Method And Apparatus For Positioning Reinforcing Members Within Hardened Material Structures

Abstract

A positioning device for accurately positioning a reinforcing member in a hardening material (e.g., concrete). The positioning device is made from a plastic material and includes a base and a support member extending from the base. The base includes at least one receiving member supported on the support member. The receiving member is in the form of a flexible clip or spring clip. The clips are C-shaped and include arms with an opening between the arms which leads to a holding area. Each clip is capable of receiving reinforcing members of varying sizes within the opening. The clips flex outward to accommodate a reinforcing member and subsequently return inward toward a rest mode to contact and secure the reinforcing member within the holding area. The clips may be positioned at various heights and orientations.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 60/987,034, entitled "Intersecting Rebar and Tension Cable Support Chair" and filed 10 Nov. 2007, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

[0002] 1. Technical Field

[0003] The present invention embodiments pertain to devices operable to support reinforcing members within concrete or other hardened material structures. In particular, the present invention embodiments pertain to positioning reinforcement members (e.g., rebar or tension cable, etc.) in an area receiving concrete or other hardening material to enable the reinforcing members to be located accurately subsequent to hardening of the material to provide sufficient reinforcement.

[0004] 2. Discussion of Related Art

[0005] In reinforced concrete structural elements (such as slabs, columns, beams, walls, floors, etc.), concrete and reinforcing steel are combined to produce an efficient and effective structural design. Concrete is effective in withstanding compressive loads, while steel is effective in withstanding tensile loads. The combination of concrete and steel ensures that allowable compressive and tensile stresses are maintained within the structure. Reinforcing concrete structures are typically formed by positioning reinforcing bars (rebar) in a volumetric design space and subsequently pouring concrete into the design space until filled. The rebar in that space must be positioned precisely within the concrete in order to support the element load by withstanding the tensile stresses. The positioning of rebar is generally defined in terms of distances from one or more edges of the structural element (e.g., the slab, column, beam, wall, floor, etc).

[0006] During formation of the structural element, positioning devices (called chairs) are placed between the reinforcing steel member and the element to position the reinforcing steel member at a prescribed design distance (e.g., 1 inch, 1.5 inches, 2 inches, etc.) from an edge of the element. In other words, the reinforcing members are supported by the positioning device at a particular elevation or distance from one or more edges of the element (e.g., distance from the top and bottom of the slab, etc). For example, if the reinforcement member is positioned too close to the slab bottom, the structural integrity of the slab may be reduced. Further, reinforcing members positioned close to the slab top surface may enable moisture to penetrate the slab and erode the reinforcing members. Accordingly, the reinforcing steel members can be precisely positioned by utilizing a positioning device to supports the reinforcing steel member at a location between the slab top and bottom conforming to prescribed design requirements (and/or engineering codes). In the case requiring several segments of reinforcing members to be precisely placed, a plurality of correctly sized positioning devices may be employed under various portions of the reinforcing steel members to fully support those members.

[0007] The positioning devices typically include one or more seat portions and may accommodate reinforcing members of differing diameters, where the seat portions enable the reinforcing members to contact the positioning device. The positioning devices may be categorized into types that support the reinforcing members at single and plural elevations. For example, the single elevation positioning devices may support a reinforcing member at a straight section, or at an intersection with two reinforcing members oriented one atop the other in a perpendicular relation. These single elevation positioning devices suffer from several disadvantages. First, they are specific to slab thicknesses, where a user maintains several different devices in order to accommodate those thicknesses, which increases shipping and supervision costs. Second, this type of positioning device tends to be manufactured at low cost, thereby resulting in devices with inadequate strength due to a deficient design and/or being molded from a low quality material or thermoplastic. Consequently, the devices fail in response to excessive loads, or deform from temperatures encountered during shipping or at a construction site. Thus, user confidence levels for these devices are significantly reduced.

[0008] The plural elevation positioning devices include plural seat portions to position reinforcing members at various elevations. These types of devices tend to be heavier and more expensive (relative to the single elevation devices), and are confusing for a user to utilize. For example, these devices are typically rotated until a correct slot of the positioning device is located that accommodates the reinforcing member diameter and supports the member at an appropriate elevation. Since a slab typically employs numerous positioning devices, the additional time to position the reinforcing member within the positioning device significantly increases costs.

[0009] Further, this arrangement complicates verification of proper installment of the positioning devices. For example, a reinforcement member may be placed within an incorrect receptacle of a positioning device, thereby resulting in that member being positioned at an incorrect elevation or being supported improperly. If the reinforcing member is placed within a slot with greater dimensions than those of the member, the slot provides poor support. However, a slot of lesser dimensions relative to the reinforcing member provides improper seating and incorrect elevation. In addition, the lesser dimensioned slot provides additional stresses that may damage the positioning device and facilitate poor support.

[0010] Finally, conventional support devices do not permit the flow of the hardening material and its aggregate completely around the support device, the rebar segments and/or the receptacles. This introduces fracture points in an around the support device, weakening the resulting structural element.

SUMMARY OF THE INVENTION

[0011] The present invention embodiments pertain to a support device for accurately and efficiently positioning reinforcing members (e.g., rebar) within a hardened material structure such as a concrete slab. In particular, the present invention embodiments provide a chair for supporting reinforcing members in predetermined positions while a design space is filled with hardening material (e.g., concrete) that hardens around the reinforcing members. The positioning device includes a base, a support member, and one or more receptacles or clips. The base contacts a support surface (e.g., a floor member on which hardening material is to be poured, etc.), while the support member is preferably H-shaped and formed generally by side members that connect to and extend from the base and a bridge member that extends between the side members. The connection of the support member to the base stably supports the support member with the base resting against the support surface. The support member further includes one or more openings appropriately sized for ensuring adequate through flow of hardening material (e.g., flow of concrete, etc.), thereby eliminating or at least minimizing voids in the hardening material caused by restricted flow. In addition, the openings allow concrete to flow through/around the support device and the rebar segments.

[0012] The distal end of the support member includes one or more receptacles or clips for receiving reinforcing members. Each clip includes curved arms that form a generally C-shape and define a holding area for receiving a corresponding reinforcing member therein. The arms are flexible and include an opening therebetween leading to the holding area. A proximal clip portion includes a plurality of branches that extend the arm length to increase flexibility. Reinforcing members force the arms apart during insertion, thereby enabling reinforcing members with slightly larger dimensions to be accommodated by the clip. The arms subsequently move toward their original position once the reinforcing member has passed through the opening into the clip holding area.

[0013] Plural clips may be positioned perpendicularly relative to each other and at different elevations (e.g., to avoid spatial interference between the reinforcing members) in order to position the reinforcing members in various orientations (e.g., perpendicular, etc.) in accordance with structural designs (e.g., slab designs, etc.).

[0014] The support device may further include a series of stiffening members located in areas of the positioning device that experience elevated stresses. The stiffening members enable the positioning device to be created using minimal material without sacrificing strength, and facilitate employment of the flow opening in the support member since the stiffeners supplement the support member strength.

[0015] In addition, the positioning devices of the present invention embodiments include indicia for clearly indicating dimensions (e.g., the distance from the base to the clip, etc.) of the positioning device. This enables a user in the field to quickly and accurately identify units of the device that are appropriately sized for a specific use.

[0016] The above and still further features and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof, particularly when taken in conjunction with the accompanying drawings wherein like reference numerals in the various figures are utilized to designate like components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a view in perspective of a positioning device for placing reinforcing members in a hardening material according to an embodiment of the present invention.

[0018] FIG. 2 is a front view in elevation of the positioning device of FIG. 1.

[0019] FIG. 3 is a view in elevation of the side members of the positioning device of FIG. 1.

[0020] FIG. 4 is a view in perspective of an alternative embodiment of the positioning device of FIG. 1 to support reinforcing members at a different elevation.

[0021] FIG. 5 is a view in perspective of yet another embodiment of the positioning device of FIG. 1 supporting two reinforcing members arranged perpendicular to one another.

[0022] FIG. 6 is a view in perspective of the positioning device of FIG. 5 supporting a reinforcing member via the bridge member of the support member.

[0023] FIG. 7 is a view in perspective of the positioning device of FIG. 5 supporting a reinforcing member via the side members of the support member.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0024] The present invention embodiments pertain to an effective, low cost and lightweight support device (or chair) configured to precisely position reinforcing members (e.g., rebar) in a hardened material (e.g., concrete, etc.) structure. A support device according to an embodiment of the present invention is illustrated in FIGS. 1-3. Specifically, support device 100 includes a base 140, a support member 110 supported by base 140, and a plurality of receptacles or clips 150, 160, 170 extending from support member 110 to receive reinforcing members as described below.

[0025] Base 140 contacts a support surface 10 and supports support member 110 in a steady manner during use. Typically, support surface 10 is an interior surface of a containment structure (e.g., the temporary support decking of a building floor slab, etc.) within which the hardening material is placed. In addition, base 140 may engage support surface 10 in any orientation (e.g., horizontally for supporting reinforcing members in a slab or beam, vertically for supporting reinforcing members in a column or wall, etc.).

[0026] Base 140 is generally rectangular, but may be of any shape (e.g., rectangular, oval, circular, etc.) or form that complements support surface 10, and maintains support member 110 steadily on the support surface. The positioning device has a sufficient base surface area to contact the support surface (e.g., ground, pre-fabricated flooring, etc.) and provide maximum stability. The size, dimensions, and surface area of the base are determined based on the overall height of the positioning device, where the height of the positioning device may vary for differing applications. Base 140 may further include a series of ribs or ridges 142 spaced across the base top surface. The ribs 142 provide areas for the base 140 to bond with the hardening material, and to prevent formation of voids or gaps between the base and hardening material. Ribs 142 are generally rounded (e.g., may possess a semi-cylindrical shaped) and extend between opposing base edges (e.g., front and rear edges as viewed in FIG. 1) of the base 140 substantially in parallel. A portion of ribs 142 may extend substantially the entire distance between the opposing base edges, while another portion of ribs 142 may include rib segments each extending from a corresponding base edge for approximately half the distance between the opposing edges and including a tapered distal end. The tapered ends of opposing rib segments are in facing relation.

[0027] Support member 110 is connected to and extends upward from, and generally perpendicular to, opposing side edges of base 140. However, support member 110 may extend from base 140 at any angle sufficient to enable base 140 to support the support member stably on support surface 10. Support member 110 possesses a generally H-shaped configuration including side members 122, 124 and a bridge member 112 disposed between and through the side members. Each bridge member side edge portion is attached to and through an intermediate portion of a corresponding side member 122, 124, and extends slightly beyond the side edge of base 140 to form a stiffening member 123 that stiffens the side members 122, 124, minimizing or eliminating flexing in the side members. The stiffener 123 also provides a lip suitable for receiving indicia (e.g., engraving, etc.) as described below. The upper ends of side members 122, 124 each include a respective clip 160, 170 to accommodate a corresponding reinforcing member. The intermediate portion of the upper surface of bridge member 112 similarly includes a clip 150 to accommodate a corresponding reinforcing member. Clips 150, 160, 170 basically serve as spring clips that accept various sized reinforcement members (e.g., rebar or tension cables, etc.). The clips 150, 160, 170 utilize an open-ended spring configuration with contacts or serrations along the interior surface of the clip that create an inscribed structure (e.g., inscribed diameter and/or ellipse) and allow a reinforcement member to be snapped into place as described below.

[0028] Bridge member 112 includes a generally H-shaped configuration defined by a lower recess 114, and a first upper recess or opening 125 and a second upper recess or opening 130. The upper recesses 125, 130 are generally rounded (e.g., possessing a semi-elliptical shape). The first 125 upper recess is defined within the top surface bridge member 112 between clip 150 and side member 122, while the second upper recess 130 is defined within the bridge member top surface between center clip 150 and side member 124. Lower recess 114 is generally semi-circular and is defined within the bridge member bottom surface between side members 122, 124. Lower recess 114 (e.g., in combination with base 140) provides an opening for concrete or other hardening material to flow. The recesses 114, 125, 130 (and, hence, bridge member 112) allow maximum flow of aggregate concrete or other hardening material through and around the positioning device, thereby eliminating the possibility of voids. While rounded shapes are illustrated, the recesses 114, 125, 130 may alternatively be of any quantity, shape or size (e.g., polygonal, elliptical, circular, etc.).

[0029] Side members 122, 124 each include front and rear braces 115, 120. The braces 115, 120 are each attached to the top surface of base 140 and an opposing surface of a corresponding side edge portion of bridge member 112. Braces 115, 120 are generally right-triangular with shorter dimensioned straight first edges 116, longer dimensioned straight second edges 117, and a third or hypotenuse type edges 118. Shorter dimensioned edge 116 of braces 115, 120 are attached to base 140, while longer dimensioned straight edge 117 of braces 115, 120 are attached in facing relation to opposing bridge member surfaces and extend from the base 140 toward a corresponding side clip 160, 170. Hypotenuse edge 118 of braces 115, 120 extends from a terminal edge of shorter dimensioned edge 116 toward the upper end of longer dimensioned edge 117. The hypotenuse edge 118 is generally segmented with the segments forming a non-planar arrangement along the hypotenuse edge. The upper end of braces 115, 120 includes a contour portion 119 to accommodate and contour a side surface portion of a corresponding side clip 160, 170. The contour portion further functions as a stiffener, increasing the resiliency of the side clips 160, 170. Thus, side members 122, 124 are in the form of intersecting members (e.g., side edge portions of bridge member 112 disposed between braces 115, 120) for maximum load bearing support without providing additional weight that result in higher costs. The side members 122, 124 are efficiently designed to redistribute the axial forces and loads applied by the reinforcing members.

[0030] In addition, stiffeners may be employed to reinforce support member 110. The stiffeners enable the positioning device to be created using minimal material without sacrificing strength, and facilitate employment of the flow opening (e.g., recess 114) in the support member since the stiffeners supplement the support member strength. Specifically, first stiffeners 222 may be generally right-triangular and disposed at the junctions between intermediate portions of braces 115, 120 and bridge member 112. The longer dimensioned stiffener edge is attached to the interior surface of brace 115, 120, while the shorter dimensioned edge is attached to bridge member 112 to provide reinforcing support for the side and bridge members. Similarly, second stiffeners 224 may be generally right-triangular and disposed at the junctions between base 140 and the lower side edges of indicia portions 123. The longer dimensioned stiffener edge is attached to the base side edge, while the shorter dimensioned edge is attached to the side edge of indicia portion 123 to provide reinforcing support for the side and bridge members. In addition, third stiffeners 226 may be generally right-triangular and disposed at the junctions between clip 150 and bridge member 112. The longer dimensioned stiffener edge is attached to the bridge member, while the shorter dimensioned edge is attached to center clip 150 to provide reinforcing support for the clip and bridge member. Once advantage of the stiffening members 222, 224, 226 is that, since they provide added support, certain dimensions of positioning device 100 (e.g., support member thickness, base thickness, etc.) may be reduced, thereby providing the positioning device with decreased size and weight, and reduced costs.

[0031] Bridge member 112 may further include a series of ribs or ridges 143 spaced across the bridge member front and rear surfaces. The ribs 143 provide areas for the bridge member 112 to bond with the hardening material, and to prevent formation of voids or gaps between the bridge member and hardening material. Ribs 143 are generally rounded (e.g., possess semi-cylindrical shape) and extend between opposing side edges of the bridge member substantially in parallel. Ribs 143 typically include rib segments each extending from a corresponding bridge member side edge toward center clip 150 with distal ends in facing relation. A portion of ribs 143 include a tapered distal end to accommodate structural features of the bridge member (e.g., lower recess 114 and upper recesses 125, 130) with the tapered ends of opposing rib segments in facing relation.

[0032] Clips 160, 170 are disposed at the upper ends of side members 122, 124. Clips 160, 170 are aligned with each other, and are arranged to position a reinforcing member substantially perpendicular to a reinforcing member supported by center clip 150 of bridge member 112. Side clips 160, 170 are designed to accommodate reinforcing members of various cross-sectional dimensions as described below, and are positioned at a specific elevation relative to base 140 based on the particular dimensions of the reinforcing member being utilized. The clips provide the reinforcing members at a desired location from support surface 10 (e.g., ground, pre-fabricated flooring, etc.) toward the center of a concrete or other hardening material pour.

