U.S. patent application number 14/171082 was filed with the patent office on 2014-08-07 for paperboard shell for supporting concrete reinforcement element during concrete pour.
This patent application is currently assigned to The Newark Group, Inc.. The applicant listed for this patent is The Newark Group, Inc.. Invention is credited to Richard Clark, Arton Hamme, James O'Neill.
Application Number | 20140215954 14/171082 |
Document ID | / |
Family ID | 51257925 |
Filed Date | 2014-08-07 |
United States Patent
Application |
20140215954 |
Kind Code |
A1 |
O'Neill; James ; et
al. |
August 7, 2014 |
PAPERBOARD SHELL FOR SUPPORTING CONCRETE REINFORCEMENT ELEMENT
DURING CONCRETE POUR
Abstract
A reinforcement support is provided for use in connection with
concrete reinforcement elements and poured concrete. The
reinforcement support includes a tubular paperboard shell having
first and second ends with a channel extending therebetween. At
least a first notch is formed into the first end extending towards
the second end with the first notch being configured to
supportingly accommodate at least one concrete reinforcement
element.
Inventors: |
O'Neill; James; (Providence,
RI) ; Hamme; Arton; (Abbottstown, PA) ; Clark;
Richard; (Lebanon, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Newark Group, Inc. |
Cranford |
NJ |
US |
|
|
Assignee: |
The Newark Group, Inc.
Cranford
NJ
|
Family ID: |
51257925 |
Appl. No.: |
14/171082 |
Filed: |
February 3, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61759826 |
Feb 1, 2013 |
|
|
|
Current U.S.
Class: |
52/687 ;
52/742.14 |
Current CPC
Class: |
E04C 5/20 20130101; E04C
5/168 20130101 |
Class at
Publication: |
52/687 ;
52/742.14 |
International
Class: |
E04C 5/20 20060101
E04C005/20; E04C 5/16 20060101 E04C005/16 |
Claims
1. A reinforcement support for use in connection with concrete
reinforcement elements and poured concrete, the reinforcement
support comprising a tubular paperboard shell having first and
second ends with a channel extending therebetween, the shell having
a first notch formed into the first end extending towards the
second end, the first notch being configured to supportingly
accommodate at least one concrete reinforcement element.
2. The reinforcement support of claim 1, wherein a second notch
being formed into the first end extending towards the second end,
the second notch being configured to supportingly accommodate one
concrete reinforcement element.
3. The reinforcement support of claim 2, wherein the first and
second notches being aligned along a common axis which extends
across a portion of the channel.
4. The reinforcement support of claim 2, wherein the shell having
third and fourth notches formed into the first end extending
towards the second end, the first, second, third and fourth notches
being spaced apart approximately uniformly around the first
end.
5. The reinforcement support of clam 4, wherein the alignment of
the first and second notches being at approximately right angles to
the alignment of the third and fourth notches.
6. The reinforcement support of claim 1, wherein the first notch
has sides extending convergently away from a mouth at the first
end.
7. The reinforcement support of claim 6, wherein the mouth having a
mouth width, the first notch extending a distance from the first
end defining a notch depth.
8. The reinforcement support of claim 7, wherein, the first notch
has an aspect ratio where the notch depth is greater than the mouth
width.
9. The reinforcement support of claim 7, wherein the first notch
has an aspect ratio where the notch depth is equal to or less than
the mouth width.
10. The reinforcement support of claim 6, wherein said sides extend
to an enlarged opening.
11. The reinforcement support of claim 6, wherein a generally
straight end extends between said sides.
12. The reinforcement support of claim 1, wherein the first notch
has an arcuate shape.
13. The reinforcement support of claim 1, wherein the first notch
terminates at an arcuate end.
14. The reinforcement of claim 13, wherein the first notch includes
at least one side extending between the first end and the arcuate
end.
15. The reinforcement support of claim 1, wherein the shell is
polygonal in cross-section transverse to a longitudinal axis of the
shell.
16. The reinforcement support of claim 1, wherein the shell is
generally circular in cross-section transverse to a longitudinal
axis of the shell.
17. The reinforcement support of claim 1, wherein, the shell having
at least one vent hole extending therethrough so as to allow flow
of concrete into the shell.
18. The reinforcement support of claim 1, wherein at least a
portion of the shell is of double thickness construction with
overlapping material joined together.
19. The reinforcement support of claim 1, wherein a second notch is
formed into the second end extending towards the first end, the
second notch being configured to supportingly accommodate at least
one concrete reinforcement element.
20. A method of reinforcing concrete, said method comprising:
providing a tubular paperboard shell having first and second ends
with at least one notch; disposing said shell at a location where
concrete is to be poured; placing at least one concrete
reinforcement element into engagement with said at least one notch;
and, pouring concrete about said shell and said engaged at least
one concrete reinforcement element.
