Patent Publication Number: US-7905680-B2

Title: Concrete dowel placement device and methods of use

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the field of concrete construction. Specifically, the present invention relates to a concrete dowel placement device that holds itself in position for concrete construction applications. 
     2. Description of the Related Art 
     The efficient placing of concrete dowel placement devices in a time and cost effective manner while maintaining the proper position of the dowels placed therein during a concrete pour is an ongoing concern in concrete construction. In solving this problem, for example, U.S. Pat. No. 5,005,331 discloses slip and non-slip concrete dowel placement devices. The device has sleeves with a hollow tubular sheath and a perpendicular flange formed at the opening to facilitate attachment of the sheath to a concrete form via conventional means, such as nails or screws. 
     U.S. Pat. No. 5,678,952 discloses a concrete dowel placement apparatus that comprises interconnectable components. The apparatus has a base member and an elongate tubular dowel receiving sheath. The base member comprises an outer sleeve and an inner sleeve attached to a flange which accommodates a nail for attachment to a concrete form. The receiving sheath slides over the outer sleeve. In a related apparatus, U.S. Pat. No. 5,934,821 discloses a concrete dowel placement apparatus as in U.S. Pat. No. 5,678,952 with the addition of at least one reinforcement wall between the outer and inner sleeves of the base member. 
     Alternatively, systems that don&#39;t require dowel rods have been used. U.S. Pat. No. 6,926,463 discloses a disk plate concrete dowel system. The system uses a positioner bracket which is attachable at a flange to a concrete form by standard fasteners, a pocket former which extends from the bracket base and a dowel plate which slides into the pocket former after the concrete form and the base flange are removed after a concrete pour. The disk plate system is interposed between adjacent concrete pours and defines a pour joint. 
     However, problems still exist with the prior art devices. The prior art devices require that a plurality of fasteners be used to attach them to the concrete forms. Also, some devices require assembly of component parts. In addition, some devices must be removed from a concrete pour. This requires additional materials and labor which increases fabrication time and costs. 
     A recognized need is present in the art for a concrete dowel placement device that facilitates its own placement and that of a concrete dowel in a concrete structure. More specifically, the prior art is deficient in a concrete dowel placement device that has an integral locking structure formed thereon which secures the device to a concrete form. The present invention fulfills this long-standing need and desire in the art. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a concrete dowel placement device. The device comprises a dowel receiving sleeve having a substantially cylindrical body with an outer surface, an open proximal end, a distal end, and an inner hollow compartment extending longitudinally therethrough, a flange formed to extend perpendicularly and completely about the open end of the dowel receiving sleeve and at least one tooth-like locking structure integrally formed on the outer surface of the sleeve proximate to the inner flange surface. A related device may further comprise a stop on the receiving sleeve proximate to the distal end and extending a distance into the inner hollow compartment. Another related device may further comprise one or more gussets formed longitudinally along the outer surface of the receiving sleeve and in supporting contact with an inner surface of the flange. 
     The present invention also is directed to a related concrete dowel placement device. The device comprises a dowel receiving sleeve having a substantially cylindrical body with an outer surface, an open proximal end, a distal end, and an inner hollow compartment extending longitudinally therethrough and a stop on the receiving sleeve proximate to the distal end and extending a distance into the inner hollow compartment. The device also comprises a flange formed to extend perpendicularly and completely about the open end of the dowel receiving sleeve, said flange having substantially flat outer surface and inner surfaces. The device further comprises at least one reverse tooth integrally formed from the outer surface of the sleeve proximate to the inner flange surface where the reverse tooth has a distal end projecting angularly from the outer sleeve surface toward the inner flange surface and a proximal end formed on the outer surface of the sleeve. A related device may further comprise one or more gussets formed longitudinally along the outer surface of the receiving sleeve and in supporting contact with the inner surface of the flange. 
     The present invention is directed further to a method for securing a dowel placement device to a concrete form. The method comprises providing a wooden concrete form having a plurality of holes along a length thereof and inserting the dowel placement device described through each of the holes. The inner surface of the flange abuts an outer surface of the wooden form and the tooth-like locking structure(s) abuts an inner surface of the wooden form to lock the device against the wooden form thereby securing the device thereto. The present invention is directed to a related method comprising the further step of positioning a dowel rod or piece of rebar within the receiving sleeve of each device. The present invention is directed to a further related method comprising the step of pouring concrete within the concrete form. 
     Other and further aspects, features and advantages of the present invention will be apparent from the following description of the presently preferred embodiments of the invention given for the purpose of disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the matter in which the above-recited features, advantages and objects of the invention, as well as others which will become clear, are attained and can be understood in detail, more particular descriptions and certain embodiments of the invention briefly summarized above are illustrated in the appended drawings. These drawings form a part of the specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and therefore are not to be considered limiting in their scope. 
         FIG. 1A  depicts a cross-sectional view of the concrete dowel placement device. 
         FIG. 1B  depicts a end view of the flange of the concrete dowel placement device. 
