Abstract:
The present invention relates to bulkheads and brackets for use a part of a bulkhead. The bulkhead includes an upstanding portion including a bracket-mounting end, a mitering portion including a bracket-engaging end, and a bracket including a seat cavity adapted to receive the bracket-engaging end of the mitering portion. The bracket is configured to orient the mitering portion at an acute angle with respect to the upstanding portion with the bracket-engaging end of the mitering portion adjacent the bracket-mounting end of the upstanding portion. Methods are also provided that comprise the steps of arranging a plurality of upstanding portions to define a casting area, pouring uncured precast material into the casting area, and curing the precast material to provide a panel with a mitered corner. In accordance with 37 CFR 1.72(b), the purpose of this abstract is to enable the United States Patent and Trademark Office and the public generally to determine quickly, from a cursory inspection, the nature and gist of the technical disclosure. The abstract will not be used for interpreting the scope of the claims.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention is directed to bulkheads and methods of fabricating a panel with a mitered corner. More specifically, this invention relates to bulkheads and methods of fabricating a panel with a mitered corner from a precast material in order to fabricate a cured panel.  
       BACKGROUND OF THE INVENTION  
       [0002]     Many residential and commercial construction methods involve the use of pre-cast tilt-up panels to construct structural walls. In order to fabricate the pre-cast tilt-up panels, concrete forms, such as bulkheads, are arranged on a flat casting surface to provide a casting area in the shape and dimension of the desired tilt-up panel. The casting area is then typically filled with concrete and thereafter allowed to cure in the shape of the casting area. Once the concrete cures, the tilt-up panel and the form are separated and the panel is tilted up into a typically vertical orientation where it can be joined to structural frames or other tilt-up panels to provide the desired structural wall configuration.  
         [0003]     There is a need for bulkheads, including bulkhead components, configured to facilitate assembly and maintenance of the bulkhead components with respect to on another and to provide methods of fabricating a panel with a mitered corner with desired characteristics.  
       BRIEF SUMMARY OF THE INVENTION  
       [0004]     This need is met by the present invention wherein improvements in bulkhead, various components of bulkheads, and methods of fabricating a panel with a mitered corner are introduced. In accordance with one embodiment of the present invention, a bulkhead for fabricating a panel with a mitered corner is provided. The bulkhead includes an upstanding portion including a bracket-mounting end, a mitering portion including a bracket-engaging end, and a bracket including a seat cavity adapted to receive the bracket-engaging end of the mitering portion. The bracket is configured to orient the mitering portion at an acute angle with respect to the upstanding portion with the bracket-engaging end of the mitering portion adjacent the bracket-mounting end of the upstanding portion.  
         [0005]     In accordance with another embodiment of the present invention, a bracket is provided that is adapted to orient a mitering portion and an upstanding portion of a bulkhead at an acute angle with respect to one another. The bracket includes a first portion with a first surface adapted to engage an upstanding portion of a bulkhead, and a second portion offset from the first portion to at least partially define a seat cavity. The seat cavity is adapted to receive an end of a mitering portion of a bulkhead and orient a mitering portion and upstanding portion of a bulkhead at an acute angle with respect to one another.  
         [0006]     In accordance with yet another embodiment of the present invention, a method of fabricating a panel with a mitered corner is provided. The method comprises the steps of arranging a plurality of upstanding portions to define a casting area, engaging a bracket with a selected one of the upstanding portions. The method further includes the steps of inserting a bracket-engaging end of a mitering portion in a seat cavity of the bracket to facilitate maintenance of an acute angular orientation between the mitering portion and the selected upstanding portion and to further define the casting area. The method also comprises the steps of pouring uncured precast material into the casting area, and curing the precast material to provide a panel with a mitered corner.  
         [0007]     Accordingly, it is an aspect of the present invention to provide improvements to bulkheads, various components of bulkheads, and methods of fabricating a panel with a mitered corner. Other aspects of the present invention will be apparent in light of the description of the invention embodied herein. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:  
         [0009]      FIG. 1  is a partial sectional view of a bulkhead in accordance with one embodiment of the present invention;  
         [0010]      FIG. 2  is an enlarged view of portions of the bulkhead taken at view  2  of  FIG. 1 ;  
         [0011]      FIG. 3  is a partial sectional view of a panel structure including panels fabricated with the bulkhead of  FIG. 1 ;  
         [0012]      FIG. 4  is a partial sectional view of a bulkhead in accordance with a second embodiment of the present invention;  
         [0013]      FIG. 5  is an enlarged view of portions of the bulkhead taken at view  5  of  FIG. 4 ;  
         [0014]      FIG. 6  is a partial sectional view of a panel structure including panels fabricated with the bulkhead of  FIG. 4 ; and  
         [0015]      FIG. 7  is a perspective view of an exemplary casting structure with portions of an upstanding portion being removed to reveal the profile of the bulkhead of  FIG. 4  with respect to the remaining casting structure. 
