Patent Publication Number: US-10767377-B1

Title: Concrete form spreader

Description:
RELATED APPLICATIONS 
     The present invention claims the benefit of U.S. Provisional Application No. 62/220,268 filed on Sep. 18, 2015, the entire disclosures of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the field of concrete construction and, more particularly, to a spreader for reinforcement bar support structures and concrete formworks used in concrete construction. 
     BACKGROUND OF THE INVENTION 
     In general, concrete construction often requires a formwork to maintain the specified shape and dimensions of the concrete structure, such as a concrete wall, during the pouring of the concrete. In order to maintain the required shape and specifications, the formwork must be properly reinforced because the weight of the wet, flowable concrete can alter the shape of the walls of the formwork without such proper reinforcing. In certain applications, adequately reinforcing the formwork with external bracing can be expensive due to the cost of the additional materials and labor. Additionally, often there is inadequate space around the forms to provide proper reinforcing and structural support to hold the concrete forms. 
     To prevent the forms from moving outward away from the concrete, ties are generally used to resist the outward forces of the concrete by pulling the forms inwardly. These ties are generally permanently embedded within the concrete and cannot be removed once the concrete has been set. These types of ties often pose problems when the completed concrete walls are indented to be sealed to prevent water from seeping in or out of the completed concrete wall. 
     Further, to prevent the concrete formwork from bowing inwardly, the forms must either be externally reinforced or have a spreader installed within the formwork to push outwardly on the formwork. One (1) disadvantage of the current method for spreading the form is that the spreading devices sometimes interfere with the fabrication of the reinforcing structure of the concrete wall. Additionally, spreaders can often pose problems with sealing the concrete wall from leaking water from or into the concrete walls. 
     Accordingly, there exists a need for a concrete formwork spreader that addressed the disadvantages described above. 
     SUMMARY OF THE INVENTION 
     The inventor has recognized the aforementioned inherent problems and lack in the art and observed that there is a need for a device to maintain a concrete formwork from bowing inwardly during concrete construction, while maintaining the ability to provide a concrete wall that provides adequate sealing from water moving into or out of the completed concrete wall. The development of the present invention, which will be described in greater detail herein, fulfills this need. 
     In an exemplary embodiment, the disclosed concrete formwork spreading device includes a tie rod including opposing ends, and a pair of end caps connected to the opposing ends of the tie rod. Each one (1) of the pair of end caps includes a contacting face, wherein the contacting face is flat. Each one (1) of the opposing ends of the tie rod is one (1) of permanently connected or removably connected to an associated one (1) of one (1) pair of end caps. The contacting face of each one (1) of the pair of end caps is spaced apart by a distance, the distance is equal to a thickness of a concrete wall formed using the device. The distance between the contacting face of each one (1) of the pair of end caps is one of fixed or adjustable. 
     In another exemplary embodiment, the disclosed method for forming a concrete structure includes the steps of: 1). constructing a reinforcing frame including a plurality of reinforcing bars, 2). using at least one (1) concrete formwork spreading device including a tie rod including opposing ends, and a pair of end caps connected to the opposing ends of the tie rod, 3). placing at least one (1) concrete formwork spreading device in contact with and supported by an opposing pair of the plurality of reinforcing bars, 4). constructing a formwork around the reinforcing frame with the pair of end caps abutting an interior surface of the formwork, and 5). pouring concrete within the framework and around the reinforcing frame and the at least one (1) concrete formwork spreading device. 
     Furthermore, the described features and advantages of the disclosure may be combined in various manners and embodiments as one skilled in the relevant art will recognize The disclosure can be practiced without one (1) or more of the features and advantages described in a particular embodiment. 
     Further advantages of the present disclosure will become apparent from a consideration of the drawings and ensuing description. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The advantages and features of the present disclosure will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which: 
         FIG. 1  is an environmental side elevation view of an embodiment the disclosed concrete form spreader used during formation of a concrete wall; 
         FIG. 2  is a side elevation view of another embodiment of the disclosed concrete form spreader; 
         FIG. 3  is a cross-sectional view of an embodiment of an end cap of the disclosed concrete form spreader; 
         FIG. 4  is a side elevation view of another embodiment of the disclosed concrete form spreader; 
         FIG. 5  is a cross-sectional view of another embodiment of an end cap of the disclosed concrete form spreader; 
         FIG. 6  is a cross-sectional view of another embodiment of an end cap of the disclosed concrete form spreader; 
         FIG. 7  is a side elevation view of another embodiment of the disclosed concrete form spreader; and, 
         FIG. 8  is a cross-sectional view of another embodiment of an end cap of the disclosed concrete form spreader. 
     
