Patent Publication Number: US-11021875-B2

Title: Rebar clamp assembly with clip

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/450,790 filed on Jan. 26, 2017, which is incorporated by reference herein in its entirety for all purposes. 
    
    
     STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     TECHNICAL FIELD 
     This application relates to a clamp assembly for attachment which may be incorporated in, for example, a modular trench drain to connect the trench drain to rebar rods. More specifically, this application relates to an improved clamp assembly that can be easily clamped onto and unclamped from supporting rebar rods of varying size diameters during installation of the modular trench drain. 
     BACKGROUND 
     Trench drains are used where extensive amounts of liquid must be moved from one place to another. The trench drains typically transport the liquid to a drainage sewer. Typically, trench drains are U-shaped or V-shaped troughs and are installed adjacent to either roadways or buildings. They are installed in the ground and secured in concrete. 
     Trench drain systems include several basic designs: concrete, metal, and plastic. Generally, concrete trench drain systems use forms. The forms are placed in a ditch dug in the ground. Concrete is then poured around the forms, which are removed after the concrete has set. Trench drain systems made in accordance with this method or similar methods result in relatively expensive systems due to the cost of installing and removing the forms. 
     Many of the expenses associated with these prior art trench drain systems have been overcome by the advent of polymeric trench drains, which can be left in place after the concrete has been poured in place. These trench drains perform two functions. First, they act as a form for the concrete; and second, they act as a liner. The manufacture and transportation costs with this type of trench drain are significantly less than the other types of trench drains. 
     During installation, the polymeric trench drains are typically affixed to a supporting structure. Generally the supporting structure is formed by a multitude of supporting rebar rods, which are affixed to the polymeric trench drains using various clamps. Typically, installing the polymeric trench drains using the various clamps requires a substantial amount of hardware, i.e., nuts and bolts, which adds not only to the cost, but can also add to the installation time and possibly result in delays should the installer run out of this hardware. 
     SUMMARY 
     Various improvements to trench drains are described herein including improvements relating to fixation mechanisms for attachment of the trench drain to rebar or other supports. 
     According to one aspect, a rebar clamp assembly for engaging a rebar rod is provided that includes a clip and a rebar clamp. The clip has a pair of prongs spaced apart from one another which are connected by a bridging portion. Each prong of the pair of prongs includes an inner surface. The rebar clamp has a pair of sidewalls hingedly connected at a first end of the rebar clamp. Each sidewall includes a rebar-receiving notch on an inner surface and a plurality of clip-receiving notches disposed proximate a second end of the rebar clamp on an outer surface. The plurality of clip-receiving notches of each sidewall are configured to engage one of the inner surfaces of the pair of prongs of the clip to bring the pair of sidewalls of the rebar clamp together around the rebar rod. 
     In some forms, the clip-receiving notches of each sidewall may include a first clip-receiving notch and a second clip-receiving notch. When the inner surfaces of the pair of prongs engage the clip-receiving notches, the inner surfaces may be selectively engaged with one of the first clip-receiving notches and the second clip-receiving notches to accommodate varying sizes of the rebar rod. Each sidewall may have a first thickness at the first clip-receiving notch and a second thickness at the second clip-receiving notch. The first thickness may be different than the second thickness. The second thickness may be thinner than the first thickness. When the clip engages the second clip-receiving notches, the thinner thickness of the second thickness may allow the rebar clamp assembly to accommodate a rebar rod with a larger diameter than when the clip engages the first clip-receiving notches. The second clip-receiving notch may be disposed more proximate the second end than the first clip-receiving notch. When the clip engages the second clip-receiving notches, the second clip-receiving notches being disposed more proximate the second end may allow the rebar clamp assembly to accommodate a rebar rod with a larger diameter than when the clip engages the first clip-receiving notches. 
     In some other forms, at least a portion of the inner surfaces of the pair of prongs may be substantially parallel to one another. The inner surfaces of the pair of prongs may include angled portions, which angle away from one another proximate an open end of the clip, opposite the bridging portion, thereby providing extra clearance when the clip is being engaged with the rebar clamp. 
     In yet some other forms, the rebar clamps may be made of a flexible material. The flexible material may be at least one of a plastic material and a polymeric material. The clip may be made of a rigid material. The rigid material may be at least one of a rigid plastic material, a metallic material, and a ceramic material. 
     In still yet other forms, the rebar clamp may further have one or more additional rebar-receiving notches on the inner surface of each sidewall (to provide multiple sets of corresponding notches). The rebar-receiving notch and any additional rebar-receiving notches may be configured to receive rebar of a differing or various diameters (for example, 0.5″ or 0.375″ diameter rebar). 
