U.S. patent application number 14/634295 was filed with the patent office on 2015-06-25 for edge form system for forming simulated stone coping.
The applicant listed for this patent is Stegmeier LLC. Invention is credited to William J. Stegmeier, JR..
Application Number | 20150176294 14/634295 |
Document ID | / |
Family ID | 52472871 |
Filed Date | 2015-06-25 |
United States Patent
Application |
20150176294 |
Kind Code |
A1 |
Stegmeier, JR.; William J. |
June 25, 2015 |
EDGE FORM SYSTEM FOR FORMING SIMULATED STONE COPING
Abstract
An edge form system has a molded liner and a form board. The
molded liner has a textured imprinting on the inner surface for
forming a simulated stone coping and a first interlocking element.
The form board has a base for mounting the form board on a vertical
structure, a coping support wall, a liner receiver, and a second
interlocking element for interlocking with the first interlocking
element.
Inventors: |
Stegmeier, JR.; William J.;
(Henderson, NV) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Stegmeier LLC |
Arlington |
TX |
US |
|
|
Family ID: |
52472871 |
Appl. No.: |
14/634295 |
Filed: |
February 27, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14054053 |
Oct 15, 2013 |
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14634295 |
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14042028 |
Sep 30, 2013 |
8960636 |
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14054053 |
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Current U.S.
Class: |
249/15 |
Current CPC
Class: |
E04G 13/06 20130101;
E04H 2004/147 20130101; E04G 13/00 20130101; E04G 13/04 20130101;
E04G 9/10 20130101; E04H 4/14 20130101; E04F 19/02 20130101; E04F
13/147 20130101; E04H 4/142 20130101; E04G 21/02 20130101 |
International
Class: |
E04G 13/06 20060101
E04G013/06; E04F 13/14 20060101 E04F013/14; E04F 19/02 20060101
E04F019/02; E04G 13/04 20060101 E04G013/04 |
Claims
1. A system comprising: a pair of edge form systems, each
comprising: a molded liner comprising: an inner surface and an
outer surface connected by a top edge and a bottom edge; a textured
imprinting on the inner surface for forming the simulated stone
coping; and a first interlocking element; and a form board
comprising: a base for mounting the form board on the vertical
structure; a coping support wall for supporting the molded liner;
and a second interlocking element shaped to interlock with the
first interlocking element of the molded liner for securing the
molded liner to the form board; and a spring clamp for clamping the
pair of edge form systems together.
2. An edge form system for forming a simulated stone coping above a
vertical structure, the edge form system comprising: a molded liner
comprising: an inner surface and an outer surface connected by a
top edge and a bottom edge; a textured imprinting on the inner
surface for forming the simulated stone coping; and a first
interlocking element; and a form board comprising: a base for
mounting the form board on the vertical structure; a coping support
wall for supporting the molded liner; and a second interlocking
element shaped to interlock with the first interlocking element of
the molded liner for securing the molded liner to the form
board.
3. The edge form system of claim 2, wherein the base includes a top
surface that is adjacent to and generally perpendicular to a
support surface of the coping support wall.
4. The edge form system of claim 2, wherein the first interlocking
element is a ridge extending outwardly from the molded liner, and
wherein the second interlocking element is a groove formed in the
form board.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application for a utility patent is a continuation of a
previously filed utility patent application, currently pending,
having the application Ser. No. 14/054,053, filed Oct. 15, 2013 and
this application claims priority to previously filed utility patent
application, currently pending, having the application Ser. No.
14/042,028, filed Sep. 30, 2013.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to forms for forming a
coping, and more particularly to an edge form system for forming
simulated stone coping.
[0004] 2. Description of Related Art
[0005] There are several examples of polystyrene forms that are
used to form the front face of a coping. Examples of such prior art
forms include are shown in Deason (U.S. Pat. No. 3,526,070, and
U.S. Pat. No. D284,971), as well as to Stegmeier (U.S. Pat. No.
4,574,017 and U.S. Pat. No. 5,695,586). Various other references
include the following: Coates, U.S. Pat. No. 6,725,469; Epple, U.S.
Pat. No. 5,680,730; Smith, U.S. Pat. No. 7,861,471; and Dahowski,
U.S. Pat. No. 4,457,119. The above-described references are hereby
incorporated by reference in full.
[0006] The prior art teaches form boards that are mounted on an
edge of a pool for forming a shaped coping when the deck is poured.
However, the prior art does not teach a form board that receives a
liner that is molded to impart a realistic stone texturing, or
other form of texturing, that cannot be achieved with prior art
forms. The prior art also does not teach an interlocking mechanism
for interlocking the molded liner with the form board, so that the
liner is held securely in place without the use of tapes or
adhesives. The present invention fulfills these needs and provides
further advantages as described in the following summary.
SUMMARY OF THE INVENTION
[0007] The present invention teaches certain benefits in
construction and use which give rise to the objectives described
below.
[0008] The present invention provides an edge form system for
forming a simulated stone coping above a vertical structure. The
edge form system has a molded liner and a form board. The molded
liner has an inner surface and an outer surface, each connected by
a top edge and a bottom edge, a textured imprinting on the inner
surface for forming the simulated stone coping, and a first
interlocking element formed in the bottom edge. The form board has
a base for mounting the form board on the vertical structure, a
coping support wall extending upwardly from the base, the coping
support wall having a support surface. The base and the support
surface of the support wall together form a liner receiver shaped
to receive the molded liner. There is a second interlocking element
in the base and/or the coping support wall shaped to interlock with
the first interlocking element of the molded liner.
