Patent Publication Number: US-6991205-B2

Title: Textured brick wall form panel

Description:
This claims the benefit of U.S. Provisional Patent Application Ser. No. 60/444,460, filed Feb. 3, 2003 and hereby incorporated by reference in its entirety. 

   BACKGROUND OF THE INVENTION 
   This invention relates generally to poured concrete wall forms and, more particularly, to panels coupled together and used to construct the concrete wall form to produce a textured facade on the poured concrete wall. 
   Prefabricated, reusable panels are often used to construct a wall form for a poured concrete wall. Typically, two spaced opposed parallel sets of forms are erected and concrete is poured there between to form a wall. Each form is constructed of a number of adjacent interconnected panels. Form ties are used to maintain the spacing between the opposed forms constructed of the panels. 
   These panels are necessarily of relatively high strength, yet preferably they are compact and lightweight to effect savings in handling, transportation, and storage. Hence, the panels are commonly constructed at least in part of lightweight metal such as aluminum and have a reinforcing grid secured to the back side of the panel for providing the necessary strength to resist buckling under the weight of the poured concrete. 
   Typically, the grid on each panel has a marginal frame projecting rearwardly from the panel to include a flange along the spaced side edges of the panel. The flanges are adapted to be positioned in an abutting relationship with the flange of an adjacent panel to construct the concrete wall form. Holes in the flanges of the adjacent panels can be aligned to receive there through the shank of a pin or a bolt. The pin or bolt may pass through the ends of the ties and commonly are held in position by wedges which are driven through a slot in the shank of the pin or bolt. As the wedges are driven into the slot, the abutting flanges of the adjacent panels are drawn together. The pins and wedges offer a simple mechanism for effectively coupling the panels together. 
   When the concrete is poured between the spaced forms and assembled panels, the hydrostatic forces generated by the poured concrete tend to spread the opposed forms apart, but these outward or spreading forces are held in check by the form ties. In addition, the concrete expands as it sets creating greater spreading forces on the panels. The pin joining the adjacent panels together is subject to significant pulling forces by the form tie and an opposed force by the frame or rail on the panel. 
   Recently, such panels are commonly embossed with various designs to produce a decorative facade on the concrete wall formed by the panels. Thus, panels are available having a bat and board pattern to resemble the exterior walls of a conventional frame house, a ribbed pattern to resemble aluminum sliding or the like, and a smooth brick pattern to resemble brickwork construction. Examples of such wall form panels are shown in U.S. Pat. Nos. 1,776,999; 3,307,822; 3,549,115; and 4,407,480, each of which is hereby incorporated by reference in its entirety. 
   Panels which include an embossed or otherwise formed design to produce a decorative facade on the concrete wall optimally should produce a concrete wall facade as realistic as possible. In many known concrete wall form panels having a textured brick or other pattern, the pattern design is marred with blemishes or other marks inconsistent with the desired appearance. For example, the reinforcing grid or frame on the back surface of each panel is often spot welded to the back face of the embossed or textured face sheet of the panel. The spot welding naturally being produced at high temperatures produces a pock mark on the embossed surface of the panel. Such pock marks are typically inconsistent with the embossed pattern and produce a corresponding blemish or mark on the facade of the poured concrete wall. Obviously, such pock marks detract from the aesthetic appeal of the decorative facade on the concrete wall formed by such panels. 
   Notwithstanding the problems of producing realistic and aesthetic designs as discussed above, an additional problem common to all of the panel sections having a masonry type pattern embossed therein is that of damage to the panel and particularly the vertical marginal borders of the panels. In this regard, it is absolutely critical that these vertical marginal borders maintain their initial configuration inasmuch as the shape of the marginal borders influences the continuity in a wall formed by a plurality of form sections arranged side by side. For example, when the embossed pattern resembles smooth brickwork in an English cross-bond (joints between stretchers in one course positioned mid-length of stretchers in adjacent courses) the vertical edges of each panel traverse the pattern in such a manner as to present “half-bricks” in alternating courses along the vertical marginal borders of the sections. Thus, when sections so constructed are arranged side by side it is extremely important that the respective marginal borders match up exactly with their “half-bricks” precisely aligned to present a continuous full brick and hence, maintain the continuity of the brickwork pattern. However, in practice it has been found that panel sections having a brickwork pattern as previously described often become deformed along the vertical marginal borders thereof after only a few uses such that subsequent use of the form results in an unsightly discontinuous facade on the poured concrete wall produced by the section. 
