Abstract:
An inverted elongated ovalized cylindrical grout tube has reinforcing ribs to retain the tube in position in a pre-cast concrete member and to provide added strength to the grout/structural rod connection as it hardens so as to provide greater strength to a pre-cast concrete wall. The upper end of the grout tube has an integrated bellows-like connector that extends between the inverted grout tube and a grout fill spout which is capable of creating any of a number of angles between the grout tube and the fill spout to provide for the easy flow of grout into the tube from a point external to the pre-cast concrete wall.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates generally to connection devices for joining together pre-cast concrete members such as panels or columns stacked one on top of the other to form building walls. The connection devices employ an elongated ovalized cylindrical grout tube with reinforcing ribs formed into the bottom of a precast concrete member having an upward facing grout fill spout that extends through the sidewall of the precast member for permitting grout to be introduced into the inverted elongated ovalized cylindrical grout tube for securing one precast concrete member to another or fastening to the base foundation. 
         [0002]    By inverting the grout tube from its customary orientation of being cast into the top of a lower positioned precast concrete wall section, certain problems arise. A similar problem of locating the structural rod within the range of the opening of the grout tube has previously led to the ovalization of the grout tube opening along the longitudinal direction of the precast wall section. The ovalization permits an approximate placement of the structural rod in the upper wall panel that does not necessarily require precise measurement and placement for engagement within the grout tube in the lower panel. However, with the inverting of the grout tube to be cast into the bottom of a wall panel, although the locating of the structural rod and approximate placement of the grout tube are sufficiently resolved with the ovalization of the tube in one direction along the wall panel, the problem of properly filling the tube arises since the tube is customarily filled from the open end to the closed end using gravitational force for the grout to settle within the tube, around the structural rod, and harden in place. In the present  structural arrangement, with the grout tube inverted, another source for filling the tube with grout to surround the upstanding structural rod extending upward from a lower wall panel is required so that the grout may be uniformly distributed throughout the tube and around the structural rod. 
         [0003]    Elongated grout tubes may be referred to or known as concrete block-out tubes forming attachment openings in the precast wall sections. The elongated ovalized tubes can be mounted on a framing member in a form used to cast wall panels, oriented upwardly from the bottom wall of the panel within the form. An integrated bellows-like connector is located at the distal end of the grout tube at the inward-most point from the bottom of the yet to be formed precast concrete wall panel. A grout fill injection spout extending upwardly and away from the connector is located and extends to the outer surface of the precast panel. After pouring of the concrete panel and the setting of the concrete, the forms are removed and the open ends of the tubes can be sealed or taped, or alternatively a plug is driven into each tube. The grout fill spout that extends outward from the precast member sidewall is also sealed to close off the spout and to insure that water, moisture and dirt does not collect in the spout or connector prior to the erection of the panels. If water retained in the tube freezes, there is a risk the resultant expansion will crack and ruin the panel. Any debris collected within the spout or bellows-like connector will degrade the quality of the connection formed by the mortar when the panels are erected. 
         [0004]    The present invention is an improvement to the concrete block-out tube apparatus used previously to connect upper and lower concrete wall sections as described in U.S. Pat. No. 7,076,924 [Thompson]. The prior Thompson patent discloses a reinforced, ovalized block-out tube cast into the top of a lower concrete member to mate with a structural rod cast into the bottom of an upper concrete member. While this device provides for the dimensional variants  of the rod and receiving tube, creating the required structural strength, it does provide for the reverse structural situation with the structural rod extending upward from a lower precast panel or foundation wall and how the grout will be introduced into the grout tube to surround the structural rod. The typical method for introducing the grout is to fill the grout tube and then lower the structural rod into the tube and the grout contained therein. But due to the reversal of the structural members, the grout still needs to be introduced from an upper position to fill the tube properly and not cause cracking or gaps in the grout surrounding the structural rod to retain the wall section in a fixed position and not result in a potential failure of the wall integrity. 
         [0005]    It is, therefore, an object of the present invention to provide a reinforced pre-cast concrete block-out tube for use in joining pre-cast vertical concrete panels that continues to provide structural strength, without introducing stress concentrations into the poured concrete or grout, and allows for the continued introduction and free flow of the grout from a point above the grout tube to fill the entire tube and to not degrade the quality of the grout connection inside the tube with the structural rod extending upwardly from below. 