    
    
     DESCRIPTIVE KEY 
     
         
         
           
               10  concrete form spreader 
               10   a  fixed concrete form spreader 
               10   b  adjustable concrete form spreader 
               12  end cap 
               14  tie rod 
               16  end of tie rod 
               18  first tie rod section 
               20  second tie rod section 
               22  turnbuckle 
               24  first end of tie rod section 
               26  second end of tie rod section 
               28  coupling nut 
               30  plate washer 
               32  first end of turnbuckle 
               34  second end of turnbuckle 
               36  body of end cap 
               38  wing of end cap 
               40  contacting face 
               42  tie wire 
               44  thread 
               50  reinforcing frame 
               52  reinforcing bar 
               54  formwork 
               56  concrete 
           
         
       
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In accordance with the invention, the best mode is presented in terms of exemplary embodiments, herein depicted within  FIGS. 1-8 . However, the invention described herein is not limited to a single described embodiment and a person skilled in the art will appreciate that many other embodiments are possible without deviating from the basic concept of the disclosure and that any such work around will also fall under its scope. 
     Further, those skilled in the art will recognize that other styles and configurations can be incorporated into the teachings of the present disclosure, and that the example configurations shown and described herein are for the purpose of clarity and disclosure and not by way of limitation. 
     As used herein, the singular terms “a”, “an”, and “the” do not denote a limitation of quantity, but rather denote the presence of at least one (1), as well as a plurality of, the referenced items, unless the context clearly indicates otherwise. 
     Referring to  FIGS. 1-8 , disclosing a concrete form, or formwork, spreader, herein generally referred to as a device  10 , where like reference numerals represent similar or like parts. Generally, the disclosed device  10  is directed to a concrete formwork spreader in either an adjustable embodiment or a fixed embodiment. 
     Generally, the disclosed device  10  is a forming aid for use when pouring concrete walls. The device  10  generally includes two (2), for example, cubical, pieces of concrete or “dobies” that are cast around a short section of reinforcing bar or “rebar”. In various embodiments, the device  10  may be made available in multiple sizes to fit numerous different types of wall construction styles and thicknesses. 
     In an exemplary embodiment, the overall outside length of the device  10  is approximately the same as a wall thickness. The device  10  may be attached to existing rebar wall reinforcement with the use of tie wires  42 . The dobies ensure that the rebar remains at the proper recessed distance, while the rebar aids in holding the dobies in place, as well an insuring that the existing reinforcing rebar is properly positioned before the concrete pour and remains in place during the entire concrete pour. The ability to hold the reinforcing rebar in place also ensures that the reinforcing rebar does not drift into the middle of the wall where its strength qualities will be diminished. The dobies also make contact with the walls of the formwork to prevent the formwork from flexing inwardly during concrete construction. 
     The present disclosure recognizes various advantages provided by the disclosed device  10 , such as saving time during the wall forming process and ensuring a higher quality finish product that is the exact thickness required. 
       FIG. 1  is a schematic illustration of an environmental side elevation view of one (1) embodiment of the disclosed device  10 . The device  10  includes two opposed end caps  30 . In an example, the end caps  30  are concrete blocks, also referred to as dobie blocks or dobies. The end caps  30  are connected to a tie rod  14 . The tie rod  14  spaces the end caps  12  apart from each other by a predetermined distance D. The distance D may be substantially equal to the thickness of the concrete wall being formed. The end caps  12  abut an interior surface of the concrete formwork  54  to provide resistance to the inward deflection of the formwork  54 . The end caps  30  are consumed within the process of forming a concrete wall as the concrete  56  hardens around them and will be permanently embedded in the finished concrete wall upon removal of the concrete formwork  54 . 
     As illustrated in  FIG. 1 , in an example implementation of use, the device  10  may be used to appropriately space different sections of reinforcing bars  52  of a reinforcing frame  50 , or rebar mesh, used when pouring and forming a concrete structure, such as a concrete wall. As an example, the tie rod  14  may be positioned on and supported by a pair of opposing horizontally oriented reinforcing bar  52 . The opposed end caps  12  restrict movement of horizontally oriented and/or vertically oriented reinforcing bars  52 , for example, during the pour of concrete into a formwork over the reinforcing frame  50 . The tie rod  14  may be secured to one (1) or more horizontal and/or vertical reinforcing bars  52 , for example, with tie wire  42 . 
     Thus, the device  10  serves to appropriately position and space the sections of reinforcing bars  52  within the poured concrete wall. 
