Patent Publication Number: US-6712546-B1

Title: Polymeric forms for moldable building material structures

Description:
TECHNICAL FIELD 
     In general, the present invention relates to polymeric, permanent, forms for formable building materials. More particularly, the present invention relates to permanent forms used in conjunction with formable building materials to support fuel dispensers, ATM machines, and poles bases, walkways, handicap ramps, building and kiosk forms, among others. 
     BACKGROUND OF THE INVENTION 
     Presently, metal forms are used in connection with formable building materials to mold permanent structures. As one example, steel forms are used to create concrete islands or pedestals for fuel dispensing pumps, ATM machines, lighting pole bases, walkways, handicap ramps, building and kiosk forms, and other such structures. These forms typically have an outer and inner wall. The outer wall defines the shape of the structure while the closed form inner wall defines a cavity in which the concrete is poured and hardened to form the island. Typically the closed form inner wall has a skeletal frame supported by cross a member extending therebetween. Since each site where the form is installed presents a different environment, the forms may need to be cut and rewelded to accommodate obstructions or other irregularities found at the site. 
     The formed concrete structure or island, once completed, provides structural support and helps to protect the devices that are supported on it acting as a barrier against impact. To perform this function, the forms are typically constructed to have a height of at least six inches above the ground. The forms have several designs from simple geometric island shapes, such as ovals or rectangles to more complex shapes, such as those used in fuel dispensing applications, including so-called Dogbone® “bar-bell”, or “bowtie” styles. The more complex shapes were developed with wider ends and more narrow center sections, to force vehicles outward as they approached, while providing space to open the vehicle door once parked. 
     As previously mentioned, the outer wall of these forms is typically constructed of steel. The steel forms are susceptible to corrosion and, thus, are often painted. The forms are then periodically repainted as a result of wear or fading. The steel frames are quite heavy and, since they are welded prior to delivery, can be cumbersome to handle and install. 
     Consequently, there is a need for a form that improves over the prior art by being more corrosion resistant, having less weight, being of modular construction, such that it may be easily assembled and leveled on site, and having enhanced surface appearance and life. 
     SUMMARY OF THE INVENTION 
     It is therefore, an object of the present invention to provide a form constructed of polymeric material. It is a further object to provide a form constructed of molded polymeric members. It is still a further object that the molded polymeric members be modular such that the form may be easily assembled and leveled on site. 
     In general, the present invention provides a form for formable building material structures including a plurality of polymeric segments coupled to one another to define a cavity for receiving the concrete, or other formable construction material. 
     The present invention further provides a form for formable building material structures including at least one hollow polymeric segment, the segment having an outer surface and an inner surface spaced radially inwardly from the outer surface by top and bottom surfaces, where the inner surface transcends a pair of ribs vertically spaced from each other by a well defined by opposed sides of the ribs and a connecting surface therebetween. 
