Abstract:
An apparatus, system, and method are disclosed for preventing the intrusion of poured concrete into the space defined by a window buck installed between concrete forms. The apparatus, system, and method include a window buck panel incorporating a concrete exclusion barrier comprising a protrusion formed on the body of the window buck panel; a flange affixed to an attachment leg of the window buck panel; or an appropriately shaped leg of a window buck panel. The concrete retention barrier is configured to contact a concrete form under pressure and remain in contact as the form alters shape from the weight of infused concrete. By preventing fluid concrete from entering a defined window cavity during formation of a concrete wall the apparatus, system, and method described eliminate the need to remove hardened concrete from the interior of the cavity before window installation. Use of certain embodiments of the described invention saves time and effort in preparing the window cavity for window installation and also preserves the cleanliness and precise configuration of the window installation surface.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application No. 60/471,273, filed May 16, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to window buck panels and more particularly relates to preventing concrete from intruding into the space defined by assembled window buck panels.  
         [0004]     2. Description of the Related Art  
         [0005]     Concrete is well-known and widely used for various construction projects. Among concrete&#39;s many advantages, is concrete&#39;s transformation from a fluid state to a solid state. The concrete may be formed and mixed in a fluid state, poured it into a form, and allowed to cure into a hard and very strong object. In construction, concrete is generally used to form footings and foundation walls.  
         [0006]     The forms for a foundation wall are generally modular and may be secured together to define various shapes of walls. The fluid concrete is poured between the forms, which may be spaced approximately six inches or more, an allowed to cure to form a wall that is the same shape as the space between the forms. As the forms for a foundation wall are set in place and secured as may be necessary, a buck system may be placed and secured between the forms in order to form a cavity or recess in the concrete wall that will be constructed. The buck system is intended to retain the fluid concrete outside of the desired recess and, after the concrete is cured and the forms are removed, define an opening such as a window or doorway through the concrete wall.  
         [0007]      FIG. 1  illustrates a cross-sectional view of a conventional window buck panel  102 . The window buck panel  102  is typically formed of aluminum or a vinyl material and is used to define an opening in a concrete wall as the concrete is being poured. Generally, four separate window buck panels are oriented and joined at the ends to form a shape that defines a window opening  103  in a concrete wall, such as the finished basement foundation wall of a residence or commercial building. The shape of the window opening  103  may be rectangular, square, circular, or the like.  
         [0008]      FIG. 1  shows the window buck panel  102  secured between a pair of concrete forms  104  (shown dashed). The depicted window buck panel  102  is oriented in a position to form a bottom panel of a rectangular window opening  103 . For clarity, corresponding side and top panels are not shown. The concrete forms  104  are located on the interior and exterior sides of the window buck panel  102 . The window buck panel  102  may be secured between the concrete forms  104  using a variety of known techniques, such as nails, screws, hanger ties, and so forth.  
         [0009]     With the window buck panel  102  secured between the concrete forms  104 , a fluid concrete  108  is poured into and fills a void between the concrete forms  104 . The window buck panel  102 , in conjunction with additional panels, such as side and top panels, defines the window opening  103  within the concrete  108  as it cures and solidifies.  
         [0010]     With the fluid concrete  108  between the forms  104 , the window bucks panel  102  and additional panels substantially prevent the concrete  108  from entering the window opening  103 . The weight of the concrete  108 , however, typically generates significant pressure, indicated by the arrows  110 , on the bottom of the window buck panel  102 . The concrete  108  may also exert lateral pressure on the concrete forms  104 . These forces may move the window buck panel  102  and/or the concrete forms  104 , creating a gap  112  between one or both of the forms  104  and the window buck panel  102 .  
         [0011]     The forces drive the fluid concrete  108  through the gap  112  and create an undesirable concrete formation  114  within the window opening  103 . The concrete formation  114  within the window opening  103  must be removed prior to installation of a window frame or interior building finishes, including wall framing and finishes, as well as other materials. The movement of the interior concrete form  104  also creates an undesirable variation in the wall thickness. Additionally, more concrete  108  may be required to form the wall due to the concrete  108  that escapes into the window opening  103 .  
         [0012]     From the foregoing discussion, it should be apparent that a need exists for an apparatus, system, and method that compensate for the formation of a gap between the buck system and the concrete forms. Beneficially, such an apparatus, system, and method would block the fluid concrete from entering the window or doorway cavity defined by the buck system and retain the concrete outside of the cavity despite any lateral movement of the concrete forms away from the buck system.  
