Patent Abstract:
A method for installing a window in or within a poured concrete wall is disclosed. The method comprises a kit with at least one window block. It also includes a first spacer adapted to abut a first side of the glass block and a second spacer adapted to abut a second side of the window block. The method implementing the kit includes the steps of erecting a wall form comprising of a first and a second form, locating the kit in between the first and second form, placing concrete into the wall form around the window kit, removing the first and second wall forms, and removing the first and second spacers.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application Ser. No. 61/044,610, filed Apr. 14, 2008 and incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to an apparatus for and method of installing a window or panel within a poured concrete wall. 
     DESCRIPTION OF RELATED ART 
     Concrete walls offer resistance to rot, rodents, termites and fungus, and are not toxic. Solid concrete walls possess greater flexural and compressive strength than concrete blocks and can better resist lateral pressure. They are also more fire resistant and more impervious to water. These advantages make a poured concrete wall an excellent choice as a foundational wall. 
     Glass block windows or panels provide functional as well as aesthetic purpose. They offer medium privacy, allow light transmission, form a sound barrier, and enhance the beauty of the decor. Furthermore, glass blocks are durable and easy to clean. 
     Glass block is typically installed in a poured concrete wall after the wall is poured. It would be desirable to pour the wall with the glass block window in place, rather than installing the block after the wall is poured. 
     BRIEF SUMMARY OF INVENTION 
     A method for installing a window in or within a poured concrete wall is disclosed. The method comprises a kit with at least one window block. It also includes a first spacer adapted to abut a first side of the glass block and a second spacer adapted to abut a second side of the window block. The method implementing the kit includes the steps of erecting a wall form comprising of a first and a second form, locating the kit in between the first and second form, placing concrete into the wall form around the window kit, removing the first and second wall forms, and removing the first and second spacers. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an illustration of a perspective view of an assembled window kit. 
         FIG. 2  is an angled side view of the assembled kit. 
         FIG. 3  is an exploded view of the kit showing all the components. 
         FIG. 4  is a perspective view of the metal hanger. 
         FIG. 5A  is a cross-sectional side view of the assembled kit installed in a wall form. 
         FIG. 5B  is a top view of the assembled kit installed in a wall form. 
         FIG. 6  is a perspective view of the cured wall with the window in place. 
         FIG. 7  is a table listing the dimensions of the inside and outside spacers according to the thickness of the desired window. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described with reference to the figures, wherein like reference numerals are used to refer to like elements throughout. It is to be appreciated that the various illustrations are not necessarily absolute, and in particular that the size of the components are suitable for the example and for facilitating the understanding of the method. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It may be evident, however, that the present invention can be practiced without these specific details. Additionally, other embodiments of the invention are possible and the invention is capable of being practiced and carried out in ways other than as described. The terminology and phraseology used in describing the invention is employed for the purpose of promoting an understanding of the invention and should not be taken as limiting. 
     Disclosed is a system and method for installing a device in a poured concrete wall. Example devices which can be installed in a poured wall using the disclosed system and method include windows, (e.g., glass block, hopper, etc.), doors, vents and pipe sleeves. Conventional method of installing such devices in a poured concrete wall include making a form, placing the concrete into the form and around the device preform, then installing the desired device into the opening left from the device preform. In the current disclosure, the method hangs the device between the forms for the poured wall prior to pouring concrete. The device is held in place by the cured concrete wall and does not have to be separately installed after the wall is formed. This eliminates any need for custom preparation in the making of a form and also eliminates any need for custom fitting of the device during installation and after the concrete wall has been constructed. 
     The system and method will be described below with respect to the installation of a glass block window in a poured concrete wall. It is to be appreciated that the system and method are applicable to the installation of other devices in poured concrete walls, such as doors, vents and pipe sleeves. As used herein, the term “poured” refers to any method well known to one of ordinary skill in the art including pouring the concrete, pumping the concrete into the desired position and placing the concrete via a gravity fed method. 