       FIG. 2  is a schematic illustration of a side elevation view of one embodiment of the disclosed device  10 . The embodiment illustrated in  FIG. 2  depicts the fixed concrete form spreader, also generally referred to herein as the fixed device  10   a . The device  10   a  includes the two opposed end caps  12 . The end caps  12  are coupled to the tie rod  14 . The length of the tie rod  14  and the dimensions of the end caps  12 , defining the overall dimension D of the device  10   a , may depend upon the ultimate thickness of the concrete wall being formed. Thus, in this embodiment, the dimension D of the device  10   a  is fixed. 
       FIG. 3  is a schematic illustration of a partial section view of the device  10   a  depicting an embodiment of the end cap  12 . In this embodiment, the end caps  12  are permanently connected (e.g., affixed) to the tie rod  14 . In an example construction of this embodiment, the end caps  12  are concrete blocks formed, for example, cast, around each end  16  of the tie rod  14 . Because the end caps  12  are made of concrete, there is no need for further sealing of the concrete structure at the intersection of the end caps  12  and the finished wall. In an example construction of this embodiment, the tie rod  14  is a section of reinforcing bar, also known as rebar, such as a section of steel rebar. 
       FIG. 4  is a schematic illustration of a side elevation view of another embodiment of the disclosed device  10 . The embodiment illustrated in  FIG. 4  depicts the adjustable concrete form spreader, also generally referred to herein as the adjustable device  10   b . The device  10   b  includes the two (   2   ) opposed end caps  12 . In this embodiment, the length of the tie rod  14  is adjustable. The tie rod  14  includes a first tie rod section  18 , a second tie rod section  20  and a turnbuckle  22 . A first one (1) of the end caps  12  is coupled to the first tie rod section  18 . A second one (1) of the end caps  12  is coupled to the second tie rod section  20 . Each tie rod section  18 ,  20  includes a first end  24  and a second end  26 . In an example construction of this embodiment, at least a portion of the length of each tie rod section  18 ,  20  includes thread  44  (e.g., external threading), for example, at or near the second end  26 . In another example construction of this embodiment, the entire length of each tie rod section  18 ,  20  includes thread  44 . 
     The turnbuckle  22  is threadingly connected to the second end  26  of each tie rod section  18 ,  20  to interconnect the tie rod sections  18 ,  20 . The turnbuckle  22  is configured to be used to adjust the height or the width of the concrete formwork prior to pouring the concrete  56  ( FIG. 1 ) of the concrete wall. The turnbuckle  22  has a first end  32  where the first tie rod section  18  is capable of adjustable extension outwardly therefrom and a second end  34  where the second tie rod section  20  is capable of adjustable extension outwardly therefrom. The length of the tie rod  14  and the dimensions of the end caps  12  may depend upon the ultimate thickness of the concrete wall being formed. The turnbuckle  22  adjusts (e.g., shortens or lengthens) the length of the tie rod  14  in response to rotation of the turnbuckle  22  relative to the tie rod sections  18 ,  20 . Thus, in this embodiment, the dimension D of the device  10   b  is adjustable. 
       FIG. 5  is a schematic illustration of a partial section view of the device  10   b  depicting another embodiment of the end cap  12 . In this embodiment, the end caps  12  are removably connected (e.g., attached) to the tie rod sections  18 ,  20 . Each one (1) of the end caps  12  includes a coupling nut  28  embedded within the end cap  12 . In an example construction of this embodiment, the end caps  12  are concrete blocks formed, for example, cast, around the coupling nut  28 . The location and/or position of the coupling nut  28  within the end cap  12  may vary, however, in the illustrated embodiment, the coupling nut  28  is positioned flush with an exterior surface of the end cap  12  at an approximate center of one (1) side of the end cap  12 . Because the end caps  12  are made of concrete, there is no need for further sealing of the concrete structure at the intersection of the end caps  12  and the finished wall. In an example construction of this embodiment, each of the tie rod sections  18 ,  20  may be a section of threaded rod, coil rod or the like. 
     The coupling nut  28  includes a threaded inner diameter configured to matingly engage the thread  44  of the tie rod sections  18 ,  20 . In an example construction of this embodiment, the end cap  12  may also include one (1) or more plate washers  30 . As one (1) example, a plate washer  30  is positioned between the coupling nut  28  and the interior surface of the end cap  12 . As another example, a plate washer  30  is positioned over the exposed end of the coupling nut  28 . As yet another example, a plate washer  30  is positioned between the coupling nut  28  and the interior surface of the end cap  12  and over the exposed end of the coupling nut  28 . In any of these examples, the plate washer  30  may be bonded, for example, with an epoxy, to the end cap  12  and/or the coupling nut  28 . 
       FIG. 6  is a schematic illustration of a partial section view of the device  10   b  depicting another embodiment of the end cap  12 . In this embodiment, the end caps  12  are permanently connected (e.g., affixed) to the tie rod sections  18 ,  20  (only the first tie rod section  18  is shown in  FIG. 6 ). In an example construction of this embodiment, the end caps  12  are concrete blocks formed, for example, cast, around the first end  24  of each tie rod section  18 ,  20 . Because the end caps  12  are made of concrete, there is no need for further sealing of the concrete structure at the intersection of the end caps  12  and the finished wall. In an example construction of this embodiment, each of the tie rod sections  18 ,  20  may be a section of threaded rod, coil rod or the like. 