         FIG. 2  depicts a cross-sectional side view of the concrete dowel placement device secured to a concrete form. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As used herein, the term “a” or “an”, when used in conjunction with the term “comprising” in the claims and/or the specification, may refer to “one”, but it is also consistent with the meaning of “one or more”, “at least one”, and “one or more than one”. Some embodiments of the invention may consist of or consist essentially of one or more elements, method steps, and/or methods of the invention. It is contemplated that any device or method described herein can be implemented with respect to any other device or method described herein. 
     As used herein, the term “or” in the claims refers to “and/or” unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or”. 
     In one embodiment of the present invention there is provided a concrete dowel placement device, comprising a dowel receiving sleeve having a substantially cylindrical body with an outer surface, an open proximal end, a distal end, and an inner hollow compartment extending longitudinally therethrough; a flange formed to extend perpendicularly and completely about the open end of the dowel receiving sleeve; and at least one tooth-like locking structure integrally formed on the outer surface of the sleeve proximate to the inner flange surface. In a further embodiment the device may comprise a stop on the receiving sleeve proximate to the distal end and extending a distance into the inner hollow compartment. In another further embodiment the device may comprise one or more gussets formed longitudinally along the outer surface of the receiving sleeve and in supporting contact with an inner surface of the flange. 
     In this embodiment, the device may be formed from molded plastic, wood or metal. Also, the receiving sleeve distal end may be tapered to a substantially flat surface having an opening therethrough. In addition, the interior hollow compartment may have a size and configuration permitting a dowel rod or piece of rebar to be slidably inserted longitudinally through a central aperture comprising the flange into the receiving sleeve. Furthermore, the flange may have substantially flat outer and inner surfaces, said inner surface of the flange held in abutting contact with a flat outer surface of a concrete form. The flange may be of a substantially circular shape or of a substantially hexagonal shape. Further to this embodiment, the device may comprise one or more gussets formed longitudinally along the outer surface of the receiving sleeve and in supporting contact with an inner surface of the flange. 
     Also, in this embodiment the locking structure is a reverse tooth integrally formed from the outer surface of the sleeve proximate to the inner flange surface where the reverse tooth may have a distal end projecting angularly from the outer sleeve surface toward the inner flange surface and a proximal end formed on the outer sleeve surface. In addition, a distance between the inner surface of the flange and the proximal end of the reverse tooth may be about equal to a thickness of a concrete form against which the inner surface of the flange abuts. In this embodiment the concrete form may be wood. 
     In another embodiment of the present invention, there is provided a concrete dowel placement device, comprising a dowel receiving sleeve having a substantially cylindrical body with an outer surface, an open proximal end, a distal end, and an inner hollow compartment extending longitudinally therethrough; a stop on the receiving sleeve proximate to the distal end and extending a distance into the inner hollow compartment; a flange formed to extend perpendicularly and completely about the open end of the dowel receiving sleeve, said flange having substantially flat outer surface and inner surfaces; and at least one reverse tooth integrally formed from the outer surface of the sleeve proximate to the inner flange surface, said reverse tooth having a distal end projecting angularly from the outer sleeve surface toward the inner flange surface and a proximal end formed on the outer surface of the sleeve. 
     The dowel receiving sleeve, the flange, the reverse tooth and the materials forming the same are as described supra. Also, the positional relationship of the device components to a concrete form are as described supra. 
     In yet another embodiment of the present invention there is provided a method for securing a dowel placement device to a concrete form, comprising providing a wooden concrete form having a plurality of holes along a length thereof; and inserting the dowel placement device described supra through each of the holes such that the inner surface of the flange abuts an outer surface of the wooden form and the tooth-like locking structure(s) abuts an inner surface of the wooden form to lock the device against the wooden form thereby securing the device thereto. 
     Further to this embodiment, the method comprises positioning a dowel rod or piece of rebar within the receiving sleeve of each device. Further still, the method comprises pouring concrete within the concrete form. The concrete dowel placement device is as described supra. 
     Provided herein are devices and methods for properly positioning and maintaining position of a dowel used in a concrete application in a time effective manner. Generally, the concrete dowel placement device comprises a means for receiving and maintaining a dowel in proper position during a concrete pour and means for aligning and retaining the device in an abutting position to a concrete form. The device requires no separate fasteners to hold it in position against the concrete form and remains stably in position after a concrete pour. 
     Embodiments of the present invention are better illustrated with reference to the Figure(s), however, such reference is not meant to limit the present invention in any fashion. The embodiments and variations described in detail herein are to be interpreted by the appended claims and equivalents thereof. 