[0033] Clips 150, 160, 170 operate collectively to support reinforcing members at various elevations and orientations, where the positioning device may be configured to provide various distances from support surface 10 (e.g., 1 inch, 1.5 inches, 2 inches, etc). As noted above, stiffening members 123 may include markings defining the size elevations and particular reinforcing members that may be utilized. In addition, the markings may further be placed on bridge member 112 (e.g., below clip 150, etc.). The markings are typically associated with the corresponding clip (e.g., markings of bridge member 112 are associated with clip 150, while markings of stiffening member 123 are respectively associated with clips 160, 170). This obviates the need for the user to make the decision or choice with respect to the side the device should be located, prevents and eliminates user error in the field, and promotes correct use of the device to enable the reinforcing members to be placed in a proper position.

[0034] Center clip 150 is disposed within an intermediate portion of the bridge member top surface for optimized weight distribution, and is in the form of a flexible spring clip serving as a receptacle to receive a reinforcing member therein. Bridge member 112 includes clip contour portions 121 to accommodate and contour the side surface portions of center clip 150. The contour portion 121 further acts as a stiffener, increasing the resiliency/spring action of the center clip 150 (i.e., increasing the resiliency of the clip arms). Center clip 150 includes a spring type mechanism and contacts or serrations 151 that enable the clip to accept reinforcing members with different cross-sectional dimensions as described below. Center clip 150 is set to provide a specific distance between support surface 10 (e.g., ground, pre-fabricated flooring, etc.) and the underside of the reinforcing member.

[0035] In particular, center clip 150 (FIG. 2) includes a first arm 257, a second arm 258, and a clip base 260. The distal portions of arms 257, 258 are curved and form a generally C-shaped configuration defining a holding area 253 for securing reinforcing members (e.g., reinforcing member 410 or 420 of FIGS. 5-7) therein. The distal ends of arms 257, 258 each include a lip 259, and are spaced apart from each other to define an entrance area or opening 255 sized to receive a reinforcing member (e.g., concrete reinforcing rebar, etc). The reinforcing members are typically elongated members and may include various cross-sectional shapes (e.g., circular, polygonal, elliptical, etc.) and dimensions. However, the clip arms 257, 258 may alternatively employ various shaped configurations. Arms 257, 258 are resilient and may be moved toward and away from each other. Each arm 257, 258 includes a series of contacts or serrations 151 disposed on an interior surface thereof and projecting toward holding area 253 to enhance gripping of the reinforcing member and enable accommodation of reinforcing members with various dimensions. The contacts are generally triangular, and disposed on an intermediate portion of the arm interior surface (between front and rear ends) in substantial alignment.

[0036] Clip base 260 is generally U-shaped, and disposed at the proximal end of clip 150. The clip base 260 is attached to the proximal ends of arms 257, 258, and is constructed of sufficiently resilient materials to bias the arms to a rest position. The clip base basically includes a plurality of branches that extend the length of arms 257, 258 to increase flexibility. Clip base 260 provides resistance to movement of arms 257, 258 away from each other, and further provides force to move the arms 257, 258 apart in response to the arms being closer to each other than in the rest position. Contour portions 121 receive clip base 260 and portions of arms 257, 258, reinforcing these elements to supplement the forces provided by the clip base. Thus, the clip base 260 (and/or contour portions 121) enables the clip to function as a spring type clip.

[0037] In operation, a reinforcing member or bar is inserted through opening 255 and between lips 259 of arms 257, 258 toward holding area 253. The reinforcing bar typically includes a cross-sectional dimension greater than the dimensions of opening 255, thereby forcing lips 259, and hence, flexible arms 257, 258, apart in order to accommodate the reinforcing member in holding area 253. Serrations or contacts 151 engage the reinforcing member to provide a secure grip. The flexibility of arms 257, 258 and contacts 151 enable the clip to accommodate various sized reinforcing members. In particular, the reinforcing member is pressed against lips 259 and urged through clip opening 255 toward holding area 253. As the reinforcing member passes through lips 259, arms 257, 258 flex apart to accommodate the reinforcing member dimensions. As the reinforcing member enters holding area 253, resilient restoring forces urge arms 257, 258 of clip 150 back toward their original rest position, thereby enabling clip 150 to function as a spring type clip. Contacts 151 engage the reinforcing member, and arms 257, 258 of clip 150 secure the reinforcing member against further movement (e.g., during introduction of the hardening material, etc.).

[0038] Side clips 160, 170 possess a structure substantially similar to that described above for the center clip 150, and are disposed at the upper ends of side members 122, 124. Clips 160, 170 are each in the form of a flexible spring clip serving as a receptacle to receive a reinforcing member portion therein. Clips 160, 170 include a spring type mechanism and contacts or serrations 251 that enable the clips to accept reinforcing members with different sized dimensions as described below. Clips 160, 170 are set to provide a specific distance between support surface 10 (e.g., ground, pre-fabricated flooring, etc.) and the underside of the reinforcing member.

[0039] In particular, clips 160, 170 (FIG. 3) each include a first arm 267, a second arm 268, and clip base 260. The distal portions of arms 267, 268 are curved and form a generally C-shaped configuration defining a holding area 263 for securing reinforcing members therein. The distal ends of arms 267, 268 each include a lip 269, and are spaced apart from each other to define an entrance area or opening 265 sized to receive a reinforcing member (e.g., concrete reinforcing rebar, etc.). The reinforcing members are typically elongated members and may include various cross-sectional shapes (e.g., circular, polygonal, elliptical, etc.) and dimensions as described above. However, the clip arms 267, 268 may alternatively employ various shaped configurations. Each arm 267, 268 includes a series of contacts or serrations 251 disposed on an interior surface thereof and projecting toward holding area 263 to enhance gripping of the reinforcing member and enable accommodation of reinforcing members with various dimensions. The contacts 251 may be generally triangular, and disposed in substantial alignment along arm side edges to enable the contacts 251 of first side clip 160 to be in facing relation to the contacts of second clip 170. It should be understood, however, that the contacts 251 may be disposed at any suitable location along the clip arms 267, 268.