         [0006]    It is also an object of the present invention to provide an integrated connection or attachment point at the uppermost internal space of the grout tube for the connection of a grout fill spout or tube to allow for the introduction of grout into the grout tube from an external point of the precast wall segment. 
         [0007]    It is a further object of the present invention to provide a variable angle connector between the elongated inverted ovalized grout tube and the grout tube fill spout to permit the grout fill spout to be angled outward through the precast wall segment at an obtuse angle for ease of entry of the grout through the fill spout and into the grout tube. 
         [0008]    It is yet a further object of the present invention to provide for different dimensional placements of the grout tube within the precast wall segment which is afforded by the variable  angle connector between the elongated inverted ovalized grout tube and the grout tube fill spout so that the angle of the fill spout can be varied depending upon the placement of the grout tube within the precast wall segment. 
         [0009]    A still further object is to reduce the cost of manufacturing block out tubes by molding them in an inverted orientation and adding the integrated grout fill or injection tube, rather than the customary method of positioning top fill block out tubes in the pre-cast wall segments. 
         [0010]    Other objects will appear hereinafter. 
       SUMMARY OF THE INVENTION 
       [0011]    The present invention is an inverted elongated cylindrical grout tube has reinforcing ribs to retain the tube in position in the pre-cast concrete member and to provide added strength to the grout/structural rod connection as it hardens so as to provide greater strength to the formed concrete wall. The upper end of the grout tube has an integrated bellows-like connector that extends between the inverted grout tube and the grout fill spout. The integrated bellows-like connector is capable of creating any of a number of angles between the grout tube and the fill spout to provide for the easy flow of grout into the tube from a point external to the precast wall section. The grout fill spout extends outward to a surface of the pre-cast concrete wall panel to enable the introduction of the grout into the grout tube to secure the upper wall segment in place by surrounding an upwardly extending structural rod positioned within the grout tube and hardening in place around the rod. The reinforcing ribs are configured along the internal surface of the inverted grout tube to reduce interference with the structural rods during placement of the pre-cast wall segments during erection of the wall. 
         [0012]    The present invention may also be described as an elongated ovalized cylindrical tube member for use as a connection assisting device for joining pre-cast concrete panels or forms. The tube member comprises an integral elongate, imperforate, and ovalized hollow tubular  body having a plurality of reinforcing ribs formed into the tubular body with an integrated bellows-like connector at its distal end for connecting the tube member to a fill spout. The fill spout extends away from the cylindrical tube member toward an exterior surface of the concrete panel or form. The oval configuration of the body of the inverted grout tube prevents the tube from rotating within the panel or form during erection. The plurality of reinforcing ribs structurally anchor the tube member within the concrete panel or form and prevent the tube from being pulled out of its position in the concrete panel or form. The reinforcing ribs also act to hold the grout-like hardening substance introduced into the tube member in position so that the grout will not easily move inward or outward from said tube member, aiding in removing any trapped air, preventing collapse and adding strength to the joint between wall segments. The integrated bellows-like connector seamlessly connects the tube member with the fill spout allowing for the infinite modification of the angle between the central axis orientation of the tube member and the central axis orientation of the fill spout. The angle between the central axis orientation of the tube member and the central axis orientation of the fill spout varies depending upon the placement of the tube member closer to or farther away from a sidewall of the concrete panel or form. 
         [0013]    Another way to describe the invention is as a tube member for use as a connection device joining pre-cast concrete panels or forms. The tube member comprises an integral elongate, imperforate, and hollow tubular body of a smoothly curved generally non-cylindrical cross-section, having an outer wall including concrete-engaging circumferential corrugations propagating along the length of said body, an inner wall including grout-engaging circumferential corrugations propagating along the length of said body, a proximal open end, and an integrated bellows-like connector at its distal end for connecting the tube member to a  fill spout. The fill spout extends away from the tube member toward an exterior surface of the concrete panel or form. 
