Patent Publication Number: US-10323424-B2

Title: Concrete form system with resilient brackets securing form boards to stakes

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 62/536,695 filed on Jul. 25, 2017, the entirety of which is incorporated by this reference. 
    
    
     BACKGROUND 
     Field of the Invention 
     The present invention relates generally to devices for forming concrete forms for pouring concrete slabs and the like. More particularly, it relates to a concrete form system that includes a plurality of brackets for supporting concrete forms. 
     Description of the Related Art 
     A typical prior art concrete form system uses wooden or metal stakes attached by nails to wooden boards (such as 2×4 or 2×6 planks) that are used as forms. A typical prior art concrete form system consists of a plurality of stakes inserted vertically into the ground and flush against a concrete form board so as to abut the concrete form board. 
     Once the concrete form board is properly positioned, nails are used to secure the stakes to the concrete form board. When using metal stakes, such stakes are provided with one or more transverse holes that extend through the stake so that nails can be inserted through the holes and driven into the concrete form board, thereby securing the concrete form board to the stakes. 
     Once the stakes are nailed to the concrete form board, it is difficult to vertically adjust the concrete form boards without removing the nails that secure the stakes to the concrete form boards. That is, in a typical prior art concrete form system, the nails that are holding the stakes to the concrete form board must be removed before the concrete form board can be raised or lowered relative to the stake. Also, depending on the vertical distance the concrete form board needs to be moved, the stakes may need to be removed from the ground, after which the stakes must be driven back into the ground at another location or height and reattached to the concrete form board with nails. 
     When using typical prior art metal stakes containing nail holes as previously discussed, it is often the case that such holes become filled with hardened concrete that makes subsequent use of such metal stakes difficult or impossible without first taking time to remove the hardened concrete. In addition, when using wood stakes, such stakes have a limited number of times they can have nails driven into them before they split. Also, the cost of nails, which can typically only used once, becomes expensive over time. 
     Thus, there exists a need in the art to provide a concrete form system that allows for easy vertical adjustment of the concrete form board once attached to a stake, that is reusable and does not require the use of nails to secure the concrete form board to the stake. 
     SUMMARY OF THE INVENTION 
     The present invention provides a concrete form system comprising a plurality of concrete form board brackets. The plurality of brackets includes brackets for securing the concrete form board to a conventional type metal or wood concrete form stake without the need of nails. The plurality of brackets also includes concrete form board end brackets for securing the ends of adjacent concrete form boards together that allows for a range of angles to be formed between two adjacent concrete form boards from nearly zero degrees to 180 degrees. The present invention also includes flexible sections of concrete forms configured to be coupled to the brackets that allow for forming curved concrete edges. 
     The brackets for securing the concrete form boards to stakes are generally C-shaped brackets configured to wrap around three sides of a concrete form board and include recesses for securing the brackets to the stakes. Once attached, the brackets bias the concrete form board against the stake to securely hold it in place. 
     The brackets for securing adjacent board ends together are provided with interlocking features that allow two identical adjacent brackets to interlock and pivot relative to one another. 
     The flexible section of concrete forms are formed from thin strips that are provided with laterally extending tabs that can be received within holes in the brackets to secure the flexible concrete forms to the brackets using the C-shaped brackets previously discussed. 
     In one embodiment of the concrete form system in accordance with the present invention includes a plurality of concrete form board retaining brackets, a plurality of concrete form stakes and at least one concrete form board. Each of the plurality of concrete form board retaining brackets are configured to retain the at least one concrete form board to a respective on of the plurality of concrete form stakes. Each concrete form board retaining bracket has an upper and lower stake retaining portion that bias the respective concrete form stake against an outer surface of the at least one concrete form board. The upper and lower stake retaining portions each defining a recess that engages an outer surface of the concrete form stake to hold the stake relative to the bracket. 
     In another embodiment, the plurality of concrete form board retaining brackets comprise a generally rectangular plate having a back wall, an upper wall depending from a top edge of the back wall at a first obtuse angle from the back wall and a lower wall depending from a bottom edge of the back wall at a second obtuse angle from the back wall, the top and bottom walls depending from a front side of the back wall so as to extend from the back wall in generally a same direction. 
