U.S. patent application number 10/847640 was filed with the patent office on 2005-02-17 for window buck with retention flange.
Invention is credited to Linford, Duane M., Linford, Paul M..
Application Number | 20050034384 10/847640 |
Document ID | / |
Family ID | 34138498 |
Filed Date | 2005-02-17 |
United States Patent
Application |
20050034384 |
Kind Code |
A1 |
Linford, Paul M. ; et
al. |
February 17, 2005 |
Window buck with retention flange
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.
Inventors: |
Linford, Paul M.; (Salt Lake
City, UT) ; Linford, Duane M.; (Salt Lake City,
UT) |
Correspondence
Address: |
BRIAN C. KUNZLER
8 EAST BROADWAY
SUITE 600
SALT LAKE CITY
UT
84111
US
|
Family ID: |
34138498 |
Appl. No.: |
10/847640 |
Filed: |
May 17, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60471273 |
May 16, 2003 |
|
|
|
Current U.S.
Class: |
52/204.1 |
Current CPC
Class: |
E06B 1/16 20130101; E06B
1/28 20130101; E04G 15/02 20130101 |
Class at
Publication: |
052/204.1 |
International
Class: |
E04G 015/00 |
Claims
What is claimed is:
1. An apparatus to define at least a portion of a window opening
within a plurality of concrete forms, the apparatus comprising: a
window buck panel having a panel body, the window buck panel
configured to be secured between a plurality of concrete forms; and
a concrete retention barrier extending laterally away from the
panel and through a plane defining a lateral edge of the panel, the
concrete retention barrier configured to contact at least one of
the plurality of concrete forms under pressure and to prevent
concrete intrusion between the panel body and the at least one
concrete form.
2. The apparatus of claim 1, wherein the concrete retention barrier
is attached to the panel body.
3. The apparatus of claim 1, wherein the concrete retention barrier
is attached to an attachment surface of the panel body, the
attachment surface comprising one of an interior surface and an
exterior surface of the panel body.
4. The apparatus of claim 3, wherein the attachment surface
comprises a flexure groove configured to allow the attachment
surface to move laterally under pressure applied to the concrete
retention flange.
5. The apparatus of claim 1, wherein the concrete retention barrier
is attached to an attachment leg, the attachment leg comprising one
of an interior leg and an exterior leg connected to the panel
body.
6. The apparatus of claim 5, wherein the attachment leg is
configured to flex and move laterally under pressure applied to the
concrete retention barrier.
7. The apparatus of claim 6, wherein the attachment leg is
configured to flex at a point of junction between the attachment
leg and the window buck panel body.
8. The apparatus of claim 6, wherein the attachment leg is
configured to flex at a point between a a proximal end of the
attachment leg and a distal end of the leg.
9. The apparatus of claim 6, wherein the attachment leg is
configured to flex at a plurality of points on the attachment
leg.
10. The apparatus of claim 1, wherein the concrete retention
barrier comprises a substantially flat, horizontally projecting
flange member.
11. The apparatus of claim 1, wherein the concrete retention
barrier comprises a tapered attachment leg that is wider at the
distal end and tapers inward toward the proximate end.
12. The apparatus of claim 1, wherein the concrete retention
barrier comprises a protrusion.
13. The apparatus of claim 1, wherein the concrete retention
barrier comprises an angled leg.
14. A system to prevent intrusion of concrete into a space defined
by a plurality of buck panels, the system comprising: 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; 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.
15. The system of claim 14, wherein the concrete obstruction
barrier is further configured to laterally displace under contact
pressure from the concrete forms in the direction of the applied
pressure.
16. The system of claim 15, wherein the concrete obstruction
barrier is further configured to return from a displaced position
and maintain contact with at least one of the plurality of concrete
forms in response to a lateral displacement of the plurality of
concrete forms away from the buck panel.
17. The system of claim 14, wherein the concrete retention barrier
comprises a shape selected from at least one of a flange, a rounded
protrusion, a tapered leg, and an angled leg.
18. A method for preventing intrusion of concrete into a window
cavity defined by a plurality of window buck panels, the method
comprising: forming a window buck system and thereby partially
defining a window cavity, the window buck system comprising at
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.
19. The method of claim 18, further comprising dispensing fluid
concrete between the plurality of concrete forms.
20. The method of claim 19, further comprising preventing the fluid
concrete from entering the window cavity by maintaining contact
between the at least one concrete retention barrier and the
plurality of concrete forms.
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's many advantages, is
concrete'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 dtente 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
dtente 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
202a, 202b that are secured (fasteners not shown) between a pair of
concrete forms 104. The window buck panels 202a, 202b define a
window opening 103 (side panels are not shown for clarity) and are
encased in poured concrete 108. The window buck panels 202a, 202b
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.
* * * * *