     The present invention further provides a segment coupling assembly in a segmented form for moldable building materials, the form having a pair of ribs separated by a well, the segment coupling assembly comprising: an insert supported on each segment between said ribs to span said well, said insert defining a coupler receiving opening; and a coupling member received in said opening on at least two segments and adapted to couple said two segments to one another. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded view of a polymeric form for concrete structures according to the present invention depicting side segments, end segments and arcuate segments joined to define a form for receiving concrete with the form anchored by an anchor assembly; 
     FIG. 2 is side elevational view of a segment in a form according to the present invention having rails located thereon; 
     FIG. 2A is a sectional view as might be seen along line A—A in FIG. 2 depicting the attachment of the rails in greater detail; 
     FIG. 3 is a perspective view of a segment in a form according to the present invention depicting the male and female portions of the segment used to interconnect adjacent segments in greater detail; 
     FIG. 4 is perspective view of an arcuate segment in a form according to the present invention enlarged to show greater detail thereof; 
     FIG. 5 is an enlarged perspective view of the circled area indicated by the letter A in FIG. 1 depicting the anchor assembly in greater detail; 
     FIG. 6 is an enlarged perspective view of the anchor assembly removed from the rails on a segment to show greater detail of the anchor assembly; 
     FIG. 7 is an enlarged perspective view of a bracket in the anchor assembly enlarged to show greater detail; 
     FIG. 8 is a perspective view of a lever lock assembly according to the present invention enlarged to show greater detail thereof; 
     FIG. 9 is a perspective view of a rail used to attach the anchor assembly to the segment; 
     FIG. 10 is an end view of a rail similar to that depicted in FIG. 9, enlarged to show greater detail thereof; 
     FIG. 11 is a cross-sectional view of a form according to the present invention as might be seen along line  11 — 11  of FIG. 1 showing the form filled with a formable building material; 
     FIG. 12 is a perspective view of a pair of segments in a form according to the present invention depicting details of the attachment of one segment to the other; 
     FIG. 13 is a perspective view similar to FIG. 12 depicting an alternative attachment of the segments; 
     FIG. 14 is a perspective view of a segment according to the present invention depicting details of one embodiment of a segment trim strip and a lighting assembly; and 
     FIG. 15 is a perspective view of a segment according to the present invention depicting details of one embodiment of a segment coupling assembly and a lighting assembly. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A form for formable building material structures, generally indicated by the numeral  10 , is shown in the accompanying figures. The form  10  has an inside surface  12  that defines a cavity C in which formable building material M is received. Initially, the material M is in a liquid state and gradually gets to a solid state taking on the shape of cavity C. The form  10  may be left to form an outside barrier surrounding the hardened material M and, thus, is referred to as a permanent form in the industry. There are many formable materials M that are commercially available and used in the industry in conjunction with a form  10  including but not limited to asphalt, concrete, shotcrete, fiber reinforced concrete, and other cementitious materials. All of these materials M may be suitably formed by the form  10  and are included within the definition of formable material M as used to in this description. To provide a light-weight structure for forming material M, the form  10  may be constructed of polymeric material, such as olefins including polypropylene and polyethylene, and polyamides, including nylon. Form  10  is of any desirable shape, which may be determined by the particular application for the form  10 , including, for example, oval, bowtie, barbell, Dogbone®, or rectangular shapes, often used in fuel dispensing island applications. It will be appreciated that the form  10  may define a cavity C of any shape including geometric shapes or custom shapes as desired by the ultimate consumer. As shown in FIG. 1, the form  10  may be constructed of a plurality of segments including side segments  11 , and corner segments  13 . The segments  11 ,  13  may be of any shape or configuration and include straight and curved portions. Reference to side sections  11  and corner sections  13  are made to simplify the description and are not limiting. To assemble the form  10 , the segments  11  and  13  may be coupled by fasteners, adhesives, or other suitable methods, including the interlocking of segments  11 ,  13  as shown in the figures. By way of example, as shown in FIG. 1, a male portion  14  of one side segment  11  A may be slidably received within the female portion  15  of the adjacent corner section  13 . To more permanently fix these joints, mechanical fasteners and devices may be used and/or a glue or epoxy may be applied to each end  14 ,  15  as will be described more completely below. 
     By constructing the form  10  of multiple segments, the form  10  is more flexible in terms of its ultimate application. For example, the size of form  10  may be altered by adding or removing segments as appropriate. Further, the disassembled segments may be more easily transported than a completed form  10 . These segments, once on site, would be assembled to create a complete form  10 . 
     To provide rigidity suitable for retaining material M, form  10  is constructed with a reinforced profile. In general, the reinforcing profile is characterized as being nonlinear having at least one inwardly projecting surface. The projecting surface may take on number of shapes including various geometric shapes. Therefore, the particular shape of the inwardly projecting surface is not considered limiting and may be a function of the particular material to be used. To simplify the description, the inwardly projecting surface will be referred to as a rib. As will be described more completely below, multiple inwardly projecting surfaces or ribs may be used in accordance with the present invention. As will be understood, it is preferred, when using such ribs, to maximize the moment of inertia of the form  10  while minimizing the amount of material used to create the form  10 . 