     With reference to  FIG. 3 , the components of an assembly or kit  10  are shown in an exploded view. A pre-assembled panel  16 , such as a glass block panel, can include several individual glass blocks  14  that are held together via an adhesive, such as a silicone adhesive. The panel  16  can vary in size, shape, number of blocks, or it can be a composite of two or more window types. For example, as shown in  FIG. 6 , the window can include more than one row of glass blocks  14 , and also can contain a fully transparent window that can be adapted to open to allow for air circulation. Additionally, the kit can only contain a window panel  16  and can not include glass blocks  14 . 
     With further reference to  FIGS. 1-3 , and in one embodiment, the panel  16  can be dispersed between a first and second spacer  12 ,  18  respectively. In another embodiment, the first or second spacer  12 ,  18  can be, for example, a 2½ inch thick rectangular prism whose length and width substantially correspond to the length and width of the pre-assembled panel  16 . The second spacer  18  can be installed on the opposing side of the panel  16  with generally the same dimensions as first spacer  12 . Additionally, in one embodiment, the second spacer  18  can have an angled edge  20 , to be discussed later. 
     Furthermore, the spacers  12 ,  18  can have dimensions that are substantially equivalent to the width w and height h dimensions of the panel  16 . Moreover, the thickness of the spacers  12 ,  18  and overall thickness of the kit  10  can tend to be equivalent to the desired thickness of the wall to be constructed. The spacers  12 ,  18  in one embodiment can be formed out of extruded 2 lb. polystyrene foam, but should not be solely limited to these examples. 
     As an additional example, a 7⅝ inch thick wall can require that the overall thickness of the kit  10  be equivalent to 7⅝ inches. In one embodiment, the first spacer  12  can have a thickness of 2½ inches and second spacer  18  can have a thickness of 2 inches and panel  16  can have a thickness of about 3⅛ inches. Thus, removal of the spacers  12 ,  18  can result in a recess on both sides of the panel  16 . Accordingly, in a 7⅝ inch thick wall the inner recess can be 2½ inches and the outer recess can be 2 inches. However, the spacers  12 ,  18  can be customized to fit any desired width w, height h, and thickness to meet the specifications and requirements of an application. 
     With reference to  FIG. 7 , the example dimensions are listed showing various sizes of spacers  12 ,  18  and panels  16 . It should be noted that actual dimensions can vary slightly, as the nominal and actual dimensions are listed. The nominal dimensions are noted to simplify calculations for brick masons and other tradesmen. For example, if a wall to be constructed has an overall nominal thickness of 7¼ inches (7⅛ inches actual) and a nominal dimensioned 32×16 inch panel  16  (31×15½ inches actual dimension) is to be a installed within the wall, the first spacer  12  (inside piece) can have dimensions of 31¼″×15⅝″×2″ and the second spacer  18  (outside piece) can have dimensions of 31¼″×16¼×2″. It should also be noted that the difference in height between the first and second spacer is due to the angled edge  20 . Therefore, as the actual height of the panel  16  is 15½ inches and actual width is 31 inches, and as the spacers  12 ,  18  both have a relative height of 15⅝ inches and width of 31¼ inches, a space of about ⅛ inch remains around the sides and bottom while the top of the panel  16  is flush with the opening. As a result of the ⅛ inch, if a glass block  14  were to become damaged and require a replacement, the dimension differences between the spacers  12 ,  18  and panel  16  can aid in removal of one or more glass blocks  14  from a finished wall. 
     As discussed above and shown in  FIGS. 1 and 2 , the second spacer  18  can have an angled edge  20 . The panel  16  and related angled edge  20  are meant to be the exterior portion of the finished window  54 . After the wall has cured, the angled edge  20 , forms a wash  50 , shown in  FIG. 6 , in the finished wall  52  below the panel  16  so moisture flows away from the exterior recess. Accordingly, the side of the second spacer  18  facing away from the panel  16  can have a larger surface area than the side of the second spacer  18  abutting the panel  16 . 