     These and still other advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of some preferred embodiments of the present invention. To assess the full scope of the invention, the claims should be looked to as these preferred embodiments are not intended to be the only embodiments within the scope of the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a top perspective view of a rebar clamp assembly on a lateral side of a trench drain; 
         FIG. 2  is a top perspective view of a rebar clamp of the rebar clamp assembly of  FIG. 1  apart from the rest of the assembly; 
         FIG. 3  is a top plan view of the rebar clamp of  FIG. 2 ; 
         FIG. 4  is a perspective view of a clip of the rebar clamp assembly of  FIG. 1  apart from the rest of the assembly; 
         FIG. 5  is a front elevational view of the clip of  FIG. 4 ; 
         FIG. 6  is a top plan view of the rebar clamp assembly of  FIG. 1  shown engaging a rebar rod with the clip engaging first clip-receiving notches of the rebar clamp; 
         FIG. 7  is a top plan view of the rebar clamp assembly of  FIG. 1  shown engaging a rebar rod with the clip engaging second clip-receiving notches of the rebar clamp; and 
         FIG. 8  is a perspective view of another, modified rebar clamp design with an additional set of rebar-receiving notches. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows a rebar clamp assembly  10 . The rebar clamp assembly  10  includes a rebar clamp  12  and a clip  14  which is designed to engage the rebar clamp  12  to capture a section of rebar therein. In some forms, the rebar clamp assembly  10  can be used to rigidly fix a support rib  16  of a trench drain  18  to a supporting rebar rod during installation of the trench drain  18 . However, it is contemplated that, in other forms, the rebar clamp assembly  10  might be used to secure other bodies to which the assembly  10  is adjoined to rebar. 
     Referring now to  FIGS. 2 and 3 , the rebar clamp  12  is shown in greater detail and in isolation. The rebar clamp  12  is made of a somewhat elastically flexible material, such as, for example, a plastic material, a polymeric material, or any other suitable material. The rebar clamp  12  includes a pair of sidewalls  20  and a connection portion  22  which, in the form shown, provides a living hinge. The pair of sidewalls  20  are connected by the connection portion  22  at a first end  24  of the rebar clamp  12  and are separated by an opening  28  at a second end  26  of the rebar clamp  12 . 
     Each sidewall  20  includes a first wall portion  30  and a second wall portion  32  with a rebar-receiving portion  34  disposed therebetween. The first wall portion  30  extends between the connection portion  22  and the rebar-receiving portion  34 . The second wall portion  32  extends from the rebar-receiving portion  34  toward the second end  26  of the rebar clamp  12  and includes a chamfered edge  36  disposed between the second end  26  and the inner surface of the corresponding sidewall  20 . 
     Additionally, each of the second wall portions  32  further includes a first clip-receiving notch  38  and a second clip-receiving notch  40 . Both the first clip-receiving notch  38  and the second clip-receiving notch  40  are disposed on an outer surface of the sidewalls  20 . The first clip-receiving notch  38  reduces a wall thickness of the sidewall  20  to a first wall thickness  42 . The second clip-receiving notch  40  is disposed more proximate the second end  26  of the rebar clamp  12  than the first clip-receiving notch  38  and reduces the wall thickness of the sidewall  20  to a second wall thickness  44 . The first wall thickness  42  is different than the second wall thickness  44 . 
     It is contemplated that, while in the illustrated embodiment the first wall thickness  42  is thicker than the second wall thickness  44 , the first wall thickness  42  may alternatively be thinner than or have the same thickness as the second wall thickness  44 . 
     Additionally, it is further contemplated that while the illustrated embodiment includes a first clip-receiving notch  38  and a second clip-receiving notch  40 , in other embodiments each sidewall  20  could include any number of additional clip-receiving notches, each reducing the wall thickness of the sidewall to a corresponding wall thickness. Said differently, each sidewall could include a third clip-receiving notch, a fourth clip-receiving notch, and so forth, which would correspondingly reduce the wall thickness to a third wall thickness, a fourth wall thickness, etc., respectively. 
     The rebar-receiving portion  34  includes a rebar-receiving notch  46  on an inner surface of the corresponding sidewall  20 . The rebar-receiving notch  46  of each sidewall  20  is configured to receive rebar rods of varying sizes, as will be described further below. Additionally, the rebar-receiving portion  34  includes countersinks  48  at opposing ends of the rebar-receiving notch  46 . A first of the two countersinks  48  is disposed between the rebar-receiving notch  46  and an upper surface  50  of the rebar clamp  12  and a second of the two countersinks  48  is disposed between the rebar-receiving notch  46  and a lower surface (not shown) of the rebar clamp  12 . Opposite the rebar-receiving notch  46 , the rebar-receiving portion  34  protrudes outwardly to maintain sufficient material thickness within the rebar-receiving portion  34 . 
