Patent Publication Number: US-11649649-B2

Title: Concrete form apparatus and method of using

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Application No. 62/791,560, entitled “CONCRETE FORM APPARATUS,” filed Jan. 11, 2019, the content of which is incorporated herein by reference in its entirety for all purposes. 
    
    
     FIELD OF INVENTION 
     The described embodiments relate generally to concrete form apparatuses—and extension apparatus to bind them together—that can be utilized to establish a rigid perimeter within which concrete can be poured for curing. 
     BACKGROUND 
     Wooden planks—e.g., 2×4&#39;s, 2×6&#39;s, etc.—are commonly used to establish a rigid perimeter within which concrete can be poured for curing. However, there are several drawbacks to using wooden planks that have yet to be addressed. A first drawback is that the price of wood has considerably increased over the years. Another drawback is that wood is heavy, thereby making it expensive to transport. Yet another drawback is that wood is prone to warping, thereby limiting the supply of wood that can be used to reliably form straight concrete perimeters. A further drawback is that the wood usually must be discarded after the concrete is formed, which is wasteful. 
     Accordingly, what is needed is an improved approach for establishing a rigid perimeter within which concrete can be poured for curing. 
     SUMMARY 
     Representative embodiments described herein set forth concrete form apparatus that can be utilized to establish a rigid perimeter within which concrete can be poured for curing. According to some embodiments, the concrete form apparatus can be formed using two distinct components. The first component can be composed of a flat rigid material that is rectangular in shape and includes perforations along the lengthwise dimension of the material. In this regard, when the material is folded along the perforations, an internal cavity is formed. The second component can be composed of a material having dimensions sized in accordance with the internal cavity of the folded material. In this regard, the second component can be placed onto the first component, whereupon the first component can be folded along the perforations in the manner described above to encapsulate the second component within the internal cavity. Adhesive layers can be applied to prevent the concrete form apparatus from separating. Additionally, the exposed layers of the concrete form apparatus can be coated with a waterproofing substance to reduce the permeability of the exposed layers. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings that illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, where like reference numerals designate like structural elements. 
         FIGS.  1 A- 1 C  illustrate conceptual diagrams of a first approach for implementing a concrete form apparatus, according to some embodiments. 
         FIGS.  2 A- 2 C  illustrate conceptual diagrams of a second approach for implementing a concrete form apparatus, according to some embodiments. 
         FIGS.  3 A- 3 C  illustrate conceptual diagrams of a third approach for implementing a concrete form apparatus, according to some embodiments. 
         FIGS.  4 A- 4 B  illustrate conceptual diagrams of different approaches for implementing extension apparatuses that can be used to bind two or more concrete form apparatuses, according to some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Representative applications of methods and an apparatus according to the presently described embodiments are provided in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments can be practiced without some or all of these specific details. In other instances, well-known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments can be used, and changes can be made without departing from the spirit and scope of the described embodiments. 
       FIG.  1 A  illustrates a conceptual diagram  100  of a first approach for implementing a concrete form apparatus, according to some embodiments. Specifically,  FIG.  1 A  illustrates a high-level overview of two different components that can be utilized to establish the concrete form apparatus, which, as shown, can include a wrap layer  102  and a core  110 . According to some embodiments, the wrap layer  102  can be composed of any material, including cardboard, paperboard, fiberboard, matboard, chipboard, and so on. It is noted that the wrap layer  102  can also be reinforced using any known approach. For example, the wrap layer  102  can incorporate any number of layers of the same (or other) materials to increase overall rigidity (e.g., single face board, single wall board, double wall board, triple wall board, and so on). The wrap layer  102  can also incorporate internal structures that increase overall rigidity, including corrugated structures (e.g., C, B, E, F, and R flute structures), honeycomb structures, and so on. It is noted that the foregoing examples do not represent an exhaustive list of the different materials and reinforcements that can be incorporated into the wrap layer  102 . On the contrary, any known materials and reinforcements can be incorporated into the wrap layer  102  without departing from the scope of this disclosure. 
     As shown in  FIG.  1 A , the wrap layer  102  can include perforations  104  that enable the wrap layer  102  to be folded in a manner that establishes a cavity within the wrap layer  102 . It is noted that the perforations  104  can be established using any known approach. In one approach, a series of holes, slices, etc., can be introduced along a lengthwise dimension of the wrap layer  102  to enable the wrap layer  102  to be folded. For example, as shown in  FIG.  1 A , four perforations  104  can be established along the lengthwise dimension of the wrap layer  102  to enable the wrap layer  102  to be folded into a rectangular shape such that two of the longer edges of the wrap layer  102  overlap one another. An example of the wrap layer  102  in folded form is illustrated in  FIGS.  1 B- 1 C  and described below in greater detail. 