     In another embodiment, a distance between the first wall and the second wall at the back wall is configured to be approximately equal to a width of a concrete form board when the concrete form board is abutted against the front side of the back wall. 
     In still another embodiment, the upper wall extends upwardly and away from a top surface of the concrete form board when in a resting position of the concrete form bracket and wherein the lower wall extends downwardly and away from a bottom surface of the concrete form board when in the resting position. 
     In yet another embodiment, the upper stake retaining portion is comprised of a first recess having a first stake receiving opening along a portion of a first side of the upper wall and a first stake retaining portion configured to retain a first portion of an elongate concrete form stake therein. Likewise, the lower stake retaining portion is comprised of a second recess having a second stake receiving opening along a portion of a first side of the upper wall and a second stake retaining portion configured to retain a second portion of the elongate concrete form stake therein when the respective one of the plurality of concrete form stakes extends through the first recess and the second recess. 
     The upper wall and lower wall are compressible toward one another when the upper wall is forced toward the lower wall and the back wall is abutting against a concrete form board positioned between the upper wall and lower wall to allow the respective one of the plurality of concrete form stakes to be positioned between the at least one concrete form board and outermost edges of the upper and lower stake retaining portions. The upper and lower stake retaining portions are biased away from one another to hold the respective one of the plurality of concrete form stakes against a surface of the concrete form board. 
     In one embodiment, the concrete form system comprises at least one pair of concrete form board end joining brackets, each configured to extend over a respective end of adjacent concrete form boards and interlock in a hermaphroditic manner. 
     The concrete form board end joining brackets form a hinge to allow the adjacent concrete form boards to pivot relative to one another until held in position with the plurality of concrete form retaining brackets. 
     Each concrete form board end joining bracket wrap at least partially around the respective end of the concrete form board and comprise a stop positioned adjacent the respective end of the concrete form board to position the respective concrete form board relative to the respective concrete form board end joining bracket. 
     In another embodiment, the concrete form board is comprised of a curved form coupled to and between the plurality of concrete form board retaining brackets. 
     In yet another embodiment, the back wall of the concrete form board retaining bracket defines an aperture and the concrete form board comprises a bracket retaining member extending therefrom. The bracket retaining member is received within the aperture to position the at least one concrete form board relative to the concrete form board retaining bracket. 
     In still another embodiment, the upper wall, lower wall and back wall of each of the plurality of concrete form brackets are each inwardly curved in a resting position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description of the illustrated embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings exemplary embodiments which illustrate what is currently considered to be the best mode for carrying out the invention, it being understood, however, that the invention is not limited to the specific methods and instruments disclosed. In the drawings: 
         FIG. 1  is a perspective view of a first embodiment of a concrete form system in accordance with the principles of the present invention. 
         FIG. 2  is a perspective back side view of a concrete form board bracket securing a concrete form board to a stake in accordance with the principles of the present invention. 
         FIG. 3  is a perspective front side view of the concrete form board bracket securing the concrete form board to the stake as illustrated in  FIG. 2 . 
         FIG. 4  is a perspective view of a first embodiment of a pair of interlocking end brackets for securing the ends of two adjacent concrete form boards in accordance with the principles of the present invention. 
         FIG. 5  is a perspective view of the pair of interlocking end brackets shown in  FIG. 4  securing the ends of two adjacent concrete form boards in accordance with the principles of the present invention. 
         FIG. 6  is a perspective view of the pair of interlocking end brackets shown in  FIG. 4 . 
         FIG. 7  is a perspective view of the concrete form bracket shown in  FIG. 2 . 
         FIG. 8  are side views of the concrete form bracket shown in  FIG. 7  illustrating the steps for coupling a concrete form board to a stake. 
         FIG. 9  is a perspective view of a second embodiment of a concrete form system in accordance with the principles of the present invention. 
         FIG. 10  is a perspective view of a concrete form bracket and a concrete form strip configured to be retained by the concrete form bracket in accordance with the principles of the present invention. 
         FIG. 11  is a perspective view of the concrete form bracket with the concrete form strip retained by the concrete form bracket in accordance with the principles of the present invention. 