     The connection portion  22  of the rebar clamp  12  includes a thickness-reducing notch  54 . The thickness-reducing notch  54  and the material compliance of the flexible material of the rebar clamp  12  allow for the sidewalls  20  to be slightly rotated relative to one another about the connection portion  22 , giving the sidewalls  20  a hinge-like connection. It is contemplated that, while the sidewalls  20  are connected by the connection portion  22  in the present embodiment, in other embodiments, the sidewalls  20  could alternatively be connected by a hinge, or any other suitable hinge-like connection. 
     Referring now to  FIGS. 4 and 5 , the clip  14  is made of a rigid material, such as, for example, a rigid plastic material, a metallic material, a ceramic material, or any other suitable rigid material. The clip  14  also includes a pair of prongs  56  spaced apart from one another and connected by a bridging portion  58  at a first end of the clip  14  and are separated by an opening  60  at a second end of the clip  14 . Additionally, the pair of prongs  56  and the bridging portion  58  have a constant thickness and, as such, conjunctively form a substantially U-shaped feature of even thickness. 
     Each of the prongs  56  include an inner surface  62 , an outer surface  64 , and an end surface  66 . The inner surface  62  of each prong  56  is disposed on an inner face of the U-shaped feature formed by the pair of prongs  56  and the bridging portion  58 . Each inner surface  62  includes a first portion  68  and a second portion  70 . Each of the first portions  68  are substantially perpendicular to an inner surface  72  of the bridging portion  58 , which is similarly disposed on an inner face of the U-shaped feature. As such, the first portions  68  are substantially parallel to one another. The second portions  70  are disposed adjacent to the end surfaces  66  and are angled with respect to the corresponding first portions  68  (i.e., a plane defined by each first portion  68  is angled from a plane defined by each corresponding second portion  70 , such that the planes intersect along a single line and are not coplanar). As illustrated, the second portions  70  of the inner surfaces  62  further angle away from one another proximate the second end of the clip  14 , thereby increasing the opening  60 . 
     Now that the structure of the various components of the rebar clamp assembly  10  have been described above, a method of assembly and use will be described below. It will be understood that the following description is meant to be exemplary and is in no way meant to be limiting. The rebar clamp assembly  10  can be assembled or used in accordance with other methods, for other functions, or in other settings generally. 
     Referring now to  FIG. 6 , the rebar clamp assembly  10  can be used to grasp or clamp onto a rebar rod  74 . To grasp or clamp onto the rebar rod  74 , the rebar rod  74  is first inserted between the rebar-receiving notches  46  of the rebar clamp  12 , typically without the clip  14  in its final place. The countersinks  48  provide extra clearance between the rebar-receiving notches  46 , making inserting the rebar rod  74  easier and guiding the rebar rod  74  through the opening. Once the rebar rod  74  is disposed between the rebar-receiving notches  46  of the rebar clamp  12 , the clip  14  can be used to bring the pair of sidewalls  20  of the rebar clamp  12  together around the rebar rod  74 . As the sidewalls  20  are brought together around the rebar rod  74 , the rebar-receiving notches  46  come into contact with the rebar rod  74 , providing a compression-fit grasp or clamp onto the rebar rod  74 . 
     To bring the pair of sidewalls  20  together around the rebar rod  74 , the clip  14  is slid onto the rebar clamp  12 , with the inner surfaces  62  of the pair of prongs  56  (shown in  FIGS. 4 and 5 ) engaging the first clip-receiving notches  38  of each of the sidewalls  20 . As the clip  14  is slid onto the rebar clamp  12 , the angling of the second portions  70  of the inner surfaces  62  (shown in  FIGS. 4 and 5 ), which increases the opening  60  of the clip  14  (also shown in  FIGS. 4 and 5 ), provides extra clearance for the inner surfaces  62  to be slid into their respective first clip-receiving notches  38 . Further, when the clip  14  is slid onto the rebar clamp  12  and the rebar-receiving notches  46  of the sidewalls  20  compress the rebar rod  74 , the sidewalls  20  flex slightly around the rebar rod  74 . Being made of the flexible material, the sidewalls  20  tend to resist this flexing, resulting in a force imparted upon the inner surfaces  62  of the clip  14 . The parallel configuration of the first portions  68  of the inner surfaces  62  prevents the clip  14  from sliding off of the rebar clamp  12 . 
     The rebar clamp assembly  10  can also release the rebar rod  74  by sliding the clip  14  off of the rebar clamp  12 . Once the clip  14  is slid off of the rebar clamp  12 , the sidewalls  20  no longer compressively grasp or clamp onto the rebar rod  74 , and the rebar rod  74  can be removed from between the rebar-receiving notches  46 . 