     As best shown in FIG. 2A, the exposed surface  16  of form  10  resembles a typical concrete form having a generally planar lower portion  17  with an overhanging rim  20 . Within the inner portion of the form  10 , the form  10  is provided with one or more reinforcing ribs  25 . Ribs  25  may be tapered inwardly toward an inner rib wall  27  spaced inwardly from the exposed surface  16  of the form  10 . As will be understood, the taper facilitates manufacturing of form  10 . In the embodiment shown in FIG. 4, a pair of ribs  25 A,  25 B project inwardly from the segments  11  and  13 . The first rib  25 A is located at a distance D below the top surface  19  of the rim  20  such that, when the material M is poured, a layer of formable material M fills the generally L-shaped recess  29  formed between the inner wall  31  of the rib  20  and the upper side wall  32  of reinforcing rib  25 A. The recess  29  aids the installer in filling the form  10  without overflow and helps to prevent cracking of the material commonly found in prior art systems where a planar form is used. The top surface  19  of the rim  20  may be made level to facilitate the pouring and leveling of the concrete within the form  10 . The lower rib  25 B is generally similar to rib  25 A having a taper toward its inner rib wall  27 B. Since the lower reinforcing rib  25 B may rest on the ground, as shown in FIG. 1, the lower surface may be made level to allow the form  10  to lay flush on a supporting surface. The transition between the exposed surface  16  of the form  10  and the lower reinforcing rib  25 B, may be eased with the use of a corner round  34 . 
     Since the form  10  is constructed of a polymeric material, it is lighter than a steel form, of similar dimension. To further reduce the weight of the form  10 , its segments may be made hollow, thus defining a bore  30 . Bore  30  may generally conform to the cross sectional shape of the form  10  and may be closed by an end cap  36  formed on the male portion  14  of each segment. As best shown in FIG. 2, the bore  30  is truncated to an extent at the male portion  14  of a segment, due to the dimensional reduction necessary to fit the male portion  14  within the female portion  15  of an adjacent segment. 
     In terms of individual segments, the cross section of each segment  11 ,  13  is generally the same to provide continuity in the form  10 . The arcuate segments  13  shown in FIG. 4 may have an L-shape configuration with an intermediate portion  37  joining the male and female portions  14 ,  15 , which are opposed substantially at a right angle. The intermediate portion  37  may be square or rounded as shown. It will be appreciated that due to the transition at an arcuate segment, the cross section may be varied as necessary. While a 90° arcuate section  13  is shown, it will be appreciated that arcs tracing any angle may be formed as necessary for the form  10 , such as the ends of a barbell form. Further, the length of the intermediate portion  37  may be varied to achieve the appropriate shape of the form  10 . As in the case of other segments, the arcuate corner segments  13  may be provided with interlocking portions  14 ,  15  in a configuration other than the male/female configuration shown. It will be appreciated that a segment may have two male ends or two female ends such that an intermediate segment having the opposite type of end is used to join adjacent segments. In fact, a coupler (not shown) with the appropriate ends may be provided to join adjacent ends of the same type such as a male or female juncture. 
     To facilitate transport, the form  10  may be constructed at the site, such that the individual segments may be boxed or otherwise transported for assembly. Appropriately shaped segments would be provided for a desired form  10  or customized forms  10  may be constructed by assembling necessary segments at the site. The form  10  is laid out to perform its function, such as protecting and elevating fuel pumps. To that end, the form  10  may be laid out on a supporting surface such as the ground and once the desired shape is obtained, the segments  11 ,  13  would be mechanically fastened and/or glued if necessary. 