       SUMMARY OF THE INVENTION  
       [0013]     The present invention has been developed in response to the present state of the art, and in particular, the need to prevent the intrusion of concrete into the cavity defined by assembled window buck panels. Accordingly, the present invention has been developed to provide an apparatus, system and method for defining a window cavity in poured concrete walls that overcome many or all of the above-discussed shortcomings in the art.  
         [0014]     The apparatus for preventing the intrusion of concrete into the cavity defined by assembled window buck panels includes a window buck panel configured to contact a concrete form under pressure when the window buck panel is installed between concrete forms and to flex outward, thus maintaining tight contact with the form, when the form alters shape due to the weight of the concrete.  
         [0015]     In one embodiment of the apparatus a rounded protrusion running the length of the panel body is associated with a flexture groove that allows the protrusion to move laterally in response to pressure from the concrete forms. In a further embodiment of the apparatus the concrete retention flange is attached to a leg extending from the window buck body. In another embodiment of the apparatus, the concrete retention flange comprises a substantially flat member projecting horizontally from the leg of the window buck panel.  
         [0016]     In another embodiment of the apparatus the leg is further configured to flex inward under pressure from the concrete form. In another embodiment of the apparatus, the leg includes a rounded protrusion configured to bend the leg under pressure from the concrete forms. In a further embodiment of the apparatus, the leg may be configured to flex at the point of attachment to the window buck panel body, or at any point along the length of the leg. In a further embodiment of the apparatus, the leg may bow. In another embodiment of the apparatus, the leg is wider at the distal end and tapers inward toward the proximate end and is thus configured to assume the concrete retention function of the flange.  
         [0017]     In a further embodiment of the apparatus the leg is positioned at an outward angle to the window buck panel, bringing the leg into contact under pressure when the window buck is installed between concrete forms. In a further embodiment of the apparatus the window buck panel includes securing flanges configured to become embedded in the cured concrete and hold the window buck in place.  
         [0018]     A system of the present invention is also presented for preventing the intrusion of concrete into the space defined by the assembled window buck. They system may be embodied in a plurality of concrete forms configured to contain concrete during a curing period of the concrete: at least one buck panel defining a cavity between the concrete forms; and a concrete retention barrier attached to one of the at least one of the buck panels, the concrete retention barrier configured to contact at least one of the plurality of concrete forms under pressure and to prevent concrete intrusion into the cavity.  
         [0019]     The system may be further embodied in a concrete obstruction barrier that is attached to the lateral edge of a window buck panel and configured to deform under contact pressure from a concrete form when installed. In a further embodiment the concrete obstruction barrier is configured to rebound toward its original form as contact pressure decreases, thereby maintaining contact with the concrete form. In a further embodiment the concrete retention barrier may comprise a shape selected from at least one of a flange, a rounded protrusion, a tapered leg, and an angled leg.  
         [0020]     A method of the present invention is also presented for preventing the intrusion of poured concrete into the space defined by assembled window buck panels. The method in the disclosed embodiments substantially includes the steps necessary to carry out the functions presented above with respect to the operation of the described apparatus and system. In one embodiment the method includes the steps of: forming a window buck system and thereby partially defining a window cavity, the window buck system comprising least one concrete retention barrier and one or more window buck panels; orienting the window buck system between a plurality of concrete forms and thereby fully defining the window cavity; and securing the window buck system between a plurality of concrete forms and displacing the at least one concrete retention barrier under pressure from the plurality of concrete forms.  
         [0021]     Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.  
         [0022]     Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention. These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]     In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:  
         [0024]      FIG. 1  is a cross-sectional view of one embodiment of a window system utilizing a conventional window buck;  
         [0025]      FIG. 2  is a cross-sectional view of one embodiment of a window buck panel according to the present invention;  
         [0026]      FIG. 3  is a side view of one embodiment of a window buck panel according to the present invention;  
         [0027]      FIG. 4  is a perspective view of one embodiment of a window buck panel according to the present invention;  
         [0028]      FIG. 5  is a perspective view of one embodiment of a window buck panel according to the present invention;  
         [0029]      FIG. 6  is a cross-sectional view of one embodiment of a window system utilizing the present invention;  
         [0030]      FIG. 7  is a cross-sectional view of one embodiment of a window system utilizing the present invention; and  
         [0031]      FIG. 8  is a perspective cut-away view of one embodiment of a window forming system incorporating the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0032]     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.  