     As shown in  FIGS. 1-3 , a flex band  24  can be installed around the panel  16  and the first and second spacers  12 , 18  along the width, w, of the first and second spacers. The flex band  24  can provide enough force to hold the first and second spacers  12 ,  18  in place around the panel  16 . More than one flex band  24  can be used to hold the kit together, depending on the strength of the flex band and the weight of the kit  10 . In another embodiment, if the flex band  24  is a single length having two opposing ends, a fastener  22  can be used to connect the two ends of the flex band  24  together around the kit  10 . In yet another embodiment, the flex band  24  can be a continuous loop, thus a fastener  22  would not be required. Therefore, if a plurality of kits were being constructed having a standard number of glass blocks, a continuous loop flex band can be used to eliminate the fastener  22 . However, if constructed kits were variable as to width, w, height, h and thickness, one flex band  24  would not appropriately hold the kit together, fasteners  22  can be used. 
     In yet another embodiment, the spacers  12 ,  18  can be secured directly to the panel  16 . This can be done by placing a small amount of glue or epoxy onto each glass block  14 , contacting the spacers  12 ,  18  to the panel  16  and applying pressure to the spacers  12 ,  18  to form a secure connection. It should be noted that flex bands  24  are optional in this embodiment. After both spacers  12 ,  18  have been secured to the panel  16 , a bead of epoxy can be laid around the edge between the panel and each spacer. The dried glue acts as barrier and prevents the viscous concrete from flowing between the panel  16  and each spacer  12 ,  18  at the time of construction. In a related embodiment, the spacers  12 ,  18  can be substantially wrapped in packing tape. The packing tape is designed to protect the foam spacers  12 ,  18  and also aids in separating the spacers  12 ,  18  from the panel  16  after construction of the wall is complete. 
     Additionally, a handle feature can be added to assist in transporting the kit  10 . By using two fasteners  22  at opposing ends of the shorter flex band and secured to the flex band  24 , the shorter flex band creates a handle to provide a single-handed carrying method for the kit  10 . In another embodiment, more than one short flex band can be attached to more than one flex band  24 , for increased load capability. For example, a first short flex band can be attached to a first flex band  24 , and a second short flex band can be attached to a second flex band  32 . The first and second short flex bands can then be fastened together to create one handle, thus adding additional stability and increased durability. 
     In yet another embodiment, a large number of glass blocks in a single panel  16  can require that the fasteners  22  can be made of a metal or metal alloy. The fastener  22  can be required to hold the two ends of the flex band  24  together while being subjected to the large amount of force produced by the weight of the panel  16 . However, less demanding applications can permit the use of a plastic fastener  22 . In yet another embodiment, fasteners  22  can be integrated into the two ends of the length of flex band  24 . The fasteners can posses other means of fastening the two ends of the flex band  24  together, such as hook and loop fasteners or an interlocking means. 
     With further reference to  FIGS. 1-3 , 90° side protectors  26  can be positioned at the four edges of the kit  10  with respect to the width w where the flex band  24  would contact the spacers  12 ,  18 . Depending on the strength of the flex bands  24 , a large amount of force can be subjected onto the corner of each spacer  12 ,  18  and can create a groove in the corners of the spacers  12 ,  18  which would possibly result in unwanted movement between the glass block panel and spacers  12 ,  18 . Thus, the side protectors  26  would protect the corners of the spacers  12 ,  18  from the concentration of force that the flex bands  24  can apply and prevent any component shifting. Additionally, side protectors  26  can protect the spacers  12 ,  18  during shipment to the construction site and during the placement and pouring process. In another embodiment, a 30° protector  28  is positioned on the lip  30  of second spacer  18  which protects the lip  30  of the second spacer during shipment to the site and during the placement and pouring process. The edge of the 30° protector  28  that contacts the second spacer  18  can be coated with an adhesive, so that the 30° protector  28  stays in contact and protects the second spacer until the second spacer is separated from the panel  16 . In an alternative embodiment where the spacers  12 ,  18  are glued to the panel  16 , side protectors  26  can not be required. 