     Additionally, as shown in  FIG.  1 A , the wrap layer  102  can include several extension inlets  106  that enable an extension apparatus to bind two or more of the concrete form apparatuses together. According to some embodiments, the extension inlets  106  can represent cavities within the wrap layer  102  that align with extension outlets on the extension apparatus when the concrete form apparatus is in a completed state, which is illustrated in  FIG.  1 C  and described below in greater detail. It is noted, however, that such extension inlets  106  are optional and can be omitted from the wrap layer  102  for applications that do not require the utilization of extension apparatuses. 
     Additionally, as shown in  FIG.  1 A , the concrete form apparatus can include a core  110  that is sized in accordance with the wrap layer  102 , the perforations  104 , and the extension inlets  106 . In particular, the core  110  can be sized in accordance with the cavity that is formed when the wrap layer  102  is folded along the perforations  104 . In this regard, when the extension inlets  106  are not included in the wrap layer  102 , the length of the core  110  can match the length of the wrap layer  102 . Alternatively, when the extension inlets  106  are included in the wrap layer  102 , the length of the core  110  can be shorter (relative to the length of the wrap layer  102 ) so that the extension inlets  106  remain internally exposed within the concrete form apparatus. This notion is illustrated in  FIG.  1 C , which is described below in greater detail. 
     According to some embodiments, the core  110  can be composed of any material, including cardboard, paperboard, fiberboard, matboard, chipboard, and so on. According to some embodiments, the core  110  can be formed by layering any of the foregoing materials together using any known technique for adhering the layers together to achieve the desired shape of the core  110 . Additionally, one or more of the layers can also be reinforced using any known approach. For example, a given layer can incorporate any number of layers of the same (or other) materials to increase overall rigidity (e.g., single face board, single wall board, double wall board, triple wall board, and so on). The core  110  can also incorporate internal structures that increase overall rigidity, including corrugated structures (e.g., C, B, E, F, and R flute structures), honeycomb structures, and so on. Alternatively, the core  110  can be composed of any type of foam, either in whole or in part. It is noted that the foregoing examples do not represent an exhaustive list of the different materials and reinforcements that can be incorporated into the core  110 . On the contrary, any known materials and reinforcements can be incorporated into the core  110  without departing from the scope of this disclosure 
     As shown in the conceptual diagram  125  of  FIG.  1 B , the core  110  can be wrapped within the wrap layer  102  as it is folded along the perforations  104 . Although not explicitly illustrated in  FIGS.  1 A- 1 B , it is noted that any form of adhesive can be applied to any portion of the wrap layer  102  and/or core  110  without departing from the scope of this disclosure. For example, an adhesive layer can be applied to one or more sides of the core  110 , an adhesive layer can be applied to one or more of the (internal) sides of the wrap layer  102  that contact the core  110 , and so on. Additionally, it is noted that an adhesive layer can be applied to one or more of the two long edges of the wrap layer  102  that overlap one another to ensure that the wrap layer  102  does not unravel. This notion is illustrated in  FIG.  1 B  by the adhesive layer  116 . In this regard, the wrap layer  102 , the core  110 , and the adhesive layer(s) can work together to form an assembled unit  112  that exhibits a level of rigidity that enables it to function as a concrete form. 
     Additionally, the conceptual diagram  150  in  FIG.  1 C  illustrates another view of the assembled unit  112 . In particular, the conceptual diagram  150  covers a scenario in which the extension inlets  106  are included in the wrap layer  102 , and where the length of the core  110  is shorter (relative to the length of the wrap layer  102 ) so that the extension inlets  106  remain exposed within the assembled unit  112 . 
     Accordingly,  FIGS.  1 A- 1 C  illustrate conceptual diagrams of a first approach for implementing a concrete form apparatus, according to some embodiments.  FIGS.  2 A- 2 C —which set forth a second approach for implementing a concrete form apparatus—will now be discussed below in greater detail. 