     
    
       [0016]     The embodiments set forth in the drawing are illustrative in nature and are not intended to be limiting of the invention defined by the claims. Moreover, individual features of the drawing and the invention will be more fully apparent and understood in view of the detailed description.  
       DETAILED DESCRIPTION  
       [0017]      FIGS. 1 and 2  depict an exemplary bulkhead  10  in accordance with one embodiment of the present invention. The bulkhead  10  includes an upstanding portion  12  including a bracket-mounting end  14  and may include another end  16  disposed on an opposite end of the upstanding portion  12 . The upstanding portion  12  further includes an upstanding face  18  and might further include another face  20  on an opposite side of the upstanding portion  12 . As shown in  FIG. 1 , one exemplary upstanding portion  12  might comprise a rectangular cross section. However, the upstanding portion  12  might have a wide variety of configurations and/or cross sectional shapes. For example, the upstanding portion  12  might comprise any polygonal cross sectional shape with three or more sides. Still further, the upstanding portion  12  might include a circular or other cross sectional shape. The upstanding face  18  of the upstanding portion  12  can also include numerous shapes and sizes and can be oriented a wide range of angles with respect to a support surface  80 . In one embodiment, the upstanding face  18  comprises a substantially planar face that is oriented at approximately 90° with respect to the support surface  80 . The upstanding portion  12  may also be formed from varous materials that are sufficient to provide structural integrity to the bulkhead  10 . The upstanding portion might comprise wood, metal, plastic, paper products, composites or the like.  
         [0018]     The bulkhead  10  further comprises a mitering portion  30  including a bracket-engaging end  32  and might include another end  34  disposed on an opposite end of the mitering portion  30 . The mitering portion further includes a first face  36  and might further include another face  38  on an opposite side of the mitering portion  30 . As shown, the mitering portion  30  can comprise a panel with a substantially rectangular-shaped cross section. However, the mitering portion  30  might have a wide variety of configurations and/or cross sectional shapes. For example, the mitering portion  30  might comprise any polygonal cross sectional shape with three or more sides. Still further, the mitering portion  30  might include a circular or other cross sectional shape. The first face  36  of the mitering portion  30  can also include a wide variety of shapes, sizes and/or surface textures. In one embodiment, the first face  36  comprises a substantially planar face that might include a substantially smooth planar face. The mitering portion  30  may also be formed from a wide range of materials that are sufficient to resist deformation during lateral loading of the mitering portion in use. For example, the mitering portion  30  might comprise wood, metal, plastic, paper products, composites or the like.  
         [0019]     The bulkhead  10  further includes a bracket  40  including a seat cavity  42  adapted to receive the bracket-engaging end  32  of the mitering portion  30 . The bracket  40  might be configured to orient the mitering portion  30  at an acute angle with respect to the upstanding portion  12 , with the bracket-engaging end  32  of the mitering portion  30  being adjacent the bracket-mounting end  14  of the upstanding portion  12 . As shown, the bracket  40  can be configured to orient the mitering portion  30  at a 45° angle with respect to the upstanding portion  12 . In alternative embodiments the bracket  40  may be configured to provide any range of acute angles. Still further, as shown, the bracket  40  might be configured with a fixed seat  42  to provide a predetermined angular relationship between the mitering portion  30  and the upstanding portion  12 . Although not illustrated, the seat may be adjustable to allow the bracket  40  to provide alternative configurations to facilitate a wide range of predetermined angular relationships between the mitering portion  30  and the upstanding portion  12 .  