     An anchor assembly  40  is provided for leveling and to restrict movement of the form  10  during installation. Anchor assembly  40  may include an anchor bracket  41 , which may be constructed of metal (FIG. 7) and attached to the interior surface of the form  10 , such as inner rib walls  27 . Anchor bracket  41  is provided with a receiver  44  to allow for some adjustment of the position of anchor member  42  in which an anchor member  42 , such as a rod, a threaded member, or reinforcement bar is received. Receiver  44  may be an opening to allow for some adjustment of the position of anchor member  42  or slot as shown. Receiver  44  may be formed on a pair of bracket arms  43  extending inwardly from the base  53  of the bracket. Bracket arms  43  may be stamped from the base and have a slot type receiver  44  near to the base  53 . In that regard, the bracket arms  43  may be characterized as having an L-shape. 
     A locking assembly  45  may be provided to fix the anchor member  42  within receiver  44 . A number of suitable mechanisms available in the art, including fasteners or clamps, may be used to hold the anchor member  42  within receiver  44 . 
     In the embodiment shown in FIG. 6, a lever-type locking assembly  45  is used to apply a clamping force holding the anchor member  42  in receiver  44 . The locking assembly  45  includes a lever arm  46  pivotally attached to the bracket  41 , as by a pin P, and is generally located adjacent to receiver  44  such that upon actuation, it applies a clamping force to the anchor member  42  to hold the anchor member  42  within receiver  44 . Lever arm  46  is provided with lock arms  47  that extend toward the anchor member  42  and may extend in a plane perpendicular to the plane of the lever arm  46 , as shown. Lock arms  47  may be located within bracket arms  43  and each provided with corresponding pin receivers  48  to accept the pin P and pivotally couple lever arm  46  to bracket  41 . While the embodiment depicted has two arms  47  used to create locking contact at two points, it will be appreciated that one or more contact points may be used. In the embodiment shown a pair of locking arms  47  are spaced from each other and grasp the anchor member  42  at two points. Lock arms  47  are provided with a cam-like edge  49 , which may generally be semi-circular, that applies the greatest clamping force when in its locked position (FIG.  6 ). As shown in FIG. 6, when edges  49  are in the locked position they effectively trap the anchor member  42  within receiver  44 . By rotating the lever arm  46  toward the unlocked position, the force applied to the anchor member  42  is reduced and the cam-like lock edges  49  clear the anchor member  42  such that it may be moved within receiver  44 , Vertical adjustment of the form  10  may be attained by releasing anchor member  42  and moving the segments vertically to the desired position. Once the proper height has been attained, the locking assembly  45  is used to hold the form  10  relative to the anchor member  42 . 
     It will be appreciated that this horizontal adjustment of the bracket  40  relative to the anchor member  42  allows for horizontal adjustment of the individual segments or the entire form  10 , as necessary. To provide horizontal adjustment, bracket  40  may be slidably received on a rail (FIG.  9 ), generally indicated by the numeral  50 , which may be made of metal as shown in FIG.  2 A. Rail  50  may be formed to define a bracket receiver  51  that slidably receives at least a portion of the bracket  41  such as its edge  52 . In that respect, the rails  50  may be provided with a slot-form receiver  51  having a mouth  54  to receive the edge  52  of a planar bracket base  53 . When a pair of opposed rails  50  are used the mouths  54  of each rail  50  would face each other. Opposite edges  52  of the base  53  would be slidably received, between the proposed rails  50 . With the bracket  41  so mounted, the horizontal position of the form  10  for the individual segments  11 ,  13  may be adjusted by sliding the segments  11 ,  13  or form  10  relative to the anchor assembly  40 . Ordinarily, the position of the anchor member  42  is generally fixed because the anchor member  42  is driven into the ground or otherwise attached to a supporting surface . It will be appreciated that similar adjustment of the form or segment position may be made by moving the anchor member  42  relative to the form  10 . If necessary to accommodate this movement, the bracket  41  could be slid along the rails  50 . Thus, the form  10  may be positioned vertically and horizontally in the desired position and modified through the use of segments to achieve the appropriate configuration for the particular site without resorting to rewelding or producing a new form. 
