U.S. patent application number 12/243167 was filed with the patent office on 2009-05-14 for method and apparatus for positioning reinforcing members within hardened material structures.
This patent application is currently assigned to 3GM PRODUCTS. Invention is credited to Francisco L. Garza.
Application Number | 20090120030 12/243167 |
Document ID | / |
Family ID | 40622404 |
Filed Date | 2009-05-14 |
United States Patent
Application |
20090120030 |
Kind Code |
A1 |
Garza; Francisco L. |
May 14, 2009 |
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.
Inventors: |
Garza; Francisco L.;
(McAllen, TX) |
Correspondence
Address: |
EDELL, SHAPIRO & FINNAN, LLC
1901 RESEARCH BOULEVARD, SUITE 400
ROCKVILLE
MD
20850
US
|
Assignee: |
3GM PRODUCTS
McAllen
TX
|
Family ID: |
40622404 |
Appl. No.: |
12/243167 |
Filed: |
October 1, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60987034 |
Nov 10, 2007 |
|
|
|
Current U.S.
Class: |
52/686 ; 52/688;
52/741.1 |
Current CPC
Class: |
E04C 5/20 20130101 |
Class at
Publication: |
52/686 ; 52/688;
52/741.1 |
International
Class: |
E04C 5/20 20060101
E04C005/20; E01C 11/18 20060101 E01C011/18 |
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.
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.
* * * * *