         [0033]     Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of several embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.  
         [0034]      FIG. 2  depicts a cross-sectional view of a window buck panel  202  according to one embodiment of the present invention. The window buck panel  202  preferably includes an interior surface  204  and an exterior surface  206 . The interior surface  204  in one embodiment is substantially vertical and is parallel with an interior plane  205  (shown dashed) defining an interior lateral edge. Similarly, the exterior surface  206  in one embodiment is parallel with an exterior plane  206  (shown dashed) defining an exterior lateral edge. Extending downward from the interior surface  204  of the window buck panel  202  is an interior leg  208 . Likewise, an exterior leg  210  extends downward from the exterior surface  206 .  
         [0035]     In one embodiment, the interior and exterior legs  208 ,  210  may be integrally formed with the body of the window buck panel  202 , or alternatively may be attached to the panel  202 . In either of these embodiments, the legs  208 ,  210  include a point of attachment  212  (proximal end) that defines the intersection where the interior and exterior surfaces  204 ,  206  meet the interior and exterior legs  208 ,  210 , respectively. In the preferred embodiment, the interior leg  208  includes a concrete retention flange  214 . In the depicted embodiment, the concrete retention flange  214  is shown at the distal end of the interior leg  208 . The concrete retention flange  214  preferably runs the length of the window buck panel  202  and extends laterally away from body of the window buck panel  202  and through the interior plane  205 .  
         [0036]     The interior leg  208  may flex or bend at the point of attachment  212  due to external forces, such as the direct contact pressure exerted by one of the concrete forms  104 . Alternatively, the interior leg  208  may flex or bend between the point of attachment  212  and the concrete retention flange  214 . The interior leg  208  preferably flexes under pressure produced when one of the concrete forms  104  contacts the concrete retention flange  214 .  
         [0037]     The concrete retention flange  214  is located, in one embodiment, at the distal end of the interior leg  208 . Alternatively, the concrete retention flange  214  may be located anywhere along the interior leg  208  or the interior surface  204 , so long as the placement allows suitable displacement concrete retention flange  214  when in contact with one of the concrete forms  104 . The contact pressure between one of the concrete forms  104  and the concrete retention flange  214  prevents concrete  108  from creating and entering a gap  112  (see  FIG. 1 ).  
         [0038]     In another embodiment, the concrete retention flange  214  may be located on the exterior leg  210  or on the exterior surface  206  of the window buck panel  202 . In a further embodiment, the window buck panel  202  may include one or more flanges  214  on each of the interior and exterior surfaces  204 ,  206  and legs  208 ,  210 .  
         [0039]     The concrete retention flange  214  is designed and located to provide increased contact pressure between the window buck panel  202  and the concrete forms  104  so as to resist concrete  108  intrusion into the defined window opening  103 . The concrete retention flange  214  also may be referred to as a concrete retention barrier.  
         [0040]     The position and configuration of the concrete retention flange  214  may vary. For example, the concrete retention flange  214  may be a substantially flat, horizontally projecting member. Alternatively, the concrete retention flange  214  may comprise a tapered interior leg  208  or exterior leg  210  that is wider at the lower end. The concrete retention flange  214  may further comprise a rounded protrusion, such as a nub suitably sized and positioned to bend the interior or exterior leg  208 ,  210  to increase the contact pressure and prevent concrete  108  intrusion.  
         [0041]     In another embodiment, the interior and/or exterior surfaces  204 ,  206  may include a curved wall having a concave or convex cross-section. Alternatively, the interior and/or exterior legs  208 ,  210  may flare outwardly, away from the body of the window buck  202  panel by being connected to the respective surfaces  204 ,  206  at an appropriate angle that is substantially vertical. In the case of one or more flared legs  208 ,  210 , the window buck panel  202  may or may not include a horizontally projecting member, such as the concrete retention flange  214 . One skilled in the art will also recognize the potential cost, production, and installation benefits of a combination of one or more of the above implementations of the concrete retention flange  214 .  
         [0042]      FIG. 3  depicts a side view of the window buck panel  202 . The depicted window buck panel  202  includes a concrete retention flange  214  attached to the distal end of the interior leg  208  and running the length of the window buck panel  202 .  