     The anchor bracket  40  may be used to attach other members to the segments  11 ,  13 , including braces, a support members, or other members used to suspend items within the cavity C, such as a Power Strut System® S (FIG.  5 ). In addition, the segments  11 ,  13  may be used in conjunction with the Power Strut System® S to suspend items within the cavity C. In a fuel dispenser application, such items may include dispenser mounting boxes, containment sumps, or conduit for gases, liquids, or wiring. 
     The rails  50  may be integrally molded into or suitably attached to the form  10  such that the anchor assembly  40  is housed within the form  10 . The rails  50  may be attached by suitable commercially available methods including fasteners, adhesives, or resilient snap fasteners. As shown in FIG. 2 a , the inner rib walls  27  of reinforcing ribs  25  may define a rail receiver, generally indicated by the numeral  55 . Rail receiver  55  includes a generally T-shaped recess  56  which has a mouth  57  forming the lower portion of the T and a base portion  58  forming the upper portion of the T. In general, the mouth portion  57  is sized smaller than the base portion  58  such that a tab, generally indicated by the numeral  60 , received within recess  56  is prevented from withdrawing inwardly from receiver  55 . It will be appreciated that receiver  55  of this type may be used such as an L-shaped recess  56 . 
     As best shown in FIG. 10, tab  60  is shaped to generally conform to the receiver  55  and one or more tabs  60  may be formed or attached to the rail  50  for purposes of securing the rail  50  to the form  10 . In FIG. 9, the rail  50  is formed with a single tab  60  extending substantially the entire length of the rail  50 . This tab  60  is slidably inserted within the receiver  55 . To correspond with the T-shaped recess  56 , tab  60  includes a neck portion  61  that extends outwardly from a backing member  62  of the rail  50 , which may extend toward the horizontally extending center line of the segment to a greater extent than the face member  63 . The neck portion  61  extends generally perpendicular to the backing member  62  conforming substantially to the gap defined by the mouth portion  57  of recess  56 . A head portion  64  extends laterally outwardly on either side of the neck portion  61  forming a generally T-shaped tab  60 . Like neck portion  61 , the head portion  64  generally conforms to the dimensions of the base portion  58  such that the tab  60  fits snugly within the rail receiver  55 . Thus, in response to a force attempting to pull the rail  50  inward away from the form  10 , the interior surfaces  65 ,  65  of the tab  60  engage the wall  66  of receiver  55  to prevent the rail  50  from being pulled from the form  10 . As an alternative to fastening, the rails  50  may be integrally formed into one or more of the segments. 
     As previously mentioned, the individual segments  11 ,  13  may be attached in various combinations to create a selected cavity C, as desired or necessary to the individual application. Segments  11 ,  13  may be attached using the male and female interlocking method described above. To further secure the male female connection or as an alternative thereto, mechanical devices or fasteners may be used. To that end, any of the numerous fasteners commercially available including traditional fasteners, such as screws, bolts, nuts, and rivets, and deformable fasteners, such as, expandable clips, plastic rivets, or Christmas trees may be used to join adjacent sections. In addition to these techniques, segments may be fastened as follows. 
     A segment coupling assembly, generally indicated by the numeral  80  may be provided and generally includes at least one segment coupling receiver  81 . Segment coupling receiver  81  may be carried on each segment  11 ,  13  to provide an attachment point for joining the segments  11 ,  13 . As shown in FIG. 15 the segment coupling receiver  81  may be one or more openings in a wall  82  of the segment  11  through which a fastener F, such as a screw, may be passed to secure adjacent segments. The openings may be formed in the male and female portions  14 ,  15  such that when the male portion  14  is fitted within the female portion  15  the openings on the adjacent segments align and the fastener F may be inserted therethrough. Alternatively, fastener F may be driven through adjacent segments without using a pre-made opening. It will be appreciated, however, that driving the fastener F through the adjacent segments  11 ,  13  will create openings in the segments, which are considered to fall within the receiver terminology. 