         FIG. 12  is a perspective view of a second embodiment of a pair of interlocking end brackets for securing the ends of two adjacent concrete form boards in accordance with the principles of the present invention. 
         FIG. 13  is a top side view of a concrete form bracket coupled to a cylindrical stake. 
         FIG. 14  is a top side view of a concrete form bracket coupled to a cylindrical stake and a rectangular stake. 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS 
     In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. Thus, the full scope of the invention is not limited to the examples that are described below. 
     With reference now to the drawings in which like reference characters designate like or similar parts throughout the several views,  FIG. 1  illustrates a first embodiment of a concrete form system, generally indicated at  10 , in accordance with the principles of the present invention. The concrete form system  10  is comprised of a plurality of concrete form board retaining brackets  12 , each configured to retain a concrete form board  14  to a respective stake  16 . Each concrete form board retaining bracket  12  includes upper and lower stake retaining portions  18  and  20  that bias the stake  16  against the outer surface  22  of the concrete form board  14 . The upper and lower stake retaining portions  18  and  20  define recesses  24  and  26 , respectively, that engage an outer surface  28  of the stake  16  to hold the stake  16  relative to the bracket  12 . 
     As will be described in more detail, once the stakes  16  are driven into the ground G and the form board  14  is secured to stakes  16  with brackets  12 , the brackets  12  and thus the form board  14  can be vertically adjusted relative to the stake  16  without having to raise or lower the stake  16 . This is accomplished by manually squeezing the end portions  18  and  20  of the bracket  12  toward each other until they are approximately parallel, which loosens the engagement of the bracket  12  with the stake  16  and allows the bracket  12  to be vertically adjusted by sliding it up or down relative to the stake  16 . When the end portions  18  and  20  are released, the end portions  18  and  20  reengage with the stake to hold the bracket  12  relative to the stake  16 . 
     A pair of substantially identical concrete form board corner brackets  30  and  32  each have a generally C-shaped configuration and are sized to slide over respective ends  34  and  36  of concrete form boards  14  and  38 , respectively. The corner bracket  30  includes a pair of interlocking tabs  40  and  42  for engaging with corresponding interlocking tabs  44  and  46 , respectively, of corner bracket  32 . The engagement of the interlocking tabs  40  and  42  with interlocking tabs  44  and  46  connect the corner brackets  30  and  32  together in a hermaphroditic manner that allows the two corner brackets  30  and  32  to be pivotable relative to one another, thereby allowing the formation of an angle A between form board  14  and form board  38  to form a corner of concrete slab  50  having a desired angle A. 
     As further shown in  FIGS. 2 and 3 , the concrete form board bracket  12  defines a generally rectangular channel  51  between the upper and lower portions  18  and  20  and the back portion  52  that is vertically sized to receive a concrete form board  14 . The height of the back portion  52  is sized to be slightly larger than a particularly sized height of a concrete form board  14  so that the concrete form board  14  can be fitted within the channel  51  of the bracket  12 . The upper and lower portions  18  and  20  are outwardly arched or angled relative to the back portion  52 . The back portion  52  is also arched when the bracket  12  is in its free state such that when portions  18  and  20  are flexed toward one another and become substantially parallel, back portion  52  becomes straight and perpendicular to portions  18  and  20 . In addition, the bracket  12  is formed from spring steel or other resilient material, such as plastic, that will allow the curved end portions  18  and  20  to be flexed toward and become substantially parallel to one another during installation, but that will try to return to their pre-flexed state when released in order to bias the stake  16  against the form board  14  when released. 
     As best seen in  FIG. 2 , the upper and lower portions  18  and  20  of the bracket  12  each have a generally J-shaped configuration that define stake-retaining recesses  54  and  56 , respectively. The stake-retaining recesses  54  and  56  have a generally J-shaped configuration configured to partially wrap around the stake  16  when engaged therewith. That is the stake-retaining recesses  54  and  56  include stake-retaining portions  55  and  57 , respectively, that engage a portion of the stake  16  proximate the open sides  58  and  60 , respectively, of the upper and lower portions  18  and  20 . The stake-retaining portions  55  and  57  define a stake receiving recess  62  and  64 , respectively. To accommodate a cylindrical stake  16  as shown, the stake receiving recesses  63  and  64  have an arcuate configuration to substantially match the radius of the stake  16 . 