       FIG. 1A  is a cross-sectional view of the concrete dowel placement device  100 . The device comprises a receiving sleeve  110  with a substantially cylindrical interior hollow body  112  comprising an open proximal end  114  and a distal end  116 . The outer surface  111  of the receiving sleeve may be tapered at the distal end to a flat surface  113  smaller than the proximal end opening and may have an opening  115  therethrough. The receiving sleeve has a stop  117  near the distal end  116  thereof which extends into the interior hollow body  112  to stop the dowel rod or piece of rebar within the receiving sleeve. The distance d 1  from the distal end of the receiving sleeve to the stop may be a minimum of 0.25 inches and represents a gap between the distal end of the receiving sleeve and the stop. The stop allows for maximum theoretical expansion and contraction of the adjoining concrete slabs. Also, the stop also is a safety measure in case the receiving sleeve should be infiltrated by incompressible materials, e.g., aggregate, such as river rock or limestone, depending upon the concrete application. A flange  120  is perpendicularly extended around the proximal open end  114 . The flange has an outer surface  122  and inner surface  124  and comprises a central aperture  126  therethrough which matches with the open proximal end of the receiving sleeve such that a dowel rod or piece of rebar  150 , as shown in  FIG. 1B , may be slid through the central aperture and the open proximal end into and along the length of the receiving sleeve. 
     Optionally, it is contemplated that the outer surface  111  may have one or more structures or gussets  130  raised or extruded from the outer surface of the receiving sleeve  110  at the proximal end thereof and disposed lengthwise along the outer surface and perpendicular to the flange  120 . The one or more gussets may provide additional support at the juncture of the flange and the receiving sleeve  110 . 
     In addition, the receiving sleeve comprises one or more locking structures  140   a , 140   b  formed on the outer surface thereof as an integral structure. The locking structure may comprise a reverse tooth structure with proximal  141   a , 141   b  and distal  142   a , 142   b  ends. The distal end of the reverse tooth projects angularly from the outer surface  111  of the receiving sleeve  110  and points toward the inner flange surface  124 . The proximal end  140   a , 140   b  of the reverse tooth integrates with the outer surface of the receiving sleeve. 
     The distal end  142   a , 142   b  of the reverse tooth is sufficiently angled toward the proximal end so that it is effective to support or lock a concrete form in a position perpendicular to the concrete dowel placement device after inserting it through the concrete form. The reverse tooth component supports and stabilizes the angle juncture therebetween. The distance d 2  between the distal end of the locking structure or reverse tooth and the inner flange surface  124  is about equal to the thickness of a concrete form used in a concrete application. 
     The distal ends  142   a , 142   b  of the locking structures are disposed over indents or indented areas  144   a , 144   b  formed on the outer surface of the receiving sleeve  110 . The space provided by these indents allows for compression of the reverse tooth or distal end of the locking structure when the concrete dowel placement device is inserted through a wooden concrete form prior to receiving a dowel rod or piece of rebar therein. 
     Preferably, the device is formed of molded plastic using well-known and standard techniques. Alternatively, the device may be formed of wood or metal. One of ordinary skill in the art is well able to determine which materials and methods of manufacture would be suitable for the concrete dowel placement device described herein. 
     With continued reference to  FIG. 1A ,  FIG. 1B  is an end view of the concrete dowel placement device depicting an outer surface  122  view of the flange  120  on the proximal end  114  of the dowel receiving sleeve  110 . Although depicted with a substantial hexagonal shape, this is not intended as a limiting feature. For example, the flange may be circular in shape. In this view, the central aperture  126  is aligned with the open proximal end  114  of the receiving sleeve  110  showing the stop  117 . A dowel rod  150  or piece of rebar is disposed within the receiving sleeve. 
     With continued reference to  FIGS. 1A-1B ,  FIG. 2  depicts a side cross-sectional view of the concrete dowel placement device secured to a wooden concrete form. The wooden form  200  has outer  202  and inner  204  surfaces parallel to the flange  120 . A plurality of holes are formed through the form connecting the inner and outer surfaces. The diameter of each is sufficient to accommodate the receiving sleeve  110  of the concrete dowel placement device. The device  100  is pushed through the hole until the inner flange surface  124  abuts the outer surface  202  of the wooden concrete form and the distal end  142   a , 142   b  of the locking structure is in contact with the inner surface  204  of the concrete form. Without being limiting, a standard thickness of a concrete form is about 11/16 in. Concrete forms may be made of wood, such as redwood. 
     Because the distance between the inner flange surface and the proximal end of the reverse tooth is about equal to the thickness of the form, the receiving sleeve can neither be pushed through nor pulled from the concreted form and is, therefore, held securely in place. Thus, so secured to the concrete form a dowel rod  150  or piece of rebar may be slidably positioned longitudinally through the flange central aperture  126  into the hollow interior body  112  of the receiving sleeve  110 . Concrete may then be poured up to the form. Thus, the dowel receiving sleeve holds a dowel, e.g., a smooth dowel rod, in a parallel position to both the centerline of the form and the surface of the pavement. This is effective to prevent uncontrolled cracking, spalling or blowups in the concrete pavement. 
     One skilled in the art will appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those objects, ends and advantages inherent herein. Changes therein and other uses which are encompassed within the spirit of the invention as defined by the scope of the claims will occur to those skilled in the art.