     Referring now to  FIG. 7 , the rebar clamp assembly  10  can similarly be used to grasp or clamp onto a rebar rod  76  having a diameter that is larger than the rebar rod  74 . Similarly, to grasp or clamp onto the rebar rod  76 , the rebar rod  76  can first be inserted between the rebar-receiving notches  46  of the rebar clamp  12 . Once the rebar rod  76  is disposed between the rebar-receiving notches  46  of the rebar clamp  12 , the clip  14  can again be used to bring the pair of sidewalls  20  of the rebar clamp  12  together around the rebar rod  74 . 
     To accommodate the larger diameter of the rebar rod  76 , to bring the pair of sidewalls  20  together around the rebar rod  76 , the clip  14  can be slid onto the rebar clamp  12  with the inner surfaces  62  of the pair of prongs  56  (shown in  FIGS. 4 and 5 ) alternatively engaging the second clip-receiving notches  40 . Due to the second wall thickness  44  being thinner than the first wall thickness  42  (shown in  FIGS. 4 and 5 ), and the second clip-receiving notch  40  being disposed more proximate the second end  26  of the rebar clamp  12  than the first clip-receiving notch  38  (also shown in  FIGS. 4 and 5 ), the sidewalls  20  are permitted to open farther (i.e., to a greater angular extent relative to that depicted in  FIG. 6 ) while the clip  14  engages the second clip-receiving notches  40 . The sidewalls  20  opening farther allows for the rebar clamp  12  to receive the rebar rod  76  with the larger diameter, while still being able to compressively grasp or clamp onto the rebar rod  76 . 
     The rebar clamp assembly  10  can then similarly release the rebar rod  76  as described above with reference to the rebar rod  74 . 
     Referring now to  FIGS. 1, 6, and 7  generally, the rebar clamp assembly  10  can be affixed to various objects, such as the illustrated support rib  16  of the trench drain  18  shown in  FIG. 1 . The rebar clamp assembly  10  can then be used to grasp or clamp onto varying sizes of rebar rods, such as the illustrated rebar rods  74 ,  76  shown in  FIGS. 6 and 7 . As such, the rebar clamp assembly  10  can be used to rigidly fix the trench drain  18  to various rebar rods  74 ,  76 . This may be useful, for example, during installation of the trench drain  18 , to provide support to the trench drain  18  while concrete is poured around the trench drain  18  and allowed to set. 
     Referring to  FIG. 8 , an alternative embodiment of a rebar clamp  112  is shown. The rebar clamp  112  differs from the rebar clamp  12  in  FIGS. 1 through 7 , in that instead of a single set of rebar-receiving notches, there are multiple sets of rebar-receiving notches to better or further accommodate different or variously-sized diameters of rebar. In  FIG. 8 , similar reference numerals are used to refer to similar features from  FIGS. 1 through 7 , except that a “100” series number is provided in  FIG. 8  to distinguish the different embodiment. 
     As illustrated in  FIG. 8 , the rebar clamp  112  has a set of additional rebar-receiving notches  147  (one on each sidewall) which set is configured to receive a different sized rebar (that is, of different diameter) than the other set of rebar receiving notches  146 . As with the first embodiment, there are a first set of clip-receiving notches  138  and a second set of clip-receiving notches  140  which may be selectively engaged by a clip  114 . As noted above, this can permit or accommodate differential closing amounts of the rebar-receiving notches, here both of the sets of notches  146  and  147  (instead of just a single set of notches  46  as in  FIGS. 1 through 7 ). By virtue of this structure having both dual rebar-receiving notches and dual clip-receiving notches, both of the set of the rebar-receiving notches can clamped to two levels (by the clip  114  engaging either the first set of clip-receiving notches  138  or the second set of clip-receiving notches  140 ), thereby providing four possible clamping diameters by the various configurational permutations. 
     While a first arrangement has been shown with one set of rebar-receiving notches and two sets of clip-receiving notches and a second arrangement has been shown with two sets of rebar-receiving notches and two sets of clip-receiving notches, it will be appreciated that other configurations for a rebar clap are contemplated with the rebar clamp having multiples of one or both of the rebar-receiving notches and the clip-receiving notches. For example, there may be multiple sets of rebar-receiving notches and only one set of clip-receiving notches. As another example, there may be multiple sets of clip-receiving notches and only one set of rebar-receiving notches. Still further, there could be multiple sets of clip-receiving notches and multiple sets of rebar-receiving notches. While sets of two and two are shown in  FIG. 8 , there could be more than two of one or each type of notch. 
     It should be appreciated that various other modifications and variations to the preferred embodiments can be made within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced.