Patent Document

FIELD OF THE INVENTION  
         [0001]    This invention relates to the construction industry, and particularly to a device and method for creating a receptacle for receiving steel beams or wood girders at desired heights in walls consisting of insulated concrete forms or any poured concrete walls.  
         BACKGROUND OF THE INVENTION  
         [0002]    The prior art teaches a method of constructing poured concrete walls in which modular wall preforms, each comprising a pair of high-density foam panels which are maintained in a parallel-spaced relationship by a series of bridging “webs” extending between and through and molded into the panels, are interlockingly stacked together to define a concrete form for the poured concrete wall. With reinforcing steel bars optionally suspended within the assembled wall form, preferably through use of hooks or other retainers provided on each bridging web, the concrete is thereafter poured between the panels to complete the wall.  
           [0003]    Unlike other known methods of constructing poured concrete walls in which the form&#39;s panels are removed from the poured concrete wall prior to the complete curing thereof, in the method employing these modular foam-panel preforms, the preforms become a permanent part of the resulting composite wall structure, with the interlocking foam panels providing a highly-effective layer of insulation on both sides of the finished wall. Further, where the webbing terminates on the outside of each panel to define integral furring strips, finishing materials may be conveniently applied directly to the interior and exterior of the wall.  
           [0004]    While this method has proved highly successful in constructing poured concrete basement walls, with first-floor joists supported by the wall&#39;s top surface in a conventional manner, there remains a need to provide a simple yet effective apparatus and method by which beams may be supported by the wall at a height beneath its top surface.  
           [0005]    More specifically, in a first known method of making beam pockets in the foundation for receiving support beams is through precast construction, wherein the foundation units have beam pockets that are cast in place. These beam pockets support steel beams or wood girders at adjustable or desired locations along the wall. Therefore, in order to accommodate this need, special panels must be precast for each specific construction job, which seriously hampers or eliminates mass production runs.  
           [0006]    In accordance with a second known method for creating beam pockets at a required location within the form walls, a void is created within the wall and a block consisting of either Styrofoam or wood is placed within the void. After the concrete is poured and allowed to set, the material used to fill in the void is chiseled out to expose the pocket. A drawback of this method is the inability to determine the correct fill of the poured concrete beneath the Styrofoam or wood blocks placed within the void. In addition, the removal of the Styrofoam or wood block is time consuming and may cause damage to the set concrete. Furthermore, the Styrofoam or wood blocks must be maintained between the two opposing form walls and, as a result, the void must be created through both walls such that two ledges are created to support the same, thereby preventing secure maintenance of the beam or girder.  
           [0007]    The prior art does not address the need for a more effective method and device for creating beam pockets in perform walls at desired locations. Therefore, there remains a long standing and continuing need for an advance in the art of beam pocket creation that is simpler in both design and use, is more economical, efficient in its construction and use, and eliminates the need for complex and time expensive methods and devices for creating beam pockets.  
         SUMMARY OF THE INVENTION  
         [0008]    Accordingly, it is a general object of the present invention to overcome the disadvantages of the prior art.  
           [0009]    In particular, it is an object of the present invention to provide a device for creating beam receptacles in poured concrete walls.  
           [0010]    It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls featuring ease of use.  
           [0011]    It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls that reduces or eliminates the presence of deleterious voids within the concrete around such beam receptacles.  
           [0012]    It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls that is economical in cost to manufacture and use.  
           [0013]    It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls that that is easy to manufacture.  
           [0014]    In keeping with the principles of the present invention, a unique device is disclosed for creating a receptacle to receive an I-beam or wood or metal girders used in creating floor systems within preformed walls that allow a curable material to be poured therein. The device is made of a top panel located above a bottom panel and interconnected by a pair of side panels. A back panel may be attached to the top, bottom, and side panels at an inner edge such that an opening is defined by the panels at an outer edge thereof and is distal to the back panel.  
           [0015]    The device is inserted into a cavity defined by the internal wall of the preformed walls such that the outer edge of the panels is flush with the internal wall. A flange may extend from the outer edge of the panels to secure the device to the wall while the curable material is poured between the internal wall and the external wall of the preformed walls. In order to ensure the proper formation of the curable substance beneath the device, an aperture may be provided on the bottom panel to allow inspection of the curable material. In addition, the aperture may be used to accommodate a rebar therethrough to add structural integrity to the curable material below the device.  
           [0016]    Such stated objects and advantages of the invention are only examples and should not be construed as limiting the present invention. These and other objects, features, aspects, and advantages of the invention herein will become more apparent from the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings and the claims that follow. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    It is to be understood that the drawings are to be used for the purposes of illustration only by and not as a definition of the limits of the invention.  
         [0018]    In the drawings, wherein similar reference characters denote similar elements throughout the several views:  
         [0019]    [0019]FIG. 1 is a plan view of a device in an unassembled state illustrating one preferred embodiment thereof.  
         [0020]    [0020]FIG. 2 is perspective view of the device assembled and mounted within a composite wall.  
         [0021]    [0021]FIG. 3 is a partial cross-sectional view of the device in an assembled and mounted state taken along the line  3 - 3  of FIG. 2.  
         [0022]    [0022]FIG. 4 is a partial cross-sectional view of the device in an assembled and mounted state taken along the line  4 - 4  of FIG. 5 illustrating receipt of a member within the device.  
         [0023]    [0023]FIG. 5 is a perspective view of the device in an assembled and mounted state illustrating receipt of a member within the device. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]    Referring to FIG. 1, therein is illustrated a device  10  in an unassembled state which is preferably used for creating beam pockets within insulated concrete form (“ICF”) walls or similar structures. It is to be understood that although a unitary method of construction of device  10  is herein illustrated in one preferred embodiment, device  10  may be constructed from several disjoined elements in alternate preferred embodiments. In addition, although several preferred dimensions or shapes may be assigned to device  10  in a preferred embodiment, it is to be understood that alternate sizes and shapes are also contemplated hereby.  
         [0025]    Device  10  has at least a first panel  12 , a second panel  14 , a third panel  16 , a fourth panel  18  and a fifth panel  20 . First panel  12  has a first outer end  22  and an opposing first inner end  24  which are interconnected by a pair of first side ends  26 . First side ends  26  may have at least a first attaching means  28  thereon that extend beyond an edge defined by said first side ends  26 . For purposes of illustration but not limitation, first attaching means  28  may be a panel that extends along the length of said first side ends  26 , or in an alternate preferred embodiment first attaching means  28  may extend along only a certain length of said first side ends  26 .  
         [0026]    Second panel  14  has a second outer end  30  and an opposing second inner end  32  interconnected by a second top end  34  and a second bottom end  36 . Second top end  34  has an outer region  38  and an inner region  40 . In a preferred embodiment, inner region  40  is angled towards second bottom end  36  at a predetermined angle and outer region  38  is substantially parallel to second bottom end  36 . However, it is to be understood that second top end  34  may be substantially parallel to second bottom end  36  along the entire length thereof. Second bottom end  36  may have at least a second attaching means  37  thereon that extends beyond an edge defined by second bottom end  36 . For purposes of illustration but not limitation, second attaching means  37  may be a panel that extends along the length of second bottom end  36 , or in an alternate preferred embodiment second attaching means  37  may extend along only a certain length of second bottom end  36 .  
         [0027]    Third panel  16  has a third outer end  42  and an opposing third inner end  44  interconnected by a third top end  46  and a third bottom end  48 . Third top end  46  has an outer portion  50  and an inner portion  52 . In a preferred embodiment, inner portion  52  is angled towards third bottom end  48  at a predetermined angle and outer portion  50  is substantially parallel to third bottom end  48 . However, it is to be understood that third top end  46  may be substantially parallel to third bottom end  48  along the entire length thereof. Third bottom end  48  may have at least a third attaching means  49  thereon that extends beyond an edge defined by third bottom end  48 . For purposes of illustration but not limitation, third attaching means  49  may be a panel that extends along the length of third bottom end  48 , or in an alternate preferred embodiment third attaching means  49  may extend along only a certain length of second bottom end  48 .  