21. The method of reinforcing concrete of claim 20, wherein the
concrete reinforcement element is selected from the group
consisting of wire mesh, rebar, cabling, electrical conduit, piping
and tubing.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This Application claims priority to U.S. Provisional Patent
Application No. 61/759,826, filed Feb. 1, 2013, the entire contents
of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] The presently disclosed technologies are directed generally
to an article and method for supporting reinforcing in concrete,
and in particular, to an article made of paperboard and a method
for supporting reinforcing elements in concrete during the pouring
of the concrete.
[0003] It is well known in the construction trades that
reinforcement consisting of steel bars (rebar), or cable, or wire
mesh is used to strengthen poured concrete. The reinforcement must
be supported in a form, above the base and below the top of the
form, so that the concrete flows under and over the reinforcement.
Further supports are needed for conduit to carry electrical wiring
through the concrete, as well as, piping and tubing.
[0004] A support currently used for this purpose is known in the
trade as a "mesh-up" or a "chair." Typically, it is made from sheet
metal, wire metal, molded plastic, or concrete. These materials are
not entirely environmentally benign. Metals and plastics take
energy to recycle. Plastics are not made from renewable sources.
Concrete is not recyclable, and is heavy to transport.
[0005] The mesh-up support has notches or grooves that receive the
reinforcement. The mesh-up is available in various heights and
widths depending upon the design requirements of the reinforcement.
Cutouts in the mesh-up allow concrete to flow into the mesh-up
during the pour, to preclude the forming of voids in the
concrete.
[0006] Apparatus and methods for reinforcement support are known in
the art. Some examples are disclosed in the following U.S.
Patents.
[0007] Lowery, U.S. Pat. Nos. 6,962,029 and 7,458,192, discloses a
plastic support having four legs, U-shaped notches on top, and a
flange base. The plastic legs of Lowery are designed to bow or bend
outward under the forces imposed by the concrete pour, then
straighten back up later. The legs may not return to the proper
height, leaving the reinforcement at varying heights.
[0008] Sorkin, U.S. Pat. No. 5,555,693 and Sizemore, U.S. Pat. No.
4,682,461, each show a plastic support having a V-shaped notch at
the top end. Sorkin discloses a shaped support which cannot be
shipped or stored in a flat state. Sizemore discloses a two-piece
construction which requires maintenance of inventory of the two
pieces.
SUMMARY
[0009] In accordance with the present invention, there is disclosed
a reinforcement support for use in connection with reinforcement
and poured concrete. The reinforcement support includes a shell
made from paperboard. As used herein, "paperboard" refers to any
paperboard construction (e.g., corrugated, non-corrugated, etc.)
which may be wholly paperboard or which includes at least a layer
of paperboard (e.g., treated or coated or laminated
paperboard).
[0010] In particular, a reinforcement support is provided for use
in connection with concrete reinforcement elements and poured
concrete. The reinforcement support includes a tubular paperboard
shell having first and second ends with a channel extending
therebetween. At least a first notch is formed into the first end
extending towards the second end with the first notch being
configured to supportingly accommodate at least one concrete
reinforcement element.
[0011] These and other aspects, objectives, features, and
advantages of the disclosed technologies will become apparent from
the following detailed description of illustrative embodiments
thereof, which is to be read in connection with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a first embodiment of a
reinforcement support, rectangular in section, constructed in
accordance with the invention.
[0013] FIG. 2 is a front elevational view of the reinforcement
support of FIG. 1.
[0014] FIG. 3 is a top plan view of the reinforcement support of
FIG. 1.
[0015] FIG. 4 is a top plan view of a blank useable to form the
reinforcement support of FIG. 1.
[0016] FIG. 5 is a perspective view of a second embodiment of a
reinforcement support, rectangular in section, constructed in
accordance with the invention.
[0017] FIG. 6 is a front elevational view of the reinforcement
support of FIG. 5.
[0018] FIG. 7 is a top plan view of the reinforcement support of
FIG. 5.
[0019] FIG. 8 is a top plan view of a blank useable to form the
reinforcement support of FIG. 5.
[0020] FIG. 9 is a perspective view of a third embodiment of a
reinforcement support, circular in section, constructed in
accordance with the invention.
[0021] FIG. 10 is a front elevational view of the reinforcement
support of FIG. 9.
[0022] FIG. 11 is a top plan view of the reinforcement support of
FIG. 9.
[0023] FIG. 12 is a perspective view of a fourth embodiment of a
reinforcement support, circular in section, constructed in
accordance with the invention.
[0024] FIG. 13 is a front elevational view of the reinforcement
support of FIG. 12.
[0025] FIG. 14 is a top plan view of the reinforcement support of
FIG. 12.