   An additional problem with known panels of this type is the tendency for the panels to accumulate concrete. By their very nature, panels of this type have an irregular and non-planar face sheet. The configuration of the face sheet presents many openings, pockets, channels or grooves along the marginal edges of the face sheet adjacent the grid or flanges on the back face of the panel. When such panels are used to construct a poured concrete wall, the fluid concrete often finds its way into the openings, pockets, channels or grooves between the face sheet and the grid or flanges. When that concrete hardens or cures, it is permanently embedded in the panel and significantly increases the weight of the panel. Moreover, such embedded concrete often promotes separation or peeling of the face sheet from the grid or flanges ultimately resulting in damage to the panel and requiring disposal of the equipment. 
   Accordingly, it is apparent that there is a need to provide a panel section having a textured pattern embossed therein that produces a blemish-free, realistic facade while maintaining the structurally robust, compact and lightweight characteristics desirable in such panels. 
   SUMMARY OF THE INVENTION 
   These and other objectives of the invention have been attained by a textured wall form panel for a poured concrete wall. The panel, according to a presently preferred embodiment of this invention, includes an embossed aluminum face sheet that has a textured pattern such as a masonry or brick facade. The panel includes a frame or grid projecting rearwardly on the panel and, advantageously, the frame is welded along the entire height of the side flanges to the face sheet. As such, the strength of the resulting panel is significantly increased. Likewise, the contour of the front edges of the side flanges corresponds to that of the embossed face sheet. In one presently preferred embodiment, the embossed pattern resembles smooth brickwork in an English cross-bond pattern such that each panel edge terminates with every other brick being a half brick. The frame edges are contoured to correspond to the textured or embossed pattern thereby increasing strength of the panel in those regions. 
   Moreover, the grid or frame on the rear of the panel includes at least one and typically a pair of vertical interior beams which extend the entire height of the panel thereby providing increased strength and robust construction. However, the vertical interior beams are not welded directly to the embossed face sheet thereby avoiding weld marks on the embossed pattern which would then result in blemishes on a poured concrete wall. The grid or frame on the back of the panel also includes a number of spaced generally horizontal struts which likewise enhance the structural integrity of the panel. Advantageously, each of the struts or hat sections is sized and configured to be seated within the representative mortar joints in the embossed or textured configuration of the face sheet. In one embodiment, the shape of the terminal edges of the struts are configured to mate with the contour of the representative mortar joints on the face sheet. 
   As such, the profile of the grid and associated struts is reduced providing for a more compact and manageable panel without sacrificing structural integrity or strength. Likewise, any blemishes or marks resulting from the welding of the struts to the face sheet are concealed within the mortar joint portion between the courses of bricks represented in the poured concrete wall facade. As such, blemishes and unsightly pock marks are concealed in the resulting poured concrete wall. 
   Additionally, the holes in the side flanges of the grid through which the pin and wedge assemblies project to secure a pair of adjacent panels together are reinforced with flared bushings to provide for a more robust and stronger panel and associated connection scheme. Moreover, the openings, pockets, channels or grooves along the marginal edges of the face sheet adjacent the grid or frame members are filled with plugs or portions of the frame members to prevent the entry of mortar therein. 
   As a result, this invention provides a panel section having a textured pattern embossed therein that produces a blemish free, realistic facade while maintaining structurally robust, compact and light weight characteristics desirable in concrete wall form panels. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
       FIG. 1  is a view of the back side of a concrete wall form panel according to a presently preferred embodiment of this invention; 
       FIG. 2  is a view of the front face of the panel of  FIG. 1  showing the textured surface of the face sheet of the panel; 
       FIG. 3  is a view similar to  FIG. 2  of an alternative embodiment of the panel according to this invention; 
       FIG. 4  is a cross-sectional view taken along line  4 — 4  of  FIG. 1 ; 
       FIG. 5  is a perspective view of a portion of a back side of a panel according to this invention; 
       FIG. 6  is a side elevational view of a flange on a panel according to one embodiment of this invention; 
       FIG. 7  is an enlarged view of a portion of the side flange of  FIG. 6  focusing on a half-brick pattern on the face sheet; and 
       FIG. 8  is a view taken along line  8 — 8  of  FIG. 1  showing a plug in an opening between the face sheet and the reinforcing grid on the panel. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to the drawings, a wall form panel  20  is illustrated in  FIGS. 1–3  and includes a generally rectangular embossed face sheet  22  having a front face  24  for contacting concrete or other poured construction material and an opposed back face  26 , and a reinforcing grid  28  secured thereto. While only one panel  20  is illustrated, it is to be understood that a plurality of panels  20  are normally employed in upright, side by side relationship to collectively comprise a form structure for temporarily supporting poured concrete or the like. 