     In embodiments illustrated in  FIGS. 2-6 , each one of the end caps  12  has an approximately cubical shape. However, in other embodiments, the shape of the end caps  12  may vary depending upon the particular application or implementation of the device  10 . As examples, the end caps  12  may have various other three-dimensional, for example, polyhedron, shapes. 
       FIG. 7  is a schematic illustration of a side elevation view of another embodiment of the disclosed device  10 .  FIG. 8  is a schematic illustration of a partial section view of the device  10  depicting another embodiment of the end cap  12 . As described above, the end cap  12  may have various alternate shapes depending on the specific application or implementation of the device  10  and/or required specifications of the concrete structure or the concrete formwork  54  ( FIG. 1 ). 
     In the illustrated embodiment, each of the end caps  12  includes a body  36  and two (2) or more wings  38  extending radially outward from the body  36 . Each pair of two (2) wings  38  may be directly opposite to one (1) another. The shape of the body  36  and the number of wings  38  may vary depending on the specific application or implementation of the device  10 . In the illustrated embodiment, the body  36  has an octagonal prism shape. Four (4) equally spaced apart wings  38  extend from four (4) of the eight (8) sides of the body  36 . In other embodiments, the body  36  may have other three-dimension shapes Similarly, different numbers of wings  38  may extend from the body  36 , for example, depending upon the total number of side of the body  36 . 
     The embodiment illustrated in  FIG. 7  depicts the fixed device that includes a fixed length tie rod  14  coupled to the two (2) end caps  12 . However, in other embodiments, the tie rod  14  may be adjustable, including the first tie rod section  18 , the second tie rod section  20  and the turnbuckle  22 , as illustrated in  FIG. 4 . 
     In an example construction of this embodiment, the end caps  12  are permanently connected (e.g., affixed) to the tie rod  14 . For example, the end caps  12  may be concrete blocks formed, for example, cast, around each end  16  of the tie rod  14 . In another example construction of this embodiment, the end caps  12  are removably connected (e.g., attached) to the tie rod sections  18 ,  20  via the coupling nut  28  embedded within the end cap  12 . For example, the end caps  12  may be concrete blocks formed, for example, cast, around the coupling nut  28 . In yet another example construction of this embodiment, the end caps  12  are permanently connected (e.g., affixed) to the tie rod sections  18 ,  20 . For example, the end caps  12  are concrete blocks formed, for example, cast, around the first end  24  of each tie rod section  18 ,  20 . 
     Referring to  FIGS. 2, 3 and 5-8 , in another embodiment, the device  10  includes integral tie wires  42 . In an example construction, at least two (2) tie wires  42  are permanently connected (e.g., affixed) to each one (1) of the pair of end caps  12 . As an example, the tire wires  42  may be cast within the concrete end caps  12  during the casting process. The tie wires  42  may extend from the end caps  12  in the same general direction as the tie rod  14 . The tire wires  42  may be positioned adjacent to or otherwise in close proximity to the tie rod  14 . As an example, the tire wires  42  may be sixteen-and-a-half (16½) gauge wire. 
     Referring to  FIGS. 1-7 , in the various embodiment, each one (1) of the end caps  12  includes a contacting face  40 . As illustrated in  FIG. 1 , the contacting face  40  defines the surface of the end cap  12  that is configured to abut the concrete formwork  54 . In the various embodiments of the end cap  12 , the contacting surface is substantially flat. 
     The materials required to produce the device  10  are all readily available and well known to manufacturers of goods of this type. In a preferred embodiment, the end caps  12  are made of concrete that is precast around the tie rod  14  that is made of a pre-cut length of rebar. Individual forms may be needed for each type/model of device  10 . Should large scale production of the disclosed device  10  be undertaken, suitable jigs and other assembly aids would be needed to speed production and ensure consistency. The raw materials as used in the disclosed device  10  would best be obtained from wholesalers and manufacturers that deal in goods of that nature and assembled at a final location. The relatively simple design of the invention and the material of construction make device  10  a cost-effective design due to the relatively low material and labor costs involved. 
     Those skilled in the art will recognize that other styles and configurations of the disclosed device  10  can be easily incorporated into the teachings of the present disclosure, and only particular configurations have been shown and described for purposes of clarity and disclosure and not by way of limitation of scope. 
     The foregoing descriptions of specific illustrated embodiments have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit to the precise forms disclosed and many modifications and variations are possible in light of the above teachings. The embodiments were chosen and described in order to best explain principles and practical application to enable others skilled in the art to best utilize the various embodiments with various modifications as are suited to the particular use contemplated.