         [0020]      FIG. 2  depicts an enlarged view of portions of  FIG. 1 , taken at view  2  of  FIG. 1 . As shown, the bracket  40  can include a first portion  44  including a face  78 , such as an upstanding face, for mounting with respect to the bracket-mounting end  14  of the upstanding portion  12 . The bracket  40  can also include a second portion  60  that can be offset from the first portion  44  to at least partially define the seat cavity  42 . As described above, the seat cavity  42  is adapted to receive the bracket-engaging end  32  of the mitering portion  30 . For example, the first portion  44  can include a first seat surface  42   a  adapted to engage the face  38  of the mitering portion  30  while the second portion  60  can include a second seat surface  42   b  adapted to engage the first face  36  of the mitering portion  30 . In particular embodiments, the first seat surface  42   a  and the second seat surface  42   b  are substantially planar seat surfaces that are substantially parallel with respect to one another. In addition, the first face  36  and the second face  38  of the mitering portion  30  might each comprise a substantially planar face that are substantially parallel with respect to one another. Providing the bracket  40  with first and second seat surfaces  42   a ,  42   b  that are substantially parallel planar seat surfaces and providing a mitering portion  30  with first and second faces  36 ,  38  as substantially parallel planar faces may allow quick assembly and breakdown of the bulkhead components. Moreover, providing substantially planar surfaces/faces permits accurate and precise orientation between the mitering portion  30  and the upstanding portion  12 . Although not shown, the first and second seat surfaces  42   a ,  42   b  might include nonplanar seat surfaces and/or the first and second seat surfaces  42   a ,  42   b  might comprise a wide range of shapes, sizes, surface conditions, etc. that facilitate function of the bracket  40 . For example, the first and/or second seat surfaces  42   a ,  42   b  might include a cleating arrangement, friction surface, scored surface or other arrangement that is adapted to facilitate reception of the bracket-engaging end  32  in the seat cavity  42  and/or that is adapted to maintain the desired acute angle between the upstanding portion  12  and the mitering portion  30 .  
         [0021]     Brackets in accordance with the present invention are adapted to simultaneously engage the support surface  80  and the upstanding portion. For example, as shown in  FIG. 2 , the first portion  44  includes a first abutment surface  78  (e.g., upstanding face) adapted to engage the upstanding portion  12  while the second portion  60  includes a second abutment surface  79  (e.g., support surface face) adapted to engage the support surface  80 . In further examples, the first abutment surface  78  and second abutment surface  79  are perpendicular with respect to one another. In still further embodiments, the first and second abutment surfaces  78 , 79  comprise substantially planar surfaces that are substantially perpendicular with respect to one another.  
         [0022]     As shown, the bracket can further include a third portion  70  that can connect the first portion  44  to the second portion  60  and can provide a third seat surface  42   c  adapted to provide a registration stop for the mitering portion  30  to thereby limit insertion of the bracket-engaging end  32  within the seat cavity  42 . In one example, the third seat surface  42   c  comprises a planar surface that engages a planar end surface  32   a  of the bracket-engaging end  32  of the mitering portion  30 .  
         [0023]     Brackets throughout this application might comprise a wide variety of structural shapes and may be formed by a wide variety of methods. In one example, the bracket might include one or more chambers to reduce material costs and the weight of the bracket. As shown in  FIG. 2 , for example, each of the first, second and third portions  44 ,  60 ,  70  comprise a chamber defined by a plurality of walls. As shown in  FIG. 2 , the chamber of the first portion  44  is defined by a first wall  46 , a second wall  48  and a third wall  50  wherein the first wall  46  provides the first seat surface  42   a , the second wall  48  provides the first abutment surface  78  and the third wall  50  acts as a reinforcement structure extending between the first and second walls.  
         [0024]     Still further, the chamber of the second portion  60  is defined by a first wall  62 , a second wall  64  and a third wall  66  wherein the first wall  62  provides the concave surface  63 , the second wall  64  provides the second seat surface  42   b  and the third wall  66  provides the second abutment surface  79 . The chamber of the third portion  70  is defined by a first wall  72 , a second wall  74  and a third wall  76  wherein the first wall  72  provides the third seat surface  42   c , the second wall  74  provides another abutment surface to engage with the upstanding portion and the third wall  76  provides yet another abutment surface adapted to engage the support surface  80 .  
         [0025]     The brackets illustrated throughout this application can have an elongated length and a substantially uniform cross section along substantially the entire elongated length. For example, as shown in  FIG. 7 , the illustrated bracket includes an elongated length “L” and a substantially uniform cross section along substantially the entire elongated length “L” of the bracket. While a wide variety of methods of fabricating a bracket with a substantially uniform cross section might be used, the embodiments of the present invention might include a bracket formed with an extrusion process to provide a substantially uniform cross section along substantially the entire elongated length of the bracket. Insignificant variations in the uniformity of the cross section due to fabrication process errors or post fabrication process steps are contemplated. For example, holes may be drilled in an extruded member in specific locations after the member is extruded. Similarly, cuts or cutouts may be formed in the extruded member after it is extruded.  