         [0028]    Fourth panel  18  has a fourth outer end  54  and an opposing fourth inner end  56  which are interconnected by a pair of side edges  58 . An aperture  60  is defined through fourth panel  18  and may be of any predetermined size. Fifth panel  20  is defined by a periphery  62  that is polygonal in a preferred embodiment. Periphery  62  of fifth panel  20  connects with first inner end  24 , second inner end  32 , third inner end  44 , and fourth inner end  56  such that a substantially cross-shaped arrangement is achieved in an unfurled and unassembled state. Although device  10  is illustrated as being formed through stamping from unitary piece of material, it is to be understood that each of the individual panels may be independent of one another and affixed accordingly in any methods that are known in the art such as, but not limited to, welding of adhering. Various materials may also be used to construct device  10  and for purposes of illustration, but not limitation, in one preferred embodiment device  10  is constructed of a metal or a metal alloy such as, but not limited to, galvanized steel or aluminum. In addition, in an alternate preferred embodiment, device  10  may be constructed of polymeric materials such as, but not limited to, plastic. If polymeric materials are utilized, device  10  may also be constructed through methods of injection molding.  
         [0029]    Now referring to FIGS. 2 and 3, device  10  is illustrated in an assembled and installed state within a composite wall  64 . Composite wall  64  is formed by pouring a suitable curable material  66 , such as concrete, between an interior panel  68  and an exterior panel  70 . Composite wall  64  for purposes of illustration, but not limitation, may be obtained from AAB Building Supplies, Inc. of Ottawa, Canada, under the trademark BLUEMAXX® which uses a plurality of interlocking modular performs to construct a composite wall  64  of desired length.  
         [0030]    Panels  12 ,  14 ,  16 , and  18  are folded inwardly such that they rest at a substantially perpendicular angle to fifth panel  20 , and panels opposing panels  12  and  18 , and opposing panels  14  and  16  are in substantially parallel relations such that a receptacle  71  is defined by panels  12 ,  14 ,  16 ,  18 , and  20 . In a preferred embodiment, first panel  12  is adapted to be integral with inner region  40  and outer region  38  of second panel  14  and also integral with inner portion  52  and outer portion  50  of third panel  16  and covering panels  14  and  16 . As such, first panel  12  has a forward region  72  and a rearward region  74 , such that rearward region  74  is angled towards opposing fourth panel  18 . In an assembled state, first attaching means  28  of first side ends  26  attach to an outer surface of second panel  14  and third panel  16 . In addition, second attaching means  37  and third attaching means  49  are secured to an outer surface of fourth panel  18 , attaching means  28 ,  37 , and  49  may be secured to the respective panels through any appropriate method known in the art such as, but not limited to, welding or use of an adhesive.  
         [0031]    When installing device  10  into a composite wall  64 , a hole of an appropriate size is cut in interior panel  68  of composite wall  64  and device  10  is inserted therein such that receptacle  71  is accessible. In a preferred embodiment, a first flange  76  is formed on first panel  12  at a first outer end  22  thereof, a second flange  78  is formed on second panel  14  at second outer end  30  thereof, a third flange  80  is formed on third panel  16  at the third outer end  42  thereof, and a fourth flange  82  is formed on fourth panel  18  at the fourth outer end  54  thereof. In one preferred embodiment, flanges  76 ,  78 ,  80 , and  82  may be formed by outwardly folding each respective panel or in an alternate preferred embodiment flanges  76 ,  78 ,  80 , and  82  may be adhered to each respective panel in any appropriate method that is known in the art. At least a securing means  84  or a plurality thereof, may be used to firmly secure flanges  76 ,  78 ,  80 , or  82  to interior panel  68 . For purposes of illustration, but not limitation, securing means  84  may be a nail, screw, or bolt.  
         [0032]    After device  10  is installed within composite wall  64 , curable material  66  is poured into the space between interior panel  68  and exterior panel  70  and thus encloses device  10  therein. Aperture  60  may be used to ensure that sufficient curable material  66  exists beneath fourth panel  18 . In addition, as more clearly illustrated in FIG. 4, a support element  86 , such as a rebar, may be inserted through aperture  60  into the curable material  66  before curable material  66  has solidified. Support element  86  provides greater structural support for any member  88  received within receptacle  71 . Now also referring to FIG. 5, member  88  is illustrated as received within receptacle  71 . For purposes illustration, but not limitation, member  88  may be an I-Beam or wood or metal girder that may be used in the construction industry to support the construction of a floor thereon. Device  10  may be modified to form a receptacle  71  of a predetermined dimension to accommodate member  88  of varying dimensions.  
         [0033]    While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of preferred embodiments thereof. Many other variations are possible without departing from the essential spirit of this invention. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.

Technology Category: 7