         [0043]      FIG. 4  illustrates a perspective view of a representative embodiment of the window buck panel  202  having alternative implementations of the concrete retention flange  214 . The window buck panel  202  comprises a tapered interior leg  216  that flares away from the body of the window buck panel  208  and through the interior plane  205 . The depicted window buck panel  202  also includes a rounded protrusion  218  that extends away from the exterior leg  210  and through the exterior plane  207 . The window buck panel  202  further includes securing flanges  230 ,  232  that extend inwardly from the interior and exterior legs  208 ,  210 . The securing flanges preferably become fixably embedded in the cured concrete  108  and prevent the window buck panel  202  from moving or becoming dislodged from the concrete  108 .  
         [0044]      FIG. 5  illustrates a perspective view of another representative embodiment of the window buck panel  202  having alternative implementations of the concrete retention flange  214 . The depicted window buck panel  202  comprises an angled interior leg  220  that is angled slightly away from the body of the window buck panel  202  and through the interior plan  205 . The depicted window buck panel  202  also includes a rounded protrusion  222  that is located on the exterior surface  206  and extends away from the exterior surface  206  and through the exterior plane  207 . The exterior surface  206  of the depicted window buck panel  202  includes a flexure groove  224  that allows the exterior surface  206  and rounded protrusion  222  to move laterally in response to pressure from the concrete forms  104 .  
         [0045]      FIG. 6  depicts a window buck panel  202  secured between the concrete forms  104  prior to pouring the fluid concrete  108  in the space  105  below the window buck panel  202 . The interior surface  204  and the exterior surface  206  of the window buck panel  202  each abuts one of the concrete forms  104 . Alternatively, the width of the window buck panel  202  may be slightly smaller than the width of the concrete forms  104 , in which case one or both of the interior and exterior surfaces  204 ,  206  may be slightly short of abutting the concrete forms  104 .  
         [0046]     The depicted window buck panel  202  has an interior leg  204  and a horizontally projecting concrete retention flange  214 . The illustrated interior leg  204  and concrete retention flange  214  have been moved laterally due to the lateral pressure of the concrete forms  104 . In the depicted embodiment, the interior leg  204  is hinged at the point of connection  212  (proximal end of the interior leg  204 ). In an alternate embodiment, the interior leg  204  may hinge or bend at multiple locations along the length of the interior leg  204 . In a further embodiment, the interior leg may bow across the entire interior leg  204  or along one or more portions of the interior leg  204 .  
         [0047]      FIG. 7  depicts a window buck panel  202  secured between the concrete forms  104  after pouring the fluid concrete  108  below the window buck panel  202 . With the window buck panel  202  secured in this fashion, the fluid concrete  108  is poured between the forms  104  and around the window opening  103  defined by the window buck panel  202  and additional side and top panels (not shown). After the concrete  108  solidifies and cures and the forms  104  are removed, the interior and exterior panel surfaces  204 ,  206  are exposed.  
         [0048]     In the depicted embodiment, one of the concrete forms  104  on the interior side of the window buck panel  202  has been forced outward due to the lateral force, indicated by the arrows  110 , generated by the weight of the fluid concrete  108 . As the concrete form  104  is forced laterally outward, a gap  112  may be formed between the interior surface  204  and the concrete form  104 . As the gap  112  is created, the interior leg  208  and concrete retention flange  214  returns to a détente position, maintaining a barrier between the concrete form  104  and concrete retention flange  214  that prevents the fluid concrete  108  from entering the window opening  103 . In an alternative embodiment, the concrete form  104  may only partially be forced outward, allowing the interior leg  208  and concrete retention flange  214  to only partially return to a détente position, but still maintaining an adequate barrier to prevent the fluid concrete  108  from entering the window opening  103 .  
         [0049]     Once the window buck panel  202  is installed in the cured concrete  108  and the concrete forms  104  are removed, a window frame  224  may be attached to the window buck panel  202  within the window opening  103 .  
         [0050]      FIG. 8  illustrates a cut-away perspective view of a window forming system  800 , including a plurality of window buck panels  202   a ,  202   b  that are secured (fasteners not shown) between a pair of concrete forms  104 . The window buck panels  202   a ,  202   b  define a window opening  103  (side panels are not shown for clarity) and are encased in poured concrete  108 . The window buck panels  202   a ,  202   b  each include a concrete retention flange  214 . Each of the concrete retention flanges  214  contacts one of the concrete forms  104  and prevents intrusion of the concrete  108  into the defined window opening  103 .  
         [0051]     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.