       FIG.  2 A  illustrates a conceptual diagram  200  of a high-level overview of two different components that can be utilized to establish a concrete form apparatus, which, as shown, can include a wrap layer  202  and a core  210 . According to some embodiments, the wrap layer  202  can be composed in the same manner as the wrap layer  102  of  FIG.  1 A . However, a notable difference is that the wrap layer  202  is shorter in width (relative to the wrap layer  102  of  FIG.  1 A ) and includes different perforations  204  (relative to the wrap layer  102  of  FIG.  1 A ). In this regard, when the wrap layer  202  is folded along the perforations  204 , two shorter edges of the resulting rectangular shape overlap one another (as opposed to two longer edges that overlap one another when using the wrap layer  102 ). This notion is illustrated in  FIG.  2 B . One benefit of this approach is that less material is needed to manufacture the wrap layer  202 , which can reduce weight and cost of material. However, since the overlapping sections are shorter in length, the overall rigidity of the concrete form apparatus is reduced, thus constituting a tradeoff between cost and strength. 
     Additionally, as shown in  FIG.  2 A , the wrap layer  202  can include several extension inlets  206  that enable an extension apparatus to bind two or more of the concrete form apparatuses together. According to some embodiments, the extension inlets  206  can represent cavities within the wrap layer  202  that align with extension outlets on the extension apparatus when the concrete form apparatus is in a completed state, which is illustrated in  FIG.  2 C  and described below in greater detail. Again, it is noted that such extension inlets  206  are optional and can be omitted from the wrap layer  202 . 
     Additionally, as shown in  FIG.  2 A , the concrete form apparatus can include a core  210  that is sized in accordance with the wrap layer  202 , the perforations  204 , and the extension inlets  206 . The core  210  can be composed in the same manner as the core  110  of  FIG.  1 A . As previously described herein, the core  210  can be sized in accordance with the cavity that is formed when the wrap layer  202  is folded along the perforations  204 . In this regard, when the extension inlets  206  are not included in the wrap layer  202 , the length of the core  210  can match the length of the wrap layer  202 . Alternatively, when the extension inlets  206  are included in the wrap layer  202 , the length of the core  210  can be shorter (relative to the length of the wrap layer  202 ) so that the extension inlets  206  remain exposed within the concrete form apparatus. This notion is illustrated in  FIG.  2 C , which is described below in greater detail. 
     In any case, the core  210  can be placed onto the wrap layer  202 —e.g., centered along the lengthwise dimension of the wrap layer  202 —such that the wrap layer  202  can be folded around the core  210  to establish an assembled unit  212 , which is illustrated in  FIGS.  2 B- 2 C  and described below in greater detail. 
     As shown in the conceptual diagram  225  of  FIG.  2 B , the core  210  can be wrapped within the wrap layer  202  as it is folded along the perforations  204 . Although not explicitly illustrated in  FIGS.  2 A- 2 B , it is noted that any form of adhesive can be applied to any portion of the wrap layer  202  and/or core  210  without departing from the scope of this disclosure. For example, an adhesive layer can be applied to one or more sides of the core  210 , an adhesive layer can be applied to one or more of the (internal) sides of the wrap layer  202  that contact the core  210 , and so on. Additionally, it is noted that an adhesive layer can be applied to one or more of the two shorter edges of the wrap layer  202  that overlap one another to ensure that the wrap layer  202  does not unravel. This notion is illustrated in  FIG.  2 B  by the adhesive layer  216 . In this regard, the wrap layer  202 , the core  210 , and the adhesive layer(s) can work together to form an assembled unit  212  that exhibits a level of rigidity that is commensurate for functioning as a concrete form. 
     Additionally, the conceptual diagram  250  in  FIG.  2 C  illustrates another view of the assembled unit  212 . In particular, the conceptual diagram  250  covers a scenario in which the extension inlets  206  are included in the wrap layer  202 , and where the length of the core  210  is shorter (relative to the length of the wrap layer  202 ) so that the extension inlets  206  remain exposed within the assembled unit  212 . 
     Accordingly,  FIGS.  2 A- 2 C  illustrate conceptual diagrams of a second approach for implementing a concrete form apparatus, according to some embodiments.  FIGS.  3 A- 3 C —which set forth a third approach for implementing a concrete form apparatus—will now be discussed below in greater detail. 