     As shown in  FIG. 1 , an internally threaded metal hanger  34  can be located at each of the upper corners of the panel  16 . As shown in  FIG. 4 , the metal hanger  34  can have flanges  40  that can permit a second flex band  32  to pass over the flange  40  and secure the metal hanger  34  to the panel  16  in a direction that can be parallel to the height, h. The flanges  40  can be welded to the hanger  34 . The metal hanger  34  can be, for example, a hex-coupling nut or rod coupler, with internal female threading  38  that is adapted to accept a male threaded connection. For this application, an acceptable hex-coupling nut size can be about a ¼ inch. Also, since the metal hanger  34  has a pair of flanges  40 , an additional second flex band  32  can be used to provide additional strength with which to hold the metal hanger  34  to the panel  16 . In an alternative embodiment, the hex coupling nuts are secured directly to the panel  16  using an adhesive, such as an epoxy or a waterproof two-sided tape. In this embodiment, the flange  40  can be eliminated. Accordingly, the metal hanger  34  sans flanges  40  can be glued directly to each side of the panel  16 . 
     In yet another embodiment, and as shown in  FIGS. 1 and 5A , wall anchors  48  are secured, for example glued, in between the individual glass blocks  14  of panel  16  during assembly of the panel. The wall anchors  48  extend perpendicularly from the panel  16  into the concrete wall, providing additional window reinforcement and stability. Additionally, the number of wall anchors  48  can be tailored to the specifications of the builder, so that the panel  16  is adequately secured to the poured wall. 
     A method of using the window kit is hereby described. 
     After a panel  16  is constructed from one or more glass blocks  14  and wall anchors  48  secured into place, metal hangers  34  are secured to the upper corners of the panel  16 . If the second flex band  32  has a length and is not a continuous band, the flex band is fastened together via a fastener  22 . After the metal hanger  34  has been fastened to the panel  16 , the spacers  12 ,  18  are attached to each side of the panel  16 . Side protectors  26  are placed on the edges of each spacer  12 , 18 , and the flex band  24  is then wrapped around the two spacers and contacting the protectors  28 , which secures the two spacers to the panel  16 . At this point or any point prior, the 30° protector  28  can be connected to the angled edge  20  on the second spacer  18 . After assembly of the kit  10  is completed, the entire window assembly is shipped to a construction site in its assembled form. 
     With reference to  FIGS. 5A and 5B , in preparation for pouring concrete to form a freestanding wall, opposing wall forms  42  can be erected. The opposing wall form  42  is made up of two freestanding elements that act as the barrier for the poured concrete. Thus, when the concrete is poured into the wall form  42 , the free standing elements will hold the concrete in place, allowing it to cure. Once the concrete has cured, the wall form  42  is removed, revealing the concrete wall. This process is well known to a person of skill in the art and therefore will not be discussed further. 
     Once the wall forms  42  are erected, a male threaded bolt  46  is inserted through a hole in a mount  44  or cross-bar and secured together. This process is repeated for a second male threaded bolt  46  and a second mount  44 . Then the male threaded bolt  46  is secured into the metal hanger  34  at each corner of the kit  10 . Once the bolt and mount assembly is securely fastened to the kit  10  via the metal hanger  34 , the window kit  10  is then lowered in between the wall forms  42  until the mount  44  rests on the top edges of the wall forms  42 , thus hanging the window kit  10  at the desired height and position, as shown in  FIG. 5A . In another embodiment, the metal hanger  34  can be adapted to be secured to internal concrete wall reinforcements, such as reinforcing bars, or “rebar”. 
     Additionally, as shown in  FIG. 5B , the spacers  12 ,  18  can be in flush contact with the wall form  42 . The window kit  10  should fit tightly into the wall form so that it prevents any concrete from flowing between each spacer  12 ,  18  and corresponding wall form. 
     After the window kit  10  is securely in place, concrete can be poured into the wall form  42  and around the window kit  10 . If the desired location of the window makes the window kit  10  accessible after the pouring of and drying of the concrete, any remains of the kit, such as flex bands, can be removed. Once the concrete has cured and wall forms removed, the spacers  12 ,  18  can be removed. What is left is panel  16  window securely fastened to the concrete wall, with a wash  50  on the exterior portion of the wall  52  of the finished window  54 , as shown in  FIG. 6 . 
     The invention has been described with reference to the example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Examples embodiments incorporating one or more aspects of the invention are intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.

Technology Classification (CPC): 4