[0026] FIG. 15 is a perspective view of a fifth embodiment of a
reinforcement support, rectangular in section, constructed in
accordance with the invention.
[0027] FIG. 16 shows the shell of the subject invention in a
collapsed state.
[0028] FIGS. 17-21 show different notch configurations useable with
the subject invention.
[0029] FIG. 22 is a schematic showing a method useable with the
subject invention.
DETAILED DESCRIPTION
[0030] With reference to the Figures, a reinforcement support 20 is
shown which includes a tubular shell 22. The shell 22 includes
paperboard. As will be appreciated by those skilled in the art, the
shell 22 may be wholly formed from paperboard or include at least a
layer of paperboard which may be provided in conjunction with other
materials, such as a coating, treatment or other secondary layer
(e.g., a laminated layer). The paperboard may be treated or coated
with water proofing or other protective substances. Also, the
paperboard may be formed from recovered recycled materials and may
itself be recyclable. The use of such materials may allow
contractors to claim benefit of "leeds" credits.
[0031] The shell 22 includes first and second ends 24, 26 with a
channel 28 extending therebetween. At least a first notch 30 is
formed in the first end 24 to extend towards the second end 26. The
first notch 30 is configured to supportingly accommodate at least
one concrete reinforcement element. The concrete reinforcement
element may be disposed to extend across a portion of the channel
28 or may be located to only partly extend across the channel 28
(e.g., one end of the concrete reinforcement element is located
within the channel 28 with the concrete reinforcement element
extending out from the shell 22).
[0032] As will be understood by those skilled in the art, concrete
reinforcement elements may be any element provided to reinforce a
concrete structure, including, but not limited to, wire mesh,
rebar, cabling, and the like. Concrete reinforcement elements are
typically formed of metal or plastic. As used herein, "concrete
reinforcement elements" may be not only elements which solely have
the functionality of reinforcing in poured concrete (e.g., rebar)
but may also include elements which provide additional
functionality, e.g., electrical conduits, piping, tubing, and so
forth. The presence of the latter elements in poured concrete may
provide reinforcing while also providing passageways for electrical
wires, liquids, etc. The extent, if at all, of reinforcement
provided by a concrete reinforcement element is not critical to the
subject invention; the subject invention relates to the need to
support concrete reinforcement elements during concrete pouring
(e.g., supporting electrical conduit which may or may not
ultimately provide reinforcement).
[0033] The first notch 30 may be formed with various
configurations. As shown in FIG. 17, the first notch 30 includes
sides 32 which may extend convergently away from mouth 34 located
at the first end 24. As shown in FIG. 17, the sides 32 may come to
meet to provide the first notch 30 with a general V-shape.
Alternatively, as shown in FIG. 18, the sides 32 may extend to an
enlarged opening 36. This provides the first notch 30 with a
general keyhole shape. Any accommodated concrete reinforcement
element may be urged into the enlarged opening 36 with the sides 32
restricting movement out of the enlarged opening 32. Further, as
shown in FIG. 19, a general straight end 38 may be provided which
extends between the sides 32. The first notch 30 may be also
provided with an arcuate shape (arcuate end 40), as shown in FIG.
20, or be provided with the arcuate end 40 with the sides 32
extending between the arcuate end 40 and the first end 24 (FIG.
21). As will be appreciated by those skilled in the art, the first
notch 30 may be formed with other shapes, such as other polygonal
shapes, irregular shapes, and so forth. In addition, the first
notch 30 may be sized to accommodate various sized concrete
reinforcement elements (e.g., wire mesh of different diameters,
such as #4, #6, and #8).
[0034] The first notch 30 may be formed with different aspect
ratios. Where the reinforcement support 20 is intended for use with
lighter-weight concrete reinforcement elements, the aspect ratio
may be provided so that the depth of the first notch 30 is greater
than the width of its opening. In particular, with reference to
FIG. 17, the mouth 34 defines a width W, whereas the first notch 30
extends a distance from the first end 24 which defines a notch
depth L. With lighter-weight concrete reinforcement elements, it is
preferred that the notch depth L be greater than the width W of the
mouth 34. This reduces the likelihood of the concrete reinforcement
element being dislodged from the first notch 30. Where
heavier-weight concrete reinforcement elements are to be used, the
aspect ratio can be adjusted so that the notch depth L is equal to
or less than the width W of the mouth 34 (FIG. 20). This allows for
the first notch 30 to have a wider profile which is shallower than
the deeper profile described above. Here, however, the likelihood
of dislodgment of the concrete reinforcement element is offset by
the inherent weight of the element. It is envisioned that wire mesh
and cabling may be used with the aspect ratio of the notch depth L
being greater than the width W, while rebar may be used with the
notch depth L being equal to or less than the width W. This is
generally envisioned, but may be adjusted as needed, as will be
appreciated by those skilled in the art.