     As further illustrated in  FIGS. 4, 5 and 6 , the pair of concrete form board corner brackets  30  and  32  each has a generally rectangular and C-shaped configuration and is sized to slide over the respective ends  34  and  36  of concrete form boards  14  and  38 , respectively. The pair of interlocking tabs  40  and  42  of corner bracket  30  are spaced from the proximal end  31  of the bracket  30  and define vertical slots  41  and  43 , respectively, that vertically extend partially through the tabs  40  and  42 , for engaging with corresponding slots  45  and  47  of interlocking tabs  44  and  46 , respectively, of corner bracket  32 . The engagement of the interlocking tabs  40  and  42  with interlocking tabs  44  and  46  connect the corner brackets  30  and  32  together, as shown in  FIG. 5 , in a manner that allows the two corner brackets  30  and  32  to be pivotable relative to one another, thereby allowing the formation of an angle A between form board  14  and form board  38  to form a corner of concrete slab  50  (see  FIG. 1 ) having a desired angle A. As shown in  FIGS. 4 and 5 , the corner brackets  30  and  32  are slid onto the boards  14  and  38  to their relative stopping points  33  and  35  so that the body portions  30 ′ and  32 ′ extend beyond the ends  34  and  36  of the boards  14  and  38 , respectively. This provides space for the tabs  40 ,  42 ,  44  and  46  to pivot relative to one another as the angle A is increased without the tabs  40 ,  42 ,  46  and  48  from being impeded by contacting the ends  34  and  36  of the boards  14  and  38 , respectively. 
     Referring now to  FIG. 7 , the concrete form board retaining brackets  12  configured to retain a concrete form board to a respective stake as previously described is illustrated. Each concrete form board retaining bracket  12  includes upper and lower stake retaining portions  18  and  20  for biasing a stake against an outer surface of a concrete form board. The upper and lower stake retaining portions  18  and  20  define recesses  24  and  26  for engaging an outer surface of a stake to thereby hold the stake relative to the bracket  12 . The brackets  12  are formed from spring steel or other semi-rigid, yet resilient materials, such as certain plastics. The bracket  12  shown in  FIG. 7  is shown in a first resting position in that the upper and lower stake retaining portions  18  and  20  are upwardly arched relative to the back portion  52 , which is also arched. 
     As shown in  FIG. 8 , the upper and lower stake retaining portions  18  and  20  can be flexed relative to one another and relative to the back portion  52  as indicated by the arrows. Flexing the upper and lower stake retaining portions  18  and  20  in this manner causes the perpendicular distances D 1  and D 2  (see  FIG. 7 ) from the back portion  52  to the teeth of toothed edges  25  and  27  of the recesses  24  and  26 , respectively, to increase and provide sufficient space for a stake  16  to pass between the concrete form board  22  and the edges  25  and  27 . Releasing the upper and lower portions  18  and  20  allows the upper and lower portions  18  and  20  to spring back upward and downward, respectively, thereby grasping the stake  16  with the recesses  24  and  26  or the gripping teeth  25  and  27  (see  FIG. 7 ) of round metal or wooden stakes, respectively. 
     As shown in  FIG. 9 , a second embodiment of a concrete form system, generally indicated at  100 , is illustrated in accordance with the principles of the present invention is illustrated. Like the concrete form system  10 , the concrete form system  100  is comprised of a plurality of concrete form board retaining brackets  112 , each configured to retain a concrete form board  114  to a respective stake  116 . Each concrete form board-retaining bracket  112  includes upper and lower stake retaining portions  118  and  120  that bias the stakes  116  against the outer surfaces  122  of the concrete form boards  114 . The upper and lower stake retaining portions  118  and  120  define recesses  124  and  126  that engage an outer surface  128  of the stake  116  to hold the stake  116  relative to the bracket  112 . 
     Spanning between the concrete form boards  114  is a flexible concrete form member  130  that is held between the brackets  112  and the form boards  114 . The flexible member  130  is formed from a thin sheet of flexible material, such as sheet metal or plastic. The flexible member  130  is thick enough, however, to hold its shape once positioned between the ground fixed stake brackets  112  so as to allow for curved edges  132  to be formed in the resulting concrete pad  150 . 