       FIG.  3 A  illustrates a conceptual diagram  300  of a high-level overview of two different components that can be utilized to establish a concrete form apparatus, which, as shown, can include a wrap layer  302  and a core  310 . According to some embodiments, the wrap layer  302  can be composed in the same manner as the wrap layer  102  of  FIG.  1 A . However, a notable difference is that the wrap layer  302  is shorter in width (relative to both the wrap layer  102  of  FIG.  1 A  and the wrap layer  202  of  FIG.  2 B ) and includes different perforations  304  (relative to the wrap layer  102  of  FIG.  1 A  and the wrap layer  202  of  FIG.  2 B ). However, there are only three perforations  304  in the wrap layer  302 , such that when the wrap layer  302  is folded into a rectangular shape, no edges of the wrap layer  302  overlap one another. This notion is illustrated in  FIG.  3 B . One benefit of this approach is that less material is needed to manufacture the concrete form apparatus and one less perforation is required, thus reducing manufacturing costs. However, since there are no overlapping sections when the wrap layer  302  is folded, the overall rigidity is reduced, thus constituting a tradeoff between cost and strength. 
     Additionally, as shown in  FIG.  3 A , the wrap layer  302  can include several extension inlets  306  that enable an extension apparatus to bind two or more of the concrete form apparatuses together. According to some embodiments, the extension inlets  306  can represent cavities within the wrap layer  302  that align with extension outlets on the extension apparatus when the concrete form apparatus is in a completed state, which is illustrated in  FIG.  3 C  and described below in greater detail. Again, it is noted that such extension inlets  306  are optional and can be omitted from the wrap layer  302 . 
     Additionally, as shown in  FIG.  3 A , the concrete form apparatus can include a core  310  that is sized in accordance with the wrap layer  302 , the perforations  304 , and the extension inlets  306 . The core  310  can be composed in the same manner as the core  110  of  FIG.  1 A . As previously described herein, the core  310  can be sized in accordance with the cavity that is formed when the wrap layer  302  is folded along the perforations  304 . In this regard, when the extension inlets  306  are not included in the wrap layer  302 , the length of the core  310  can match the length of the wrap layer  302 . Alternatively, when the extension inlets  306  are included in the wrap layer  302 , the length of the core  310  can be shorter (relative to the length of the wrap layer  302 ) so that the extension inlets  306  remain exposed within the concrete form apparatus. This notion is illustrated in  FIG.  3 C , which is described below in greater detail. 
     In any case, the core  310  can be placed onto the wrap layer  302 —e.g., centered along the lengthwise dimension of the wrap layer  302 —such that the wrap layer  302  can be folded around the core  310  to establish an assembled unit  312 , which is illustrated in  FIGS.  3 B- 3 C  and described below in greater detail. 
     As shown in the conceptual diagram  325  of  FIG.  3 B , the core  310  can be wrapped within the wrap layer  302  as it is folded along the perforations  304 . Again, although not explicitly illustrated in  FIGS.  3 A- 3 B , it is noted that any form of adhesive can be applied to any portion of the wrap layer  302  and/or core  310  without departing from the scope of this disclosure. For example, an adhesive layer can be applied to one or more sides of the core  310 , an adhesive layer can be applied to one or more of the (internal) sides of the wrap layer  302  that contact the core  310 , and so on. Additionally, it is noted that one or more adhesive strips  320  can be applied to the edges of the wrap layer  302  that meet when it is folded along the perforations  304  into the rectangular shape depicted in  FIG.  3 B . According to some embodiments, one or more adhesive strips  320  can run perpendicular to the edge that is formed between the edges of the wrap layer  302  that meet (as depicted in  FIG.  3 C ). Alternatively, one or more adhesive strips  320  can run parallel to the aforementioned edge that is formed. This approach can provide the advantage of reducing the permeability of the concrete form apparatus given the edge might otherwise expose the core  310  to moisture. In this regard, the wrap layer  302 , the core  310 , and the adhesive layer(s) can work together to form an assembled unit  312  that exhibits a level of rigidity that is commensurate for functioning as a concrete form. 
     Additionally, the conceptual diagram  350  in  FIG.  3 C  illustrates another view of the assembled unit  312 . In particular, the conceptual diagram  350  covers a scenario in which the extension inlets  306  are included in the wrap layer  302 , and where the length of the core  310  is shorter (relative to the length of the wrap layer  302 ) so that the extension inlets  306  remain exposed within the concrete form apparatus. The conceptual diagram  350  also illustrates how one or more adhesive strips  320  can run perpendicular to the aforementioned edge that is formed. 