   The face sheet  22  is generally non-planar and, in one embodiment, is embossed to present a textured brickwork pattern in the back face  26  and an impression of the pattern in the front face  24 . The pattern is configured to represent brickwork in an English cross-bond having a plurality of stretchers in the nature of bricks  30  arranged in a number of alternate, horizontally extending courses  32  and  34 . A vertically extending joint  36  is disposed between adjacent bricks in the courses  32 ,  34  with joints  36  in courses  32  being vertically aligned mid-length with bricks  30  in courses  34 . A pair of side marginal borders  38  extend along opposed lateral boundaries of the face sheet  22 . Likewise, upper and lower borders  39  extend along opposed upper and lower boundaries of the face sheet  22 . As shown for example in  FIGS. 1–2 , the marginal borders  38  traverse courses  32 ,  34  in alignment with the vertical joints  16  of courses  34  such that a number of half-bricks  40  are presented in courses  32  at the marginal borders  38 . It will be understood that the half-bricks in courses  32  ate intended for alignment with similar half-bricks  40  in the face sheet  22  of an adjacent panel  20  when a plurality of the panels  20  are employed in forming a wall or the like. 
   It is important to note that the textured brick pattern embossed in the face sheet  22  is of a relatively complex nature as evidenced by the numerous indentations and irregularities in the surface thereof. Nevertheless, other patterns representing bricks, stones or any other configuration, in addition to those shown and described herein, are well within the scope of this invention. 
   Once the face sheets  22  have been formed, for example in a single stamping operation from 5052 aluminum, they are provided with a reinforcing grid  28  as described above to enable the panels to support a volume of poured concrete without buckling under the weight of the concrete. The grid  28  includes a pair of spaced upper and lower flanges  42 ,  44  welded to the back face  26  of sheet  22  along borders  39 . The grid  28  further includes a pair of elongate, spaced, support flanges  46  extending vertically along respective marginal borders  38 . 
   As shown in FIGS.  1 , 5  and  6 , each flange  48  includes an elongate surface edge  48  extending along the length of the flange  46  confronting and disposed in securing contact with the back face  26  of the face sheet  22 . Surface  48  has a plurality of vertically spaced projections  50  adapted to be received within alternately spaced depressions  52  in marginal borders  38  as presented by joints  16  in courses  34  in relationship to half-bricks  42  of courses  32 . Note that the projections  50  in combination with surface  48  assure that the marginal border  38  is firmly and fully supported along its entire length such that the possibility of the border  38  being deformed from its initial configuration is greatly reduced. 
   To further enhance the tailored configuration of support flange  46  in relation to the marginal border  38  on the back face  26  or sheet  22 , the flange  48  is provided with a plurality of recesses  52  adjacent the bases of projections  50  for abutment against the bricks  30  in courses  34 . As such, the flange  46  is optimally configured to assure a desired substantially continuous contact with the face  26  along the border  38 . As shown in  FIGS. 1 and 5 , each flange  46  is secured to sheet  22  by a fillet weld  56  or the like along substantially the entire length of the flange  46  on the interior of the panel  20 . Additionally, as shown In  FIG. 7 , the exterior surface  88  of the flange  46  is preferably welded (i.e., TIG welding, gas tungsten arc welding or other technique) at the depressions  52  on the face sheet  22  representing a half-brick to inhibit separation of the face sheet  22  from the flange  46 . 
   In  FIG. 3 , a panel  120  is shown constructed substantially the same as panel  20  with the exception that the panel  120  has a face sheet  122  with a vertex brick pattern embossed therein. 
   As previously described, a plurality of panels  20  or  120  are normally secured together in upright side-by-side relationship for presenting a concrete forming structure. Of course, in this position the front face  24  is adapted to receive the poured concrete such that the pattern impressed in face  24  will ultimately appear on the formed concrete structure. 
   It is important to understand that the flanges  46  securely support marginal borders  38  and are welded to the face sheet  22  along their full lengths adjacent the interior of the panel ( FIG. 5 ) such that they are at all times protected against undesired deformation. It has been found that panels having only intermittent support and/or welds at the marginal edges thereof become significantly deformed at the edges after only a short period of use. Hence, the present invention provides an inexpensive means for greatly increasing the useful life of embossed panels. In turn, this increased life makes it feasible to produce somewhat more expensive and complex embossed patterns such as textured brick and stone. 
   A presently preferred embodiment of an attachment system for a poured concrete wall form panel  20  is shown and described in U.S. Pat. Nos. 5,802,795 and 5,904,875, each hereby incorporated by reference. The attachment system includes a pin (not shown) having a generally cylindrical stem having an enlarged disk-shaped head on one end. The shank of the pin is sized for insertion through a hole  58  in the flange  46  of the panel  20  used for constructing a concrete wall form. The hole  58  in the flange  46  is aligned with a similarly configured hole  58  in the flange  46  of an adjacent panel  20 . The flange  46  preferably includes a bushing  60  seated in the hole  58  and the diameter of the bushing  60  permits movement of the shank of the pin there through. 
   Advantageously, the bushing  60  is provided in each of the holes  58  in the side flanges  46  of the panels  20  and the bushing  60  includes a tubular neck  78  seated within the hole  58  and a flared collar  80  which abuts against a base  82  on the inner face of the flange  46  ( FIG. 5 ). The flared collar  80  has a widened flared or tapered base  82  juxtaposed toward the back face  26  of the sheet  22  to provide enhanced load-bearing capabilities in this region. The widened base  82  enhances the load-bearing capability by distributing the load experienced at the juncture between the adjacent panels  20  and the pin across a wider area thereby avoiding a load concentration which may lead to a failure of the various component parts. Another example of a bushing according to this invention is shown in U.S. Pat. No. 6,283,439, incorporated herein by reference. 
   The side flange  46  of each panel  20  includes a plurality of the spaced holes  58  preferably at approximately 12″ intervals beginning at 6″ from longitudinal top and bottom edges of the panel  20 . It will be appreciated by one of ordinary skill in the art that the width dimensions of the panels are exemplary only and should not be considered as a limitation upon this invention. Moreover, the upper and lower flanges  42 ,  44  may also include holes  58  and bushings  60  as described herein and as shown in  FIG. 8 . 
   As is well known in the art, a tie rod (not shown) having a hole proximate an end thereof extends between the adjacent panels  20 ,  20  of the concrete wall form to maintain the spacing between the opposed panels (not shown) forming a cooperating wall form (not shown). The flanges  46  may include a notch or cut-out  62  sized and configured to accommodate the tie rod seated in the notch  62  so that the flanges  46  of the adjacent panels  20 ,  20  can be juxtaposed in face-to-face abutting relationship. As is well known, a wedge (not shown) is dimensioned to fit within a slot in the shank of the pin to secure the adjacent panels  20  together. 
   When the adjacent panels  20 ,  20  are positioned with the respective holes  58  in the flanges  46  being generally aligned, the pin is projected through the hole  58  in the panel  20 . The tie rod (not shown) may then be slipped onto the shank of the pin and then the shank inserted into the hole  58  in the opposite flange  46  at which time the narrow end of the wedge is inserted into the slot and hammered or forced into place thereby drawing the panels  20 ,  20  together and releasably coupling and binding them together forming a concrete wall form. 
   Referring to FIGS.  1  and  4 – 6 , each panel  20  includes the reinforcing grid  28  on the back face of the panel  20 . Preferably, longitudinally extending vertical beams  64  having a generally rectangular configuration are on the back of the panel  20 . The beams  64  are welded, glued or otherwise adhered to the upper and lower flanges  42 ,  44 , but not the face sheet  22 . As shown in FIG.  1  and  4 – 6 , the beams  64  may extend continuously between the top and bottom flanges  42 ,  44  or only intermittently between the flanges  42 ,  44  and/or lateral struts  66 . 