         [0014]    The present invention can also be described as a structural interconnection comprising a lower concrete member, an upper concrete member resting on top of the lower concrete member, and a connection device joining the members together. The connection device includes an integral elongate, imperforate, and hollow tubular body of a smoothly curved generally non-cylindrical cross-section embedded in the bottom of the upper concrete member with said tubular body having a bottom open end facing the lower concrete member and a structural rod embedded in the lower concrete member with the rod extending upwardly through the bottom open end of the tubular body in the upper concrete member. The tubular body has an outer wall including concrete-engaging circumferential corrugations propagating along the length of said body, an inner wall including grout-engaging circumferential corrugations propagating along the length of said body, and an integrated bellows-like connector at its distal end for connecting the tubular body to a fill spout. The fill spout extends away from the tubular body toward an exterior surface of the upper concrete member. To hold the tubular member in place, the concrete in the upper member extends into said concrete-engaging corrugations surrounding the tubular body. A grout-like hardening substance, introduced into the tubular body through the fill spout, fills the interior of the tubular body extending into said grout-engaging corrugations and surrounds the structural rod in the interior of the tubular body to form the connection. 
         [0015]    In each instance the integrated bellows-like connector seamlessly connects the tube member with the fill spout allowing for the infinite modification of the angle between the central axis orientation of the tubular body and the central axis orientation of the fill spout. The angle between the central axis orientation of the tube member and the central axis orientation of the  fill spout varies depending upon the placement of the tube member closer to or farther away from a sidewall of the concrete panel or form. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
           [0017]      FIG. 1  is a front view of the inverted grout tube of the present invention showing the corrugated connector and grout fill spout in a collinear arrangement. 
           [0018]      FIG. 2  is a side view of the inverted grout tube of the present invention showing the corrugated connector and grout fill spout at an angle to the axis of the grout tube. 
           [0019]      FIG. 3  is a partially broken away end view of an insulated precast wall segment with an insulative layer between the outer precast portions of the wall segment showing an inverted grout tube located within each outer precast portion, each grout tube having a different dimensional placement within the precast wall segment and different angular relationship between the main body of the grout tube and the grout fill spout. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0020]    The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings. 
         [0021]    Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in  FIG. 1  a combination elongated ovalized grout tube  10  having a  body  12 , a bottom opening  14 , a series of reinforcing ribs  16  in the body, a grout fill spout  18  at the top end, and an integrated bellows-like connector  20  positioned between the grout tube body  12  and the fill spout  18 . The elongated body  12  is ovalized in cross-section to account for placement approximations of structural rods extending upward through the openings  14  and into the grout tubes  10  and to prevent rotation of the grout tube within the pre-cast wall panel The body  12  is reinforced with a plurality of corrugations or ribs  16  that permit the grout tube  10  to be captured within a precast concrete wall panel in order that the grout tube  10  remains in position within the wall panel and does not pull out. The reinforcing ribs  16  also provide for slightly bent rods to transit the internal surfaces of the grout tube  10  as an upper wall panel is lowered onto a lower panel or foundation wall without scoring or tearing the grout tube  10  and possibly creating an attachment problem by degrading the quality of the grout connection inside the tube. The upper shoulder  16   a  of each rib  16  is elongated and has a less severe angle relationship to the horizontal in order to deflect the structural rod inward toward the central channel of the grout tube  10 . Only the uppermost reinforcing rib  16  is shown with the upper shoulder  16   a  indicated in  FIGS. 1, 2 , but all of the ribs  16  have the identical configuration of the upper shoulder for deflecting the structural rod in the same inward direction. 
         [0022]    Due to the inverting of the grout tube  10 , a grout fill point is needed to be established from a point above the distal end of the grout tube  10  located inwardly the length of the tube from the bottom of a precast wall panel or other precast member. At the distal end of the grout tube  10  an integrated bellows-like connector  20  is positioned and molded as part of the combination grout tube of the present invention. The bellows-like connector  20  can expand longitudinally and angularly to accommodate a fill spout  18  that is to be angled away from the central axis of the combined grout tube  10 . As can be seen in  FIG. 2 , the integrated bellows-like  connector  20  is expanded on the left and compressed on the right to create an angle to the right side away from the center line or axis of the grout tube  10 . 