     Accordingly,  FIGS.  3 A- 3 C  illustrate conceptual diagrams of a third approach for implementing a concrete form apparatus, according to some embodiments. It is noted that while  FIGS.  1 A- 1 C,  2 A- 2 C, and  3 A- 3 C  primarily contemplate a single wrap layer that is folded around a single core, the invention is not so limited. For example, any number of wrap layers can be folded around any number of cores without departing from this disclosure. Additionally, the wrap layers can be perforated in various areas in order to produce additional edges that overlap one another without departing from the scope of this disclosure. Additionally, a given wrap layer can be perforated in a manner that causes it to take a non-rectangular (e.g., square, triangle, etc.) shape when folded along the perforations to increase rigidity. Additionally, it is noted that any materials, substances, etc., can be applied to one or more of the wrap layer, the core, or the concrete form apparatus itself to reduce overall permeability. For example, the exposed side of the wrap layer can be coated in one or more hydrophobic substances. In another example, the concrete form apparatus itself can be wrapped with one or more vinyl layers that renders it waterproof and increases its overall rigidity. In other examples, one or more wax coatings, form release spray, one or more layers of freezer grade coated paper, waterproof tape, one or more water resistance coatings, one or more paint coatings, etc., can be used without departing from the scope of this disclosure. 
     Additionally,  FIGS.  4 A- 4 B —which set forth different approaches that can be used for implementing extension apparatuses—will now be discussed below in greater detail. It is noted that the extension apparatuses described herein can be manufactured using any processes or materials (e.g., plastic, metal, carbon fiber, etc.) without departing from the scope of this disclosure. It is additionally noted that the extension apparatuses can be coated using any of the various substances, materials, sprays, layers, etc. disclosed herein without departing from the scope of this disclosure. 
       FIG.  4 A  illustrates a conceptual diagram  400  of a first approach for implementing a straight extension apparatus  402 , according to some embodiments. As shown in  FIG.  4 A , the straight extension apparatus  402  can be used to bind two different assembled units  112  together without changing the angle between the assembled units  112 . According to some embodiments, the two outer portions of the straight extension apparatus  402  can be sized in accordance with the cavity that is formed within the assembled units  112 . Additionally, the straight extension apparatus  402  can include extension outlets  410  that are positioned based on the extension inlets  106  within the assembled units  112  that are designed to accept the straight extension apparatus  402 . According to some embodiments, the extension outlets  410  can be fixed in position. In other embodiments, the extension outlets  410  can mechanically raise and lower to increase the ease with which the straight extension apparatus  402  can couple with the assembled units  112 . 
     Additionally, the straight extension apparatus  402  can also include a raised “ring” section (rotating about the middle of the straight extension apparatus  402 ) having a height that is sized in accordance with the thickness of the wrap layers  102  used to form the assembled units  112 . In this regard, when the outer portions of the straight extension apparatus  402  are inserted into the cavities of the assembled units  112 - 1  and  112 - 2 , there is a smooth transition between the assembled unit  112 - 1 , the straight extension apparatus  402 , and the assembled unit  112 - 2 . This can be beneficial as it mitigates any potential unevenness in the perimeter structure that might otherwise cause imperfections in the concrete as it cures. 
     Additionally,  FIG.  4 B  illustrates a conceptual diagram  425  of a second approach for implementing a turn extension apparatus  430 , according to some embodiments. As shown in  FIG.  4 B , the turn extension apparatus  430  can be used to bind two different assembled units  112  together while changing the angle between the assembled units  112  by ninety degrees. As with the straight extension apparatus  402 , the outer portions of the turn extension apparatus  430  can be sized in accordance with the cavity that is formed within the assembled units  112 . The turn extension apparatus  430  can also include extension outlets  432  that are positioned based on the extension inlets  106  within the assembled units  112  that are designed to accept the turn extension apparatus  430 . The turn extension apparatus  430  can also include a raised “ring” section (rotating about the middle of the turn extension apparatus  430 ) whose height is sized in accordance with the thickness of the wrap layers  102  used to form the assembled units  112 . Again, this enables a smooth transition to take place between the assembled unit  112 - 1 , the turn extension apparatus  430 , and the assembled unit  112 - 2 . 
     Accordingly,  FIGS.  4 A- 4 B  set forth different approaches that can be used for implementing extension apparatuses. It is noted that these approaches are merely exemplary and are not meant to be limiting in any fashion. For example, the extension apparatuses can be configured to introduce any angle between two different assembled units  112 . Moreover, any number of extension apparatus can be used to bind two or more different assembled units  112  together at any number of angles, thereby providing a system in which any perimeter shape—with any number of edges—can be established by utilizing the apparatuses described herein. additionally, it is noted that that the extension apparatuses are not required to be fixed-angle devices. For example, the turn extension apparatus  430  can incorporate a mechanical device that enables the turn extension apparatus  430  to bind two concrete form apparatuses together while establishing any desired angle between them. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it should be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It should be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.