     Aside from forming the segment coupling receiver  81  in the wall  82  of the segments  11 ,  13 , coupling brackets generally indicated by the numeral  85  (FIG. 12) may be formed into the segments  11 ,  13  or attached to the segments  11 ,  13 . As shown in FIG. 12, a plate-like member  86  may span the well  26  between ribs  25 A,  25 B. A coupling member, generally indicated by the numeral  87 , such as a clamp or fastener  88 , such as a nut and bolt combination, may be used to apply coupling forces to the coupling bracket  86  on respective segments  11 ,  13  and hold the segments  11 ,  13  together. As shown in FIG. 12, a fastener  88  may fasten coupling brackets  86 ,  86 , located on either side of a segment joint  89 , together. The segment coupling assembly  80  may alternatively include the locking member  40  as described above. 
     With reference to FIG. 13, it will be seen that to use the locking member  40 , locking member  40  is configured, as by 90° rotation, to receive a horizontally extending anchor member or coupling member  87 , which may be a rod  91 , as shown. In this embodiment a first locking assembly  40 A located on a first segment  11 A and a second locking assembly  40 B located on a second segment  11 B, to be coupled with first segment  11 A, both receive and grasp a single rod  91  such that the segments  11 A,  11 B are axially fixed with respect to the rod  91  and each other. 
     As a final note with respect to segment coupling, coupling does not necessarily have to occur between adjacent segments  11 A,  11 B. Segments on either side of one or more intermediate segments may be joined and exert sufficient compressive force to hold the intermediate segments in the desired configuration to create a form cavity of proper shape and dimension. 
     Once the form  10  is in the desired position and configuration, the form  10  may be filled with formable building material M, as is generally practiced in the art. Upon doing so, the material M fills the cavity C of the form  10  including the well  26  between reinforcing ribs  25  and the recess  29  formed between the upper reinforcing rib  25 A and the interior surface  32  of rim  20 . As previously mentioned, to assist in leveling the material M within the form, the top surface  19  of rim  20  may be made substantially flat such that the top surface of the material M may be leveled with a float supported on the top surface  19  of form  10  and dragged across the material M. Once completed, the combination form  10  and material M is an attractive functional form having an outer surface that has increased resistence to corrosion and better wearability than steel forms presently used. The use of polymeric materials allows the form  10  to be molded in a variety of shapes and profiles for functional or aesthetic purposes. To further improve the aesthetics of the form  10  and/or improve the form&#39;s ability to function as a safety mechanism, a lighting assembly generally indicated by the numeral  70 , may be attached to the form  10  or formed into form  10  and include a light receiver  71  and lights, generally indicated by the numeral  72 , including individual bulbs (FIG. 3) strip lights or filamentary lumens (FIGS. 14 and 15) such as fiber-optic lights that would aid pedestrian safety and motor vehicle operation. Conveniently, the bore  30  of form  10  may be used to house the mounting hardware for these lights and the power cables connecting the lights to a power supply. In the embodiment depicted in FIG. 15, lighting assembly  70  includes a peripheral recess on the form  10  that receives a filamentary lumen  73 . FIG. 15 shows a single segment having a portion of the peripheral notch  74  shown formed in the rim  20  of the form  10 . It will be appreciated that the lighting assembly  70  may be placed at other locations on the exterior surface  16  of the form including the top portion  19 . Alternatively, as shown in FIG. 3, form  10  may have a receiver  71  in the form of a socket for an individual bulb  72 . As a further alternative, the light assembly  70  may simply include a reflective strip. 
     To further improve aesthetics or safety, other objects may be attached to the form  10  such as a trim strip T. Trim strip T may also provide for the attachment of lighting assembly  70  and may include an integrally formed receiver  74 , such as a clip or recess, for this purpose. 
     In light of the foregoing, it will be appreciated that a new and useful form for moldable building material structures has been disclosed in accordance with the patent laws. It will further be appreciated that various modifications may be made to the disclosed invention without deviating from the spirt thereof, and thus, to determine the appropriate scope of the invention, reference should be made to the following claims.