   An important feature of this aspect of the invention is that the beams  64  are not welded along their length to the face sheet  22 . This is shown most clearly in  FIG. 5  as the representative portion of the beam  64  extending between the top flange  42  and the strut  66  is not welded to the face sheet  22  or substantially free of weld connections between the longitudinal length of the beam  64  and the face sheet  22 . As shown in  FIG. 5 , the beam  64  is welded to the strut  66  and the top flange  42 ; however, this invention substantially avoids welding the beam  64  to the face sheet  22  to avoid the blemishes and pock marks on the face sheet  22  which result from the welding process. This offers a more realistic and blemish-free facade to the resulting poured concrete wall surface. Nevertheless, the strength of the panel is maintained and increased because the beams are securely mounted between the upper and lower flanges  42 ,  44  and the associated struts  66  to transmit the appropriate load and distribute it there between. While the side flanges  46  and the top and bottom flanges  42 ,  44  are substantially welded along their entire length along the interior of the panel  20  to the face sheet  22 , this provides a more robust assembly which is less likely to result in damage or peeling of the face sheet  22  from the reinforcing grid  28 . Moreover, such a robust panel  20  is provided without the appearance of blemishes on the face sheet  22  unlike prior panels of this type. 
   The laterally extending struts  66  preferably having a cross-hat shaped configuration with a wider base  68  adjacent the back face  26  of the sheet  22  and a tapered section  70  joined to a bight  72 . The struts  66  are also welded, glued, joined or attached to the back face  26  of the sheet  22 . The struts  66  extend preferably the entire width of the panel  20  from side flange  46  to the opposite flange  46 . Preferably, the longitudinally extending beams  64  extend from the upper flange  42  to the uppermost strut  66 , between each strut  66 , and from the lower flange  44  to the lowermost strut  66  to provide enhanced strength and reinforcement to the upper and lowermost regions of the panel  20 . The section of the panel  20  which typically experiences the highest loads is the bottom and as a result of the location of the beams  64 , the panel  20  is interchangeable from top to bottom for easier installation and use. 
   One aspect of this invention is the configuration and placement of the struts  66  extending laterally across the back surface of each panel  20 . Specifically, as shown in  FIGS. 1 ,  4  and  5 , the base  68  of each strut  66  has a pair of generally parallel beads  74  which are spaced on a center line approximately 3″ apart and advantageously each bead  74  is sized and configured to mate with and be seated within one of the embossed channels  76  in the face sheet  22  representing the mortar joint between the adjacent courses  32 ,  34  of bricks  30  in the textured brick embossed face sheet  22 . Preferably, the beads  74  have the same or complementary shape as the channels  76  to be fully seated therein. This offers a more secure interface between the struts  66  and the face sheet  22  as well as a reduced profile for the panel  20 . 
   The struts  66  may be spot welded or continuously welded along their longitudinal length to the face sheet  22 , but this does not present blemishes or pock marks on the face sheet  22  because the beads  74  of the struts  66  are seated within the mortar joint sections  76  of the face sheet  22  thereby concealing any resulting blemishes or pock marks. The beads  74  of the struts  66  are welded to the face sheets  22 ; however, the welding process does not produce blemishes in the face sheet  22  that generate pock marks or other undesirable blemishes on the poured concrete wall facade because of their placement in the channels  76  along the representative mortar joints of the brickwork facade. Likewise, positioning the beads  74  of the struts  66  within the channels  76  representing the mortar joints allows for increased strength of the panel  20  while minimizing the profile. In other words, since the struts  66  are seated within the channels  76  representing the mortar joints, the present invention provides the advantages of a blemish free brickwork facade structurally robust panel in a low prof ire configuration. Alternatively, the width of each strut may be  6 ″ to span a pair of brickwork courses  32 ,  34  or another integral number of bricks  30  as is readily appreciated by those of ordinary skill in this art. 
   Another feature of the panel  20  according to this invention is shown in  FIG. 8 . Specifically, due to the textured configuration of the face sheet  22  and, in particular, the indentations and irregularities in the non-planar surface of the face sheet  22 , openings, pockets, channels or grooves formed in the face sheet  22  adjacent the marginal edges of the flanges  42 ,  44 ,  46  are present. For example, the textured brickwork pattern in the face sheet  22  includes channel joints  36  or  76  disposed between adjacent bricks  30 . The intersection of the joints with the flanges  42 ,  44 ,  46  presents openings, channels or grooves into which concrete may be splashed, poured or otherwise embedded. When such concrete cures and hardens, a significant amount of weight is added to the panel  20  and the face sheet  22  may separate from the reinforcing grid  28  thereby damaging the panel  20 . To alleviate this problem, this invention fills such gaps, openings and channels between the grid  28  and the face sheet  22  along the marginal edges. In one embodiment, a plug  86  is inserted into the mortar joint channel  36 ,  76  to prevent the entry of foreign matter, debris, mortar or other material therein. 
   From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.