         [0023]    At the distal end of the integrated bellows-like connector  20  the grout fill spout  18  is formed as part of the combination grout tube  10 . Formed at the end of the fill spout  18  is a cap  22  that is placed at that location to prevent contaminating materials or fluids from entering the grout tube prior to the time that grout will be introduced to secure the wall panel in position. The fill spout  18  has a length sufficient to extend to and through a near side wall of the precast wall panel as shown in  FIG. 3 . The bellows-like connector  20  will permit different angular relationships of the grout tube body  12  and the fill spout  18  depending upon the physical placement of the grout tube  10  within the precast wall panel. 
         [0024]    Referring now to  FIG. 3 , an insulated precast wall panel  30  is shown with an insulating member  32  located between left and right side precast concrete sections  34 ,  36 . The insulated precast wall panel  30  is mounted atop a base or foundation  38  that has two structural rods  40 ,  42  extending upwardly therefrom. The structural rods  40 ,  42  are separated by a distance that is less than the thickness of the insulated wall panel  30 , and preferably at a distance approximating the distance between the centers of each of the respective left and right side sections  34 ,  36 . In order to demonstrate the capacity of the present invention to accommodate different placements of the structural rods, the left side structural rod  40  is positioned inward of the center of the left side section  34  of the insulated wall panel  30  such that the distance to the outer surface of the wall section  34  is greater. In this instance the fill spout  18  must still extend outward from the side of the wall section  34  so that the bellows-like connector  20  is configured to create an angle between the grout tube body  12  and the fill spout  18  approximating 30° upward from the horizontal, or 60° to the left from the vertically oriented centerline of the grout tube body  12 . 
         [0025]    This adjustable angle for the fill tube  18  may be better seen and described with reference to the grout tube  10  on the right of  FIG. 3 . The grout tube  10  is shown in outline so that the structural rod  42  can be seen in the approximate center of the grout tube  10  extending upwards almost to the integrated bellows-like connector  20 . In this instance the structural rod  42  is positioned at the center of the right side section  36  of the wall panel  30 . This positioning creates a shorter distance for the fill spout  18  to extend to the exterior of the wall so that the angle between the centerline of the grout tube  10  and the fill spout  18  can be changed so that only a limited length of the fill spout  18  extends outside the right side section wall. Thus, the angle between the grout tube body  12  and the fill spout  18  will approximate 45° upward from the horizontal, or 45° to the right from the vertically oriented centerline of the grout tube body  12 . If the grout tube is positioned closer to the exterior surface of the side section of the insulated wall panel  30 , then the angle between the grout tube body  12  and the fill spout  18  will, again, be modified to accommodate the greater length of the fill spout  18  within the wall section. To protect the integrity of the fill spout  18 , only the shortest length possible should extend outward from the sidewall of the wall panel  30 . When the fill spout  18  is to be used, the cap  22  can be removed by cutting it off from the exposed fill spout  18 . Of course, when the usefulness of the fill spout  18  is concluded with the grout being introduced into the grout tube  10 , the fill spout can be cut off flush with the sidewall of the wall panel  30 . 
         [0026]    The grout tubes  10  are pre-positioned within the insulated wall panel  30  in accordance with the structural requirements of the interconnection of the wall segments and with the foundation. The placement of the grout tubes  10  approximates and mirrors the placement of  the structural rods  40 ,  42  so that the interconnection can be easily accomplished by the placement of the upper wall panel  30  over the lower wall segment or foundation by mating the grout tubes  10  with the respective upstanding structural rods  40 ,  42  and then filling the grout tubes  10  through the fill spouts  18  oriented at a predetermined angle dependent upon the placement of the grout tubes  10  within the wall sections  34 ,  36  with a material that hardens around the structural rods  40 ,  42  holding the wall panels together. The integrated bellows-like connector  20  is a necessary element to the present invention as it is the connector  20  that facilitates the angle change required for the fill spout  18  to extend only slightly through the sidewall of the wall panel  30  the shortest possible distance. As described above, the angle of the bellows-like connector  20  is also dependent upon the precise placement of the grout tube  10  within the wall section  34 ,  36  with the angle changing the closer or farther away the grout tube  10  is to the exterior surface of the wall panel. 
         [0027]    The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.