Patent Publication Number: US-2015068144-A1

Title: Rebar cap

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of application Ser. No. 61/875,848 filed Sep. 10, 2013. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     A rebar cap assembly for covering the free end of a rebar rod. 
     2. Description of the Prior Art 
     Rebar cap assemblies for covering the free end of a rebar rod are generally known in the art. One such assembly is disclosed in U.S. Design Patent D654,384 granted Feb. 21, 2012 to Curt McDonald (hereinafter, the &#39;384 patent), which discloses a rebar cap with a casing of a continuous integral metal material with a cylindrical side wall disposed about an axis and extending between an open end and a closed end with a top wall to define an interior space between the open end and the closed end for receiving the free end of the rebar rod. The rebar cap disclosed in the &#39;384 patent also includes a shoulder extending annularly about and radially from the side wall and extending into the top wall. The rebar cap of the &#39;384 patent further includes retaining tabs in the side wall for securing the rebar cap to the free end of the rebar rod, with the retaining tabs spaced axially from the open end and spaced circumferentially at regular intervals, and including a ramp extending into the interior space toward the closed end and terminating at a lip. 
     SUMMARY OF THE INVENTION 
     The invention provides for such a rebar cap assembly including a disc of a continuous integral metal material defining a layer independent of the top wall of the casing and disposed upon the axis and extending to a perimeter in a cantilevered fashion radially outwardly from the closed end of the casing. 
     ADVANTAGES OF THE INVENTION 
     The invention in its broadest aspect provides for a rebar cap that includes both a continuous integral metal casing and a continuous integral metal disc, which may be manufactured independently. The combination of the metal casing and metal disc allows the rebar cap of the subject invention to be inexpensively manufactured when compared with other rebar caps, such as those of cast metal. The separately manufactured casing and disc also allows them to be constructed of different materials and/or materials having different properties, such as thickness or treatment. This construction allows each of the casing and the disc to be independently optimized for desirable characteristics, such as strength against bending or the ability to be drawn to a formed shape. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
         FIG. 1  is a perspective view of the closed end of the casing of the subject invention. 
         FIG. 2  is a perspective view of the open end of the casing of the subject invention. 
         FIG. 3  is an exploded perspective view of a rebar cap assembly with a flat disc, shown separated from the casing. 
         FIG. 4  is a perspective view of a rebar cap assembly having a flat disc, showing the open end of the casing. 
         FIG. 5  is a perspective view of a rebar cap assembly showing a disc with a dome shape covering the casing. 
         FIG. 6  is a perspective view, showing the open end of the casing of a rebar cap assembly having a disc with a dome shape. 
         FIG. 7  is a perspective view of a rebar cap assembly showing a disc with corrugations covering the casing. 
         FIG. 8  is a perspective view, showing the open end of the casing of a rebar cap assembly having a disc with corrugations. 
     
    
    
     DESCRIPTION OF THE ENABLING EMBODIMENT 
     Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a rebar cap assembly  20 , for use in connection with a rebar rod with a free end, is generally shown in  FIGS. 3-8 . The rebar cap includes a metal casing  22  and a metal disc  24  with a surface area larger than the free end of the rebar rod alone. There are many possible uses for the rebar cap assembly  20 . The rebar cap assembly  20  may be used as a marker, such as for surveying land, with the disc providing increased visibility and providing a surface for identifying text or other symbols. The rebar cap assembly  20  may also be used as a safety cap to protect against potential hazards from an exposed free end of a rebar rod such as impalement. It should be appreciated that the above uses are merely examples and are not intended to be limiting. 
     The rebar cap assembly  20  includes a casing  22  of continuous integral metal material generally indicated in  FIGS. 1-8 . The casing  22  has a side wall  26  with a cylindrical shape disposed about an axis A to define an interior space  32  extending between the open end  28  and the closed end  30  for receiving the free end of the rebar rod. The closed end  30  includes a top wall  34  having a first diameter D1. The side wall  26  of the casing  22  features a shoulder  36  extending annularly about and radially from the side wall  26  and extending into the closed end  30 . As a result of the process of forming the casing  22 , the top wall  34  may include a circular depression  38  centered upon the top wall  34 . 
     The side wall  26  has an outer surface  40  with a plurality of retaining tabs  42 ,  44  spaced axially from the open end  28 . The retaining tabs  42 ,  44  are also spaced circumferentially at regular intervals and extending toward the axis A for engaging the free end of the rebar rod to secure the rebar cap to the rebar rod. In other words, when the free end of the rebar rod is disposed in the interior space  32  of the casing  22 , the rebar rod is secured in the casing  22  by the retaining tabs  42 ,  44 . The retaining tabs  42 ,  44  include a first retaining tab  42  with a first ramp  46  extending inwardly toward the open end  28  and terminating at a first lip  48 . The retaining tabs  42 ,  44  also include a second retaining tab  44  with a second ramp  50  extending inwardly toward the closed end  30  and terminating at a second lip  52 . The retaining tabs  42 ,  44  may be integral, with the first lip  48  and the second lip  52  connected together. Alternately, the retaining tabs  42 ,  44  may be independent, with the first lip  48  separated from the second lip  52 . 
     The rebar cap assembly  20  also includes a disc  24  of continuous integral metal material, generally indicated in  FIGS. 3-8 . The disc  24  has a circular shape defining a layer that is independent of the top wall  34  of the casing  22 . The disc  24  is disposed upon the axis A and extends to a circular perimeter  54  in a cantilevered fashion radially outwardly from the closed end  30  of the casing  22 . The disc  24 , having a relatively larger diameter than the casing  22 , functions to distribute the weight of a person falling upon the free end of the rebar rod for protection against impalement. The relatively large diameter of the disc  24  also increases the visibility of the cap and provides a surface for identifying text or other symbols. 
     The combination of the metal casing  22  and the metal disc  24  allows the rebar cap  20  to be left on a rebar rod when concrete is poured around the rebar rod and rebar cap  20 . Rebar caps made of non-metals such as plastic must be removed before concrete is poured to prevent the hardened concrete from being weakened by their presence. 
     A bond  56  is sandwiched between the top wall  34  of the casing  22  and the layer of the disc  24  for securing to the disc  24  to the casing  22 . The bond  56  may be formed of a resistance weld or any other suitable connecting means. 
       FIGS. 3-4  show an embodiment of the rebar cap assembly  20  wherein the disc  24  is flat. 
       FIGS. 5-6  show an alternate embodiment of the rebar cap assembly  20  wherein the disc  24  is dome shaped. 
       FIGS. 7-8  show an alternate embodiment of the rebar cap assembly  20  wherein the disc  24  has a face side  58  opposite the closed end  30  including a plurality of corrugations  60  for strengthening the disc  24 . 
     The corrugations  60  include a first annular indentation  62  defining a second diameter D2 which is longer than the first diameter D1 of the top wall  34  to define a flat central region  64  of the disc  24  for receiving the top wall  34  of the casing  22 . A second annular indentation  66  is disposed concentrically about the first annular indentation  62 . The corrugations  60  also include a plurality of troughs  68  that extend radially outwardly from the first annular indentation  62  to the perimeter  54 . 
     Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims. That which is prior art in the claims precedes the novelty set forth in the “characterized by” clause. The novelty is meant to be particularly and distinctly recited in the “characterized by” clause whereas the antecedent recitations merely set forth the old and well-known combination in which the invention resides. These antecedent recitations should be interpreted to cover any combination in which the inventive novelty exercises its utility. The use of the word “said” in the apparatus claims refers to an antecedent that is a positive recitation meant to be included in the coverage of the claims whereas the word “the” precedes a word not meant to be included in the coverage of the claims. In addition, the reference numerals in the claims are merely for convenience and are not to be read in any way as limiting.