     As further illustrated in  FIGS. 10 and 11 , the bracket  112  includes an aperture  162  in the back portion  152 . The aperture  162  is sized to receive a tab  164  formed in the outer surface  166  of the flexible member  130 . The tab  164  may be formed by cutting and bending a portion of the flexible member  130  or by other means known in the art, such as welding. The tab  164  is positioned to fit within the aperture  162  when the flexible member  130  is positioned against the back portion  152  between the upper and lower portions  118  and  120  in order to prevent lateral movement of the flexible member  130  relative to the bracket  112  and the form board  122  after bracket  118  is secured to the metal or wooden stake (not shown). 
       FIG. 12  illustrates another embodiment of a pair of concrete form board corner brackets  230  and  232  each having a generally C-shaped configuration and sized to slide over respective ends  234  and  236  of concrete form boards  214  and  238 , respectively. The corner bracket  230  includes a pair of hinge members  240  and  242  for engaging with corresponding hinge members  244  and  246 , respectively, of corner bracket  232 . The hinge members  240  and  242  are coupled to hinge members  244  and  246  with hinge pin  248 , which may be in the form of a large gauge nail. Once inserted, the hinge members  240  and  242  can pivot relative to hinge members  244  and  246  to allow the two corner brackets  230  and  232  to be pivotable relative to one another, thereby allowing the formation of an angle between form board  214  and form board  238  to form a corner of concrete slab having a desired angle. 
     As noted above, and as further illustrated in  FIG. 13 , the upper and lower stake retaining portions  18  and  20  of the stake retaining bracket  12  can be used with a cylindrical stake  16 . When using the cylindrical stake  16 , the curved stake retaining portion  24 ′ of the recess  24  engages an outer surface of the stake  16  to bias it against form board  22 . 
     As further illustrated in  FIG. 14 , the upper and lower stake retaining portions  18  and  20  of the stake retaining brackets  12  can alternatively be used with either a rectangular stake  17 , such as a rectangular stake  17  formed from wood. When using a rectangular stake  17 , the teeth of toothed edge  25  of the stake retaining portion  18  engages an outer surface of the stake  17  to bias it against form board  22 . 
     It is contemplated, and will be apparent to those skilled in the art from the foregoing specification, drawings, and examples that modifications and/or changes may be made in the embodiments of the invention. Accordingly, it is expressly intended that the foregoing are only illustrative of certain embodiments and modes of operation, not limiting thereto, and that the true spirit and scope of the present invention be determined by reference to the appended claims. 
     While the present invention has been described with reference to certain illustrative embodiments to illustrate what is believed to be the best mode of the invention, it is contemplated that upon review of the present invention, those of skill in the art will appreciate that various modifications and combinations may be made to the present embodiments without departing from the spirit and scope of the invention as recited in the claims. The claims provided herein are intended to cover such modifications and combinations and all equivalents thereof. Reference herein to specific details of the illustrated embodiments is by way of example and not by way of limitation. 
     Thus, aspects and applications of the invention presented here are described in the drawings and in the foregoing detailed description of the invention. Those of ordinary skill in the art will realize that the description of the present invention is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons including, without limitation, combinations of elements of the various embodiments. Various representative implementations of the present invention may be applied to any tie down cargo restraining system. 
     Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. It is noted that the inventor can be his own lexicographer. The inventor expressly elects, as his own lexicographer, to use the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise in which case, the inventor will set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such statements of the application of a “special” definition, it is the inventor&#39;s intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims. 
     The inventor is also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above. 
     Further, the inventor is fully informed of the standards and application of the special provisions of 35 U.S.C. § 112(f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description of the Invention or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112(f) to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112(f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for” and the specific function (e.g., “means for heating”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for . . . ” or “step for . . . ” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventor not to invoke the provisions of 35 U.S.C. § 112(f). Moreover, even if the provisions of 35 U.S.C. § 112(f) are invoked to define the claimed inventions, it is intended that the inventions not be limited only to the specific structure, material or acts that are described in the illustrated embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the invention, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function.