have enhanced sealing engagement with the panel forming surface when a load due to the presence of the castable material is over the body and the panel-forming surface. In one form, the sealing edge is substantially coplanar with an outward-facing surface of a corresponding one of the laterally-spaced sidewalls. In another, the sealing edge extends laterally beyond a plane defined by a corresponding one of the laterally-spaced sidewalls. In yet another option, a fastening adapter is coupled to at least one of the downward-facing surface or the pair of laterally-spaced sidewalls. Moreover, the fastening adapter is integrally formed with one of the pair of laterally-spaced sidewalls, and defines an aperture therein to facilitate the securing of the body to the panel-forming surface. In another form, the fastening adapter comprises at least one locking mechanism to facilitate clamping a portion of the downward-facing surface to the panel forming surface. A hinge may also be added such that it can connect the body and the fastening adapter. The hinge may comprise a line of weakness formed into the sidewall. In yet another option, the body defines a substantially trapezoidal-shaped cross section, while in still another option, the body defines a substantially triangular-shaped cross section, where more particularly a downward-facing surface in the triangular-shaped cross section terminates in a sealing edge such that upon placement of the castable material over the body and the panel-forming surface, the body exhibits enhanced sealing engagement with the panel forming surface. In one form, the fastening adapter is a base clip. Preferably, the base clip and the body comprise complementary surfaces such that a snap-fit engagement between the two may be affected. In still another option, the upward-facing surface is situated below the pair of laterally-spaced sidewalls when the body is placed on the panel-forming surface such that the upwardly-facing surface defines a valley into which the castable material may be placed.  
         [0007]     As another option, the support structure can be extruded. 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. Insignificant variations in the uniformity of the cross section due to fabrication process errors or post fabrication process steps are contemplated. For example, holes may be drilled in an extruded member in specific locations, while cuts or cutouts may be formed in the extruded member, all after the member is extruded. Also, as shown and described in the present invention, topographic features may be added to one or more surfaces of the member after it has been extruded. In yet another option, the support structure may additionally include a plurality of laterally-spaced stringers. As with the remainder of the support, the stringers may also be extruded. These stringers can enhance the structural rigidity of the body, thus making it more resistant to bending and surface undulations that otherwise may form due to the weight of the castable material. The body may further include a base clip that can be engaged with at least one of the stringers. In one form, the base clip and the at least one stringer have complementary surfaces such that a snap-fit engagement between the two may be affected. An example of such complementary surfaces can be a plurality of interlocking teeth. As an alternate to the extruded construction mentioned above, the body can be made of foamed construction. With either construction, the deformations that the body is substantially resistant to is flexural deformation, edgewise deformation and surface undulation. Both flexural and edgewise deformation are part of a larger class of bending deformation, where flexural bending is commonly along the longitudinal dimension of the device and normal to the plane defined by the lower moment of inertia, while edgewise bending is commonly along the longitudinal dimension of the device and normal to the plane defined by the higher moment of inertia. Surface undulation includes any dents, curvature, waviness or related change of shape of a discrete part of the surface of the object due to the presence of a load on the device. For example, a surface undulation in the form of a sag can be produced in a relatively unsupported part of a device when a load (such as a weight) is imparted to the device.  
         [0008]     According to another aspect of the invention, a rustication body for preparing reveal bands in the surface of a precast panel is disclosed. The rustication includes an upper surface configured to engage the surface of the panel, a lower surface configured to engage a panel-forming surface, a pair of laterally-spaced sidewall surfaces that extend between the upper and lower surfaces and a decorative pattern disposed on the upper surface, the decorative pattern configured to impart topographic features into the panel. Optional features similar to those of the previous aspect may also be included with the rustication.  
         [0009]     According to yet another aspect of the invention, a method of manufacturing a profile into a panel is disclosed. The method includes configuring an elongate body similar to that of the previously-discussed first aspect, placing the body on the panel-forming surface, introducing castable material to the body while the castable material is in an uncured state, curing the castable material and removing the body from the cured panel. In the present context, a panel is considered to be cured when the shape it assumes in its as-cast condition is sufficiently stable such that when forming devices used to define the panel are removed, the panel can maintain that shape. Optionally, the method may encompass additional steps, including securing the body to the panel-forming surface prior to the step of introducing the castable material, configuring the body to include at least one downward-facing surface to engage the panel-forming surface prior to introducing the castable material, and configuring at least a portion of the downward-facing surface to terminate in a sealing edge such that upon the introducing step, the body exhibits enhanced sealing engagement with the panel forming surface. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0010]     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:  
         [0011]      FIG. 1  is perspective view of a rustication according to an embodiment of the present invention;  
         [0012]      FIGS. 2A through 2D  illustrate examples of decorative patterns that can be used in the present invention;  
         [0013]      FIG. 3  illustrates an end view of an alternative embodiment of the present invention;  
         [0014]      FIG. 4  illustrates an end view of an alternative embodiment of the present invention;  
         [0015]      FIG. 5  illustrates an end view of an alternative embodiment of the present invention;  
         [0016]      FIG. 6  illustrates an end view of an alternative embodiment of the present invention;  
         [0017]      FIG. 7  illustrates a triangular-shaped embodiment of the present invention;  
         [0018]      FIG. 8  illustrates a trapezoidal-shaped embodiment of the present invention; and  
         [0019]      FIG. 9  illustrates a variation of the embodiment of  FIG. 8 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]     Referring initially to  FIGS. 1 and 2 A through  2 D, a rustication  10  with topographic features according one embodiment of the present invention is illustrated. The entire rustication  10  is a one-piece elongate body made from a semi-rigid plastics material such as polyvinylchloride (PVC), high density polyethylene (HDPE) or the like. In one form, rustication  10  can be made from conventional forming techniques, including extrusion. The rustication  10  includes a center section  20  and a pair of laterally-spaced sidewalls  30  that extend from the center section  20 . The center section  20  includes an upward-facing surface  22  and a downward-facing surface  24  such that the downward-facing surface  24  can be placed adjacent a panel-forming surface  1  (which is typically in the form of a smooth floor or related slab). Any conventional adhesive or fastening means can be used to secure the downward-facing surface  24  of rustication  10  to the panel-forming surface  1 . The upward-facing surface  22  of the center is opposite the downward-facing surface  24 . Center section  20  includes topographic features, in the form of a decorative pattern area  26 , where a pattern or related design can be formed in the rustication  10  so that when the concrete for the concrete wall panel is poured over the rustication  10 , the cement will harden around the decorative pattern. In one form, the pattern is embossed in the decorative pattern area  26  after the rustication  10  has been extruded, where the decorative pattern can be embossed either before or after cooling of the center section  20 . If the decorative pattern is embossed after cooling, then the center section  20  is preferably heated before the decorative pattern is embossed to promote diffusion and attendant thermal bonding. Once the concrete wall panel is lifted into place, the rustication  10  can be separated from the panel, leaving a profile of the decorative pattern area  26  cast into the panel. As shown with particularity in  FIGS. 2A through 2D , a few examples of repeating topographic features that can be placed in the decorative pattern area  26  are shown; however, it will be appreciated by those skilled in the art that numerous other suitable patterns can be made, depending on user need. The topographic features project above the plane formed by central section  20  so that a corresponding indentation is produced in the profile formed in the precast panel by rustication  10 .  
         [0021]     Each of the laterally-spaced sidewalls  30  includes an inner wall  32  and an outer wall  34 . The inner wall  32  is canted, with its surface that is configured to help define the shape of a profile formed in a precast panel extending in an upwardly-facing direction. In the present context, a surface is upwardly facing if a normal projection therefrom includes a vertically upward component. Thus, both the center section  20  (which is shown in the figure as facing the generally horizontal plane of the panel-forming surface  1 ) and the inner wall  32  (which is shown in the figure as facing 45 degrees zenith relative to the generally horizontal plane of the panel-forming surface  1 ) of sidewall  30 , are considered to be upward-facing. The outer wall  34  is disposed laterally beyond each inner wall  32 , and terminates in its downward-facing end in a sealing edge  40 . The sealing edges  40  extend below a plane defined by the downward-facing surface  24  so that, upon placement of uncured concrete in and around the rustication  10 , the weight of the concrete causes the sealing edge  40  to splay, thereby creating a seal and preventing the leakage of cement or related materials into the region between the rustication  10  and the panel-forming surface  1 . As shown, the outward-facing surface of sealing edge  40  and outer wall  34  are substantially coplanar with one another. In other configurations (shown and described below), the sealing edge  40  may extend laterally beyond the outer wall  34 . As can be seen in the figure, the lowermost portion of sealing edge  40  lies below a plane formed by downward-facing surface  24 , thus forming a gap  50  between the downward-facing surface  24  and panel-forming surface  1 . When a load is placed on rustication  10  (such as from concrete being poured over it), the center section  20  sags until contacting panel-forming surface  1 . By imparting its weight onto inner wall  32 , the load also encourages sealing edge  40  to splay, thereby improving the sealing between the panel-forming surface  1  and rustication  10 .  
         [0022]     Referring next to  FIG. 3 , a rustication  10  as described above for  FIG. 1  is provided, now modified to include both a fastening adapter  36  and a canted outer wall  34  of sidewall  30 . In this configuration, the fastening adapter  36  is integrally formed with one of the laterally-spaced sidewalls  30 . In addition, a hinge  38  is used to couple inner wall  32  to the outer wall  34 . In one form, hinge  38  can be formed from a line of weakness, such as a thinned-out portion in the surface of rustication  10 . In the alternate, the hinge  38  can be formed of a softer, more pliable plastic through co-extrusion. The hinge  38  aids in the placement of the rustication on the concrete forming surface, as the entire rustication  10  except for the outer wall  34  adjacent the fastening adapter  36  is bent upward with the help of the hinge  38 . A portion of the rustication  10  that is adjacent the fastening adapter  36  is secured to the panel-forming surface  1  by a fastener  39  (such as a screw, as shown, or nail) that is passed through a groove  37  (which could also be an aperture) defined in the top center of the fastening adapter  36 . Once the fastening adapter  36  and sealing edge  40  of the outer wall  34  are secured, the remainder of the rustication  10  is bent toward the panel-forming surface  1  by using the hinge  38 . The fastening adapter  36  includes a locking mechanism  41  so that to the downward-facing surface  24  of the center section  20  can be better secured to the panel-forming surface  1  through the fastening adapter  36  by locking the former into place with the latter. The slight outward cant of the lower portion of outer wall  34  relative to its upper portion promotes the splaying of sealing edge  40  when concrete or other uncured castable material is poured around rustication  10 . In addition, unlike the embodiment depicted in  FIG. 1 , the sealing edges  40  project laterally beyond a plane formed by the outer wall  34 . As before, the dimension of sealing edge  40  is sufficient to ensure that a gap  50  is present between downward-facing surface  24  and panel-forming surface  1  prior to concrete being poured over the rustication  10 . The dimensions of sealing edge  40  are shown exaggerated to emphasize both the downward-projecting nature of the sealing edge  40 , as well as gap  50 .  
         [0023]     Referring next to  FIGS. 4 and 5 , an alternate form of the fastening adapter  36  is shown, where, instead of being integrally formed with one of the laterally-spaced sidewalls  30  of rustication  10 , it is made of a discrete piece. This has the advantage of allowing the user to first secure the fastening adapter  36  without having other parts of the rustication  10  getting in the way. In the configuration shown with particularity in  FIG. 4 , the fastening adapter  36  has two locking mechanisms  41 , each on opposing sides. Once the fastening adapter  36  is secured to the panel-forming surface  1  (through fastener, adhesive or the like, none of which are presently shown), the outer wall  34  with the sealing edge  40  can be slid such that a detent projecting inward from the sealing edge  40  can fit underneath one of the locking mechanisms  41 , while the other locking mechanism  41  can be snapped into place. In an alternate configuration, detents from both the outer wall  34  and the downward-facing surface  24  can be snapped in place over both locking mechanisms  41 . Either or both the detents and the locking mechanisms  41  can be made to be elastically compliant to facilitate a snap-fit engagement between them; this can be accomplished through judicious material choice, component thickness, or both. Referring with particularity to  FIG. 5 , a variation of the rustication  10  shown in  FIG. 1  is provided. The rustication  10  includes a protrusion  31  that extends from the lower portion of the inner wall  32 . A fastening adapter in the form of a base clip  42  helps secure the rustication  10  to the panel-forming surface (not presently shown). The base clip  42  comprises a bottom wall  44  and a pair of laterally spaced sidewalls  46 , which have outwardly projecting teeth  48  that lock into the rustication  10  by engaging a complementary series of inwardly projecting teeth  47  of the outer wall  34  and a series of inwardly projecting teeth  47  of the protrusion  31  of the inner wall  32  such that a snap-fit engagement between base clip  42  and rustication  10  is formed. The base clip  42  includes a groove  37  that extends within the top center of the bottom wall  44 . The groove  37  can receive a fastening device  39 , such as a nail or screw, which secures the rustication  10  to the forming surface. In the alternate, groove  37  can be an aperture extending all the way through base clip  42 .  
         [0024]     Referring next to  FIG. 6 , a rustication  110  according to another embodiment of the present invention is illustrated. The entire rustication  110  is a one-piece member that can be made from extruded foam, thus revealing a porous core (internal) structure. The rustication  110  includes a center section  120  and a pair of laterally-spaced sidewalls  130  that extend from the center section  120 . The center section  120  includes an upward-facing surface  122  and a downward-facing surface  124 . The downward-facing surface  124  can rest on a panel-forming surface. The upward-facing surface  122  of the center section  120  includes a decorative pattern area  126  where a decorative pattern can be formed in the rustication  110 . Preferably during the extrusion process, a smooth, sealed out skin is formed that covers at least the upward-facing surface  122  of the center section  120  and the laterally-spaced sidewalls  130 . While the outer skin (and details related thereto) is not the subject of the present invention, the skin is relatively nonporous compared to that of a porous core such that it is substantially impenetrable to water and related liquids inherent in poured concrete. The presence of the relatively non-porous outer skin is beneficial in that it affects improved release properties upon concrete curing relative to a porous surface. To further reduce cost and weight, while still providing the requisite structural rigidity and resistance to warping, the foamed material can be polystyrene, PVC, acrylonitrile-butadiene-styrene (ABS) or related material. The foam can be either closed cell (where the majority of the cells are non-interconnecting), open cell (where many of the cells do interconnect), syntactic (where rigid microspheres are dispersed in a fluid polymer, then cured) or other conventional foamed structure. The nonporous outer skin can be an additional contributor to overall rustication rigidity. In the present context, the skin is formed from the same foamed material as that of porous core, with a higher density to promote the formation of the aforementioned liquid-resistant surface properties due to its relatively nonporous, shell-like configuration.  
         [0025]     Referring next to  FIG. 7 , a rustication  210  according to another embodiment of the present invention is illustrated. In this embodiment, its generally elongate body includes, in addition to center section  220  and laterally-spaced sidewalls  230 , a plurality of stringers  243  to enhance the resistance of rustication  210  to deformation under load. The stringers can be integrally formed with the center section  220  or the laterally-spaced sidewalls  230 , where in the latter case the stringer  243  may define an inner wall  232 . In addition, the stringers  243  can be made to form an interlocking fit with a base clip  242  to help secure rustication  210  to panel-forming surface  1 . Topographic features  226  (shown in this instance as a series of discrete decorative patterns) are added to, or formed in, upward-facing surface  222  of center section  220 . Although not presently shown, the lowermost parts of outer wall  234  can terminate in a sealing edge. As with the previous embodiments, the rustication  210  can be formed from an extruded part. Unlike the embodiment depicted in  FIGS. 1 and 3  through  6 , the uppermost part of center section  220  of rustication  210  is situated vertically higher than the sidewalls  230 .  
         [0026]     Referring next to  FIGS. 8 and 9 , two variations of a foamed rustication  310 ,  410  are shown. As with the embodiment shown in  FIG. 7 , the portion containing the topographic features  326 ,  426  is situated vertically higher than the sidewalls  330 . Gaps  350 ,  450  are formed in downward-facing surfaces  324 ,  424  so that the lowermost contact points can form sealing edges  340 ,  440 . As with the sealing edge  40  shown in  FIG. 3 , sealing edges  340 ,  440  are shown exaggerated for illustrative purposes. The triangular-shaped rustication  410  of  FIG. 9  is a degenerate trapezoid, such that the center section  320  and laterally-spaced sidewall sections  330  of the trapezoidal device of  FIG. 8  converge into an apex. Thus, the triangular-shaped rustication preserves the attributes of both the sidewalls and center section without having to form separate surface facets. This contributes to low-cost manufacturing, especially when the rustication is formed as an extruded part. It will be appreciated by those skilled in the art that other shapes may be contemplated, and that such shapes fall within the spirit of the present invention.  
         [0027]     Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.