[0040] Clip base 260 is substantially similar to the clip base described above, is generally U-shaped, and disposed at the proximal end of clips 160, 170. The clip base is attached to the proximal ends of arms 267, 268, and is constructed of sufficiently resilient materials to bias the arms to a rest position. The clip base 260 basically includes a plurality of branches that extend the length of arms 267, 268 to increase flexibility. Clip base 260 provides resistance to movement of arms 267, 268 away from each other, and further provides force to move the arms apart in response to the arms being closer to each other than in the rest position. Contour portions 119 of braces 115, 120 receive clip base 260 and portions of arms 267, 268, reinforcing these elements to supplement the forces provided by the clip base. Thus, the clip base 260 (and/or contour portions 119) enables the clip to function as a spring type clip.

[0041] In operation, a reinforcing member or bar is inserted into each clip 160, 170 through opening 265 and between lips 269 of arms 267, 268 toward clip holding area 263. The reinforcing bar typically includes a cross-sectional dimension greater than the dimensions of opening 265, thereby forcing lips 269, and hence, flexible arms 267, 268, apart in order to accommodate the reinforcing member in holding area 263. Contacts 251 engage the reinforcing member to provide a secure grip. The flexibility of arms 267, 268 and contacts 251 enable the clips to accommodate various sized reinforcing members. In particular, the reinforcing member is inserted into side clips 160, 170 by pressing the member against lips 269 and urging the member through clip opening 265 toward holding area 263. As the reinforcing member passes through lips 269, arms 267, 268 flex apart to accommodate the reinforcing member dimensions. As the reinforcing member enters holding area 263, resilient restoring forces urge arms 267, 268 of clips 160, 170 back toward their original rest position, thereby enabling clips 160, 170 to function as a spring type clip. Contacts 251 engage the reinforcing member, and arms 267, 268, securing the reinforcing member against further movement (e.g., during introduction of the hardening member). Clips 160, 170 may receive the reinforcing member simultaneously, or in any desired order. Thus, the support device 100 positions clips at substantially perpendicular directions and varying heights from the support surface allowing for the reinforcement member (e.g., rebar or tension cable, etc.) to be snapped into place and eliminating the need for wire tying.

[0042] The support device 100 may be configured to provide various distances from support surface 10 (e.g., 1 inch, 1.5 inches, 2 inches, etc.) as described above, where siffening members 123 may include markings defining the size elevations and particular reinforcing members that may be utilized. An example embodiment of support device 100 configured to provide greater distances or elevations from base 140 (relative to the positioning device of FIGS. 1-3) is illustrated in FIG. 4.

[0043] An alternative embodiment of support device is illustrated in FIG. 5. Specifically, the support device 200 is substantially similar to support device 100 described above, and includes a base 141, a support member 110 supported by base 141, and clips 150, 160, 170 each as described above and extending from support member 110 to receive reinforcing members. Base 141 contacts support surface 10 (e.g., an interior surface of a containment structure as described above, etc.) and supports support member 110 in a steady manner during use. Base 141 may engage support surface 10 in any orientation (e.g., horizontally for supporting reinforcing members in a slab or beam, vertically for supporting reinforcing members in a column or wall, etc.).

[0044] Base 141 is generally elliptical, but may be of any shape (e.g., rectangular, oval, circular, etc.) or form that complements support surface 10, and maintains support member 110 steadily on the support surface. Support device 200 has a sufficient base surface area to contact the support surface (e.g., ground, pre-fabricated flooring, etc.) and provide maximum stability. The size, dimensions, and surface area of the base are determined based on the overall height of the positioning device, where the height of the device may vary for differing applications. Base 141 further includes recesses 430, 440 defined in the front and rear base edges. Recesses 430, 440 are generally semi-elliptical, and defined in the base substantially coincident.

[0045] Support member 110 is substantially similar to the support member described above and includes a generally H-shaped configuration with side members 122, 124 and bridge member 112 disposed between and through the side members in substantially the same manner described above to form indicia portions 123 for receiving indicia or markings. The upper ends of side members 122, 124 each include a respective clip 160, 170 to accommodate a corresponding reinforcing member 410 as described above, while the intermediate portion of the upper surface of bridge member 112 similarly includes clip 150 to accommodate a corresponding reinforcing member 420 as described above.

[0046] Bridge member 112 is substantially similar to the bridge member described above and includes a generally H-shaped configuration defined by lower recess 114, and upper recesses 125, 130. Lower recess 114 (e.g., in combination with base 141) provides an opening for concrete or other hardening material to flow as described above. Side members 122, 124 are substantially similar to the side members described above and include front and rear braces 215, 220. The braces are substantially similar to the braces described above, and are each attached to a top surface of base 141 and an opposing surface of a corresponding side edge portion of bridge member 112 as described above. Braces 215, 220 are generally rectangular and taper toward respective clips 160, 170. The braces each include contour portion 119 to accommodate and contour side surface portions of a corresponding clip 160, 170 as described above.

[0047] In addition, stiffeners 222, 224, 226 may be employed to reinforce support member 110, where the stiffeners are substantially similar to the respective stiffeners described above. The stiffeners 222, 224, 226 enable the positioning device to be created using minimal material without sacrificing strength, and facilitate employment of the flow opening in the support member since the stiffeners supplement the support member strength. First stiffeners 222 are disposed at the junctions between intermediate portions of braces 215, 220 and bridge member 112, while second stiffeners 224 are disposed at the junctions between base 141 and the lower side edge of indicia portions 123. Finally, third stiffeners 226 are disposed at the junctions between clip 150 and bridge member 112.

[0048] Bridge member 112 may optionally include ribs or ridges 143 spaced across the bridge member surfaces as described above. The ribs 143 are substantially similar to the ribs or ridges described above and provide areas for the bridge member to bond with the hardening material, and to prevent formation of voids or gaps between the bridge member and hardening material as described above. An example embodiment of positioning device 200 without ribs or ridges 143 is illustrated in FIGS. 6-7.

[0049] Side clips 160, 170 are disposed at the upper ends of side members 122, 124. Clips 160, 170 are aligned with each other, and arranged to position a reinforcing member substantially perpendicular to a reinforcing member supported by center clip 150 of bridge member 112 as described above. Clips 150, 160, 170 support reinforcing members in substantially the same manner described above for positioning device 100.

[0050] Hardened material (e.g., a hardened slab element, etc.) frequently requires strengthening in various directions. In order to facilitate this strengthening, reinforcing members are positioned in different directions within that material. Support devices 100, 200 are adapted to facilitate the positioning of reinforcing members in this fashion. Specifically, center clip 150 is positioned to receive a reinforcing member in one direction (e.g., front to rear direction as viewed in FIGS. 1 and 5), while side clips 160, 170 are positioned to receive a reinforcing member in a second different direction (e.g., sideways or in a direction between the side members as viewed in FIGS. 1 and 5). Thus, support devices 100, 200 accommodate reinforcing members being positioned in different directions. The support devices 100, 200 are placed at the intersection of reinforcing members, and eliminates the need to wire tie those members.

[0051] Since perpendicular paths of the reinforcing members intersect, support devices 100, 200 position the intersecting reinforcing members at different elevations from the corresponding positioning device base 140, 141. Accordingly, center clip 150 supporting a reinforcing member in a first direction is provided at an elevation different than side clips 160, 170 that position a reinforcing member in a second different direction. In other words, center clip 150 is positioned on a different elevation than side clips 160, 170 to avoid collision between intersecting reinforcing members. Thus, the support devices 100, 200 may be utilized as an intersection or member support device for different elevations without manipulation of (e.g., turn, flip, rotate, turn, etc.) the device.

[0052] Operation of support device 100, 200 to accommodate reinforcing members at different elevations is illustrated in FIGS. 5-7. Initially, one or more positioning devices 100, 200 are positioned in a design space to support reinforcing members 410, 420 in preparation for receiving a hardening material. The appropriate sized positioning devices may be selected based on the indicia or markings on stiffening members 123 and bridge member 112.

[0053] When reinforcement is required in plural directions, the support devices 100, 200 are placed at a corresponding intersecting junction of the reinforcing members (FIG. 5). In particular, reinforcing member 420 is positioned within center clip 150 of a positioning device 100, 200 in substantially the same manner described above. Center clip 150 supports the reinforcing member at a first elevation relative to base 141 and in a direction extending between the front and rear of the device. Similarly, reinforcing member 410 is positioned within side clips 160, 170 of support device 100, 200 in substantially the same manner described above. Side clips 160, 170 support the reinforcing member at a second different elevation relative to base 141 and in a direction extending between side members 122, 124. The support devices 100, 200 position the reinforcing members within the hardening material in the design space to form the hardened element or slab with the desired arrangement of the reinforcing members.

[0054] When the reinforcing members are arranged without intersections, the support device 100, 200 enables support of the reinforcing members at different elevations. In the case where support devices 100, 200 are to receive a single reinforcing member (e.g., not located at an intersection of the reinforcing members), the support devices are placed at appropriate locations within the design space in accordance with a desired design. The reinforcing member may be supported by center clip 150 (FIG. 6) or side clips 160, 170 (FIG. 7) depending upon the desired elevation. For example, reinforcing member 420 (FIG. 6) may be positioned within center clip 150 of a support device 100, 200 in substantially the same manner described above. Center clip 150 supports the reinforcing member at a first elevation relative to base 141 and in a direction extending between the front and rear of the device.

[0055] Alternatively, reinforcing member 410 (FIG. 7) may be positioned within side clips 160, 170 of support device 100, 200 in substantially the same manner described above. Side clips 160, 170 support the reinforcing member at a second different elevation relative to base 141 and in a direction extending between side members 122, 124. The support devices 100, 200 support the reinforcing members within the hardening material in the design space to form the hardened element or slab with the desired arrangement of the reinforcing members. As should be understood, support device 100 may be utilized in substantially the same manner described above for support device 200 to support the reinforcing members within the hardening material in the design space to form the hardened element or slab with the desired arrangement of the reinforcing members.

[0056] Support devices 100, 200 are preferably constructed of a strong lightweight material, such as plastic. Specifically, the support devices 100, 200 can be made partly or entirely of engineering grade thermoplastic resins (e.g., polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyamide, polyoxymethylene, etc.), in varying sizes for use in various structures (e.g., concrete slabs, foundations, tilt-up wall panels, beams, etc.) of differing thicknesses (e.g., three to eight inches, etc.). Further, carbon and fiber reinforced plastics and various engineered plastics may be utilized, while the positioning devices may be made with natural or colored resins. The support devices 100, 200 may be manufactured by the processes of thermoplastic injection and/or bi-injection, gas assist, sandwich or insert molding, and are preferably designed to provide maximum stability and resist maximum axial loads at temperatures up to 200.degree. F. due to the device configurations (e.g., plurality of intersecting walls, arches or recesses, trusses (or side members), and radii (or stiffeners and/or braces)).

[0057] It will be appreciated that the embodiments described above and illustrated in the drawings represent only a few of the many ways of implementing a method and apparatus for positioning reinforcing members within hardened material structures.

[0058] The support/positioning devices 100, 200 may be of any quantity, shape, or size, and may be constructed of any suitable materials (e.g., polycarbonate, polybutylene terephthalate, polyethylene terephthalate, polyamide, polyoxymethylene, etc.) and by any suitable processes (e.g., thermoplastic injection and/or bi-injection, gas assist, sandwich or insert molding, etc.). The positioning devices may be utilized at temperatures up to approximately 200.degree. F. The positioning devices may be utilized for any desired hardened material structures (e.g., concrete slabs, foundations, tilt-up wall panels, beams, etc.) of any desired dimensions, and may be positioned at any locations (e.g., intersecting or non-intersecting junctions of the reinforcing members, engage any desired portion of the reinforcing member, etc.) and/or oriented (e.g., vertically, horizontally, angled, etc.) in any suitable fashion. Any quantity of positioning devices of any of the types described above may be utilized for a hardened material element. The positioning devices may accommodate any quantity of reinforcing members at any desired orientations or elevations relative to each other. The positioning devices preferably possess a unitary (once piece) structure for increased structural integrity (over multiple-piece structures).

[0059] The bases of the positioning devices 100, 200 may be of any quantity, shape, size, or materials, and may include any combination of ribs and recesses. The ribs may be of any quantity, shape or size, and may be arranged on any base surface in any fashion (e.g., parallel, intersecting, etc.). The support member may be attached or connected to the bases in any desired fashion (e.g., removably secured, permanently attached, integral, etc.). The recesses defined in the base may be of any quantity, shape, or size, and may be defined at any locations on the base.

[0060] The support members of the positioning devices 100, 200 may be of any quantity, shape, or size, and may be constructed of any suitable materials. The ribs may be of any quantity, shape, or size, and may be arranged on any support member surface in any fashion (e.g., parallel, intersecting, etc.). The bridge member may be of any quantity shape or size, and may be constructed of any suitable materials. The upper and lower recesses may be of any quantity, shape, or size, and may be defined in the bridge member at any desired locations. The contour portion of the bridge member may be of any quantity, size, or shape, and may be attached or secured to the clip and/or bridge member at any location and in any fashion to support the clip (e.g., removably secured, permanently attached, integral, etc).

[0061] The side members may be of any quantity, shape, or size, and may be attached or secured to the base at any desired locations and in any desired fashion (e.g., removably secured, permanently attached, integral, etc.). The braces may be of any quantity, shape, or size, and may be attached or secured to the bridge member at any desired locations and in any desired fashion (e.g., removably secured, permanently attached, integral, etc.). The contour portions of the braces may be of any quantity, size, or shape, and may be attached or secured to the clip at any location and in any fashion to support the clip (e.g., removably secured, permanently attached, integral, etc.).

[0062] The stiffening members 123 may be of any quantity, shape, or size, and may be disposed at any locations on the positioning devices. The stiffening members may include any desired information (e.g., distances or dimensions, size information, reinforcing member information, etc.) provided in any desired format. For example, the indicia may utilize a color coding scheme to convey information (e.g., related to distances, dimensions, reinforcing members, etc.), where the color represents particular, sizes, dimensions or other information. The indicia may alternatively be located at any locations on the positioning devices (e.g., bridge member, base, etc.).

[0063] The stiffeners 222, 224, 226 of the positioning devices may be of any quantity, shape, or size, may be constructed of any suitable materials and may be located at any suitable junctions to reinforce the positioning device components (e.g., base, bridge member, clips, etc). The positioning devices may alternatively be configured without the stiffeners.

[0064] The side clips 160, 170 the center clip 150 may be of any quantity, shape, or size, and may be constructed of any suitable materials. The clips 150, 160, 170 may accommodate any quantity of reinforcing members of any quantity, shape, or size, at any desired orientations. The arms of the clips may be of any quantity, shape, or size, and may include any desired resiliency to accommodate a reinforcing member. The arms may be separated by any suitable distances, and define a holding area of any shape or size. The clip base may be of any quantity, shape, or size, and may be configured to provide any suitable forces to bias the arms.

[0065] The contacts or serrations 151, 251 may be of any quantity, shape, or size, and may be disposed at any suitable locations within or external of the arms. The contacts enhance gripping of the reinforcing member by urging the member against the arms in the holding area. This enables the clip to handle reinforcing members with cross-sectional dimensions less than the holding area. The flexible arms and contacts enable the clips to receive reinforcing members of varying cross-sectional dimensions and shapes (e.g., a clip may engage reinforcing members with varying cross-sectional shapes and dimensions). Reinforcing members may be inserted into the clips in any desired order or fashion (e.g., simultaneously, sequentially or any combinations thereof). The lips of the arms may be of any quantity, shape or size and may be disposed at any locations on the arms.

[0066] The positioning devices 100, 200 may be configured for any combination of clip sizes, elevations, or orientations to support reinforcing members in any desired fashion within the hardened material element. The positioning devices may be further configured to support reinforcing members of any desired quantity, shape or size at any desired distances from the support surface (e.g., 1 inch, 1.5 inches, 2 inches, 2.5 inches, etc.). The reinforcing members may be implemented by any reinforcement elements (e.g., rebar, tension cable, rods, etc.) constructed of any suitable materials and of any quantity, shape or size. The clips 150, 160, 170 may be configured to accommodate the reinforcing members of various cross-sectional shapes and sizes.

[0067] It is to be understood that the terms "top", "bottom", "front", "rear", "side", "height", "length", "width", "distal", "proximal", "thickness", "vertical", "horizontal" and the like are used herein merely to describe points of reference and do not limit the present invention embodiments to any particular orientation or configuration.

[0068] From the foregoing description, it will be appreciated that the invention makes available a novel method and apparatus for positioning reinforcing members within hardened material structures, wherein a positioning device, including a base, a support member connected to and extending from the base and one or more receiving members, accurately and efficiently positions reinforcing members within a hardened material structure.

[0069] Having described preferred embodiments of a new and improved method and apparatus for positioning reinforcing members within hardened material structures, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the present invention as defined by the appended claims.

Claims

1. A support device operable to position a reinforcing member in a hardening material comprising: a base; a support member connected to and extending from said base, the support member comprising: a plurality of supports, and a bridge member disposed between said supports; and a plurality of receiving members each including a plurality of arms to engage a portion of a reinforcing member, wherein said arms of said receiving members are resilient to engage reinforcing members of varying dimensions, wherein at least one said receiving member is disposed on said bridge member to position a corresponding reinforcing member at a first elevation relative to said base and in a first orientation, and at least two said receiving members are each disposed on a corresponding support and collectively position a corresponding reinforcing member at a second different elevation relative to said base and in a second different orientation.

2. The support device of claim 1, wherein said bridge member includes at least one recess disposed between said bridge member and said base to enable flow of hardening material therethrough.

3. The support device of claim 3, wherein: said bridge member comprises a top edge and a bottom edge; at least one recess is formed into the top edge; and at least one recess is formed into the bottom edge disposed between said bridge member and said base member.

4. The positioning device of claim 1, wherein said bridge member includes a series of ribs disposed on an exterior surface.

5. The positioning device of claim 1, wherein said bridge member includes indicia providing information pertaining to use of said positioning device.

6. The positioning device of claim 5, wherein said indicia includes information indicating a distance between said receiving member disposed on said bridge member and said base.

7. The positioning device of claim 1, wherein said receiving member arms include a series of serrations to engage said reinforcing member.

8. The positioning device of claim 1, wherein said base includes a series of ribs disposed on an exterior surface.

9. The positioning device of claim 1, wherein said supports each include a plurality of braces attached to said base and to opposing surfaces of said bridge member.

10. The positioning device of claim 1, wherein said supports each include an indicia portion including indicia providing information pertaining to use of said positioning device.

11. The positioning device of claim 10, wherein said indicia includes information indicating a distance between said corresponding receiving member disposed on said support and said base.

12. The positioning device of claim 1, further including at least one stiffener to reinforce said positioning device, wherein said at least one stiffener is positioned in at least one of a location between said support member and said supports, a location between said supports and said base member, and a location between said receiving member and said bridge member.

13. The positioning device of claim 1, wherein said positioning device is formed from engineering grade resins and is constructed by at least one of thermoplastic injection and/or bi-injection, gas assist, and sandwich or insert molding.

14. The positioning device of claim 1, wherein said positioning device accommodates a maximum temperature of 200.degree. F.

15. A method of positioning a reinforcing member in a hardening material comprising: (a) engaging a first reinforcing member via a first receiving member of a positioning device to support said reinforcing member at a first elevation and in a first orientation, wherein said positioning device includes a base, a support member connected to and extending from said base and including a plurality of supports and a bridge member disposed between said supports, and a plurality of receiving members each including a plurality of arms to engage a portion of a reinforcing member, wherein said arms of said receiving members are resilient to engage reinforcing members of varying dimensions, and wherein said first receiving member is disposed on said bridge member and said first elevation is relative to said base; (b) engaging a second reinforcing member via at least two receiving members each disposed on a corresponding support to collectively position said second reinforcing member at a second different elevation relative to said base and in a second different orientation.

16. The method of claim 15, wherein: said bridge member includes at least one recess disposed between said bridge member and said base; and said method further includes (c) enabling flow of hardening material through said bridge member via said recess.

17. The method of claim 15, wherein: said bridge member includes a series of ribs disposed on an exterior surface; and said method further includes (c) providing areas for said hardening material to bond to said bridge member and preventing gaps via said ribs.

18. The method of claim 15, wherein: said bridge member includes indicia; and (a) comprises (a.1) providing information pertaining to use of said positioning device via said indicia.

19. The method of claim 18, wherein said indicia includes information indicating a distance between said first receiving member disposed on said bridge member and said base.

20. The method of claim 15, wherein: said first and second receiving members include spring clips; (a) includes (a.1) engaging said first reinforcing member via said spring clip of said first receiving member; and (b) further includes (b.1) engaging said second reinforcing member via said spring clips of said second receiving members.

21. The method of claim 15, wherein: said first and second receiving members each include a series of serrations; (a) comprises (a.1) engaging said first reinforcing member via said serrations of said first receiving member; and (b) further comprises (b.1) engaging said second reinforcing member via said serrations of said second receiving members.

22. The method of claim 15, wherein: said base includes a series of ribs disposed on an exterior surface; and said method further includes (c) providing areas for said hardening material to bond to said base and preventing gaps via said ribs.

23. The method of claim 15, wherein: said supports each include an indicia portion including indicia; and (b) further includes (b.1) providing information pertaining to use of said positioning device via said indicia.