[0035] To allow for a single reinforcement support 20 to be
utilized with various concrete reinforcement elements, a plurality
of notches may be utilized. With reference to FIG. 1, a second
notch 30B may be provided in the first end 24 or the second end 26.
By providing notches in both the first and second ends 24, 26, the
reinforcement support 20 may provide for further
configurations.
[0036] The first notch 30 and the second notch 30B may be formed in
the first end 24 and aligned along a common axis which extends
across a portion of the channel 28. This alignment allows for
simultaneous support of a concrete reinforcement element by both
the first notch 30 and the second notch 30B.
[0037] Further notches, such as a third notch 30C and a fourth
notch 30D, may be provided in addition to the first and second
notches 30, 30B. The notches 30, 30B, 30C, 30D may be uniformly
spaced about the first end 24. This allows for an approximate right
angle alignment of the first and second notches 30, 30B relative to
the third and fourth notches 30C, 30D. Such an alignment allows for
simultaneous support of a wire mesh which has generally right angle
criss-crossing elements (FIG. 22).
[0038] In addition, a plurality of notches may be provided about
the first end 24 of the shell 22 so that more than one concrete
reinforcement element may be supported at a time. For example,
notches 30E, 30F may be provided adjacent to the first and second
notches 30, 30B so as to allow for adjacent support of two separate
concrete reinforcement elements.
[0039] As shown in FIGS. 1, 5, 9, 12 and 15, notches may be
provided in various quantities on or both of the first and second
ends 24, 26 of the shell 22. The notches may be provided with any
characteristics discussed above with respect to the first notch 30
(shape, aspect ratio). The use of designation by reference numerals
is not intended to be limiting. As will be understood by those
skilled in the art, various combinations of the notches (shape,
location) are possible with the subject invention. In addition, the
shell 22 may be provided with various cross-sectional shapes, such
as, a polygonal cross-section, e.g., a generally rectangular
cross-section, as viewed in a direction transverse to a
longitudinal axis of the shell 22 (FIG. 1) or a circular
cross-section as viewed in a direction transverse to a longitudinal
axis of the shell 22 (FIG. 9).
[0040] The shell 22 may be collapsed to a generally flat state, as
shown in FIG. 16, for shipping and storage. The shell 22 may be
provided unassembled, e.g., as a blank as discussed below, and
assembled on-site as needed, or provided in a collapsed state and
erected on-site as needed. In either case, shipping and storage
space may be minimized.
[0041] Further, the shell 22 may be formed from a single blank B
which is formed as a continuous strip of paperboard and then
assembled into a tubular shape with ends 42 being glued, stapled
and/or fixed in any other known manner. Examples of useable blanks
B are shown in FIGS. 4 and 8. The first notch 30, and other notches
and features, may be die cut or otherwise formed in the blank B. In
assembling the shell 22, portions of the blank B may be overlapped,
as shown in FIG. 1, to have a double layer portion 44. The double
layer portion 44 may cover all or a portion of one side of the
shell 22. Also, fold lines 46 may be provided, as needed, on the
blank B by scoring, perforating, or otherwise weakening, portions
of the blank B to define fold lines for assembling the shell 22.
The fold lines 46 may be also utilized to allow for collapsing the
shell 22 into a generally flat state for shipping and storage. Fold
lines are not required for assembling a circular cross-section
shell 22, but may be provided to permit collapsing. As will be
appreciated by those skilled in the art, the shell 22 may be formed
by a plurality of assembled pieces, rather than a single blank.
[0042] One or more vent holes 48 may be formed in the shell 22 to
allow for concrete to pass therethrough during pouring. The vent
holes 48 relieve possible stress from concrete being only
introduced through the first end 24 and/or the second end 26. As
shown in FIG. 1, with the shell 22 having a polygonal
cross-section, one or more vent holes 48 may be formed at one or
more corners 50 of the shell 22.
[0043] In use, the reinforcement support 20 is located at a site
where concrete is to be poured. The reinforcement support 20 may be
stood on one of the first and second ends 24, 26 to be upright.
This allows for rigid upright support for one or more concrete
reinforcement element(s), spaced from the supporting ground. At
least one concrete reinforcement element is placed into engagement
with at least one first notch 30. A plurality of the reinforcement
supports may be used to support a matrix of concrete reinforcement
elements (e.g., a plurality of rebar, wire mesh, etc.). Once
prepared, concrete is poured about the reinforcement support 20 and
the supported concrete reinforcement element(s). While supporting
concrete reinforcement element(s), the poured concrete may enter
the shell 22: through the exposed first or second end 24, 26;
through any vent hole(s) 48; and/or, through any notches provided
on the shell 22 but not utilized to support a concrete
reinforcement element.
* * * * *