         [0026]     As shown throughout the figures, structures may also be provided to assist in maintaining the bracket-engaging end of the mitering portion within the seat cavity of the bracket. For example, with reference to  FIGS. 1 and 2 , a bolt  54  or other fastener might be used to arrest the bracket-engaging end  32  of the mitering portion  30  within the seat cavity  42  of the bracket  40 . A screw  52  or other fastener might also be used to mount the bracket with respect to the upstanding portion  12 . It is contemplated that other fasteners or fastening arrangements might be provided. For example, staples, set screws, or the like might be used in accordance with the principles of the present invention. Still further, double sided tape, adhesives (e.g., epoxy adhesives) or other fastening arrangements might be used to attach the components relative to one another.  
         [0027]     As further shown throughout the figures, structures may also be provided to assist in maintaining the mitering portion in an appropriate orientation with respect to the upstanding portion. As shown in  FIG. 1 , for example, a cross brace  224  may be provided between the mitering portion  30  and the upstanding portion  12  to assist in providing a rigid bulkhead structure and also assist in maintaining the orientation of the mitering portion with respect to the upstanding portion when pouring uncured precast material into a casting area of a casting structure.  
         [0028]     A method of using the bulkhead of  FIGS. 1-2  to fabricate a panel with a mitered corner will now be discussed. With reference to  FIG. 7 , a casting structure  400  can be formed with a pair of apposed bulkheads  10 . A first lateral upstanding portion  402  and second lateral upstanding portion  404  may be attached with fasteners  406  to upstanding portions  12  located on opposite sides of the casting structure  400 . The bracket  40  is then engaged with a selected one of the upstanding portions. For example, the bracket  40  can be placed adjacent the bracket-mounting end  14  of the upstanding portion  12  and then fastened into place. A bracket-engaging end of the mitering portion  30  is then inserted into the seat cavity  42  of the bracket  40  to facilitate maintenance of an acute angular orientation between the mitering portion and the upstanding portion  12 . As shown in  FIG. 7 , a pair of opposed bulkheads might be provided for applications where the panel includes two mitered corners.  
         [0029]     Once the casting structure  400  is formed, the uncured precast material is poured into the casting area. As shown in  FIG. 1 , the material flows laterally to engage the first face  36  of the mitering portion  30  and the curved surface  63  of the second portion  60 . As shown in  FIG. 3 , a panel is therefore formed with a mitered corner  207  including a mitered surface portion  208  and a curved surface  210  extending from the mitered surface portion. As further illustrated in  FIG. 3 , a plurality of panels  202  might be coupled together at each panels respective mitered corners  207  to form a panel structure  200 . In one particular embodiment, one or more gaskets  212  are placed between the mitered surface portions  208  and a sealing layer  214  might be used to inhibit liquid from entering into the mitered joint of the panel structure  200 .  
         [0030]      FIGS. 4 and 5  depict an alternative bulkhead  110  in accordance with the present invention wherein like reference numbers designate similar elements throughout the views. As shown in  FIG. 4 , the bulkhead  110  can be constructed similar to the bulkhead  10  as described above. However, a modified bracket  140  can be used to create different mitered corner surface characteristics. As shown in  FIG. 5 , the bracket  140  includes a first portion  144  that is similar to the first portion  44  of bracket  40 . Likewise, bracket  140  includes a third portion  170  that is similar to the third portion  70  of bracket  40 .  
         [0031]     However, the second portion  160  of the bracket  140  has been modified to provide different mitered corner characteristics. As shown, the second wall  164  of the second bracket portion  164  has been elongated and provided with a modified first wall  162 . The first wall  162  includes a linear portion  162   a  defining an upstanding planar surface  163   a  extending from the seat cavity  142  to a concave surface  163   b  defined by a curved portion  162   b  of the first wall  162 . The second portion  160  further includes first and second support surface faces  179   a , 179   b  adapted to engage the support surface  80 .  
         [0032]     A method of making a panel structure with the bulkhead  110  includes using the bulkhead  110  to form a casting structure  400 . Next uncured precast material is poured into the casting area such that the material engages the face  36  of the mitering portion  30 , the upstanding planar surface  163   a  of the bracket  140  and the concave surface  163   b  of the bracket  140  to provide the mitered corner  307  with a mitered surface portion  308 , a planar surface  311  extending from the mitered surface portion  308  and a curved surface  310  extending from the planar surface  311  of the mitered corner  307 .  
         [0033]     It is noted that terms like “preferably,” “commonly,” and “typically” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention.  
         [0034]     For the purposes of describing and defining the present invention it is noted that the term “substantially” is utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The term “substantially” is also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.  
         [0035]     Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.