[0009] A primary objective of the present invention is to provide
an edge form system having advantages not taught by the prior
art.
[0010] Another objective is to provide an edge form system for
quickly and easily forming realistic simulated stone coping.
[0011] Another objective is to provide an edge form system that
includes a molded liner that includes interlocking elements for
locking the molded liner against the form board during use, without
the use of tape or adhesives.
[0012] A further objective is to provide an edge form system that
includes molded liners that may be reused.
[0013] Other features and advantages of the present invention will
become apparent from the following more detailed description, taken
in conjunction with the accompanying drawings, which illustrate, by
way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings illustrate the present invention.
In such drawings:
[0015] FIG. 1 is a front perspective view of one embodiment of an
edge form system, illustrating one embodiment of a molded liner and
a form board;
[0016] FIG. 2 is an exploded side elevational view thereof;
[0017] FIG. 3 is a rear perspective view of the edge form system
operatively installed on a bond beam of a swimming pool for forming
a simulated stone coping on top of the bond beam of the swimming
pool;
[0018] FIG. 4 is a perspective view of the molded liner being
peeled from the simulated stone coping once it has cured; and
[0019] FIG. 5 is a perspective view of another embodiment of the
edge form system, illustrating the edge form system being held in
place on a vertical structure by a spring clamp.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The above-described drawing figures illustrate the
invention, an edge form system 10 for forming a simulated stone
coping 18 above a vertical structure 12 such as a bond beam of a
swimming pool.
[0021] FIG. 1 is a front perspective view of one embodiment of the
edge form system 10, illustrating one embodiment of a molded liner
20 and a form board 30. FIG. 2 is an exploded side elevational view
thereof. As illustrated in FIGS. 1-2, the molded liner 20 has an
inner surface 21, an outer surface 22, a top edge 23, and a bottom
edge 24. The inner surface 21 includes a textured imprinting 26
that is molded or otherwise formed so that when concrete is poured
adjacent to it, the concrete will retain the texturing so that it
resembles stone or some other desirable surface shape and texture.
The textured imprinting 26 may be shaped for imparting a rough
stone-like appearance to the concrete poured once it has dried. The
style of texture may be of any sort, including rough stone, brick
and mortar, or any other pattern, and may include any form of
patterns, words, images, etc.
[0022] In this embodiment, the outer surface 22, opposite the inner
surface 21, abuts the form board 30 in such a way that the molded
liner 20 is held in place during the pouring and curing of the
concrete. The top edge 23 may be generally aligned with the top of
the form board 30, though this is not necessary, and in this
embodiment the top edge 23 extends outwardly to impart a gentle
curve to the top edge of the simulated stone coping 18 (shown in
FIGS. 3 and 4).
[0023] In the embodiment of FIGS. 1 and 2, the form board 30 has a
base 40 for mounting the form board on the vertical structure 12,
and a coping support wall 50 extending upwardly from the base 40.
The base 40 includes a top surface 48, a support surface 52, and a
liner receiver 60 which is the space formed by the top surface 48
of the base 40 and the support surface 52 of the coping support
wall 50, and is where the molded liner 20 is seated. When seated in
the liner receiver 60, the textured imprinting 26 of the molded
liner 20 is exposed, and the outer surface 22 abuts the support
surface 52, with the bottom edge 24 of the molded liner 20 resting
on the form board 30 which supports the molded liner 20.
[0024] In the embodiment of FIGS. 1 and 2, the molded liner 20
further includes a first interlocking element 25 for locking the
molded liner 20 against the form board 30. The first interlocking
element 25 may be located at the bottom edge 24 of the molded liner
20 and may be used to properly seat the molded liner 20 within the
form board 30. In one embodiment, the first interlocking element 25
is a ridge that extends lengthwise along the bottom edge 24 of the
molded liner 20.
[0025] Also as shown in FIGS. 1-2, the form board 30 includes a
second interlocking element 70 that is adapted to interlock with
the first interlocking element 25. In this embodiment, the second
interlocking element 70 may be a groove shaped to lockingly engage
the ridge 25 to hold the molded liner 20 in place. As shown in
FIGS. 1 and 2, when properly seated, the shapes of the ridge 25 and
the groove 70 prevent movement of the molded liner 20 while
positioned in the liner receiver 60.
[0026] In another embodiment, the first interlocking element 25 may
include a plurality of posts or other forms of interlocking
elements, along with a corresponding plurality receivers that form
the second interlocking element 70 on the top surface 48 shaped to
receive and lockingly engage the plurality of the first
interlocking elements 25. The elements may be reversed, and/or
replaced with any other forms of structure or structures that
interlock in a similar manner for holding the liner 20 in place.
Other forms of interlocking mechanisms may be posts and holes,
triangular wedges and triangular-shaped receivers, locking pins,
elastic protrusions from the molded liner 20 which may be pried
from the receiver liner receiver 60 on the form board 30, or others
known to those skilled in the art, all being equivalent and within
the scope of the present invention. In some embodiments, the liner
20 is held in place without the use of tape or adhesives. Other
methods of holding the molded liner 20 in place on the form board
30 may also be used, including the use of an adhesive, fasteners,
ties, locks, clamps, etc. known to those skilled in the art. Also,
any number, orientation, and combination thereof, of the first
interlocking elements 25 and the corresponding second interlocking
elements 70 may be used, such variations considered equivalent and
within the scope of the present invention.
[0027] The coping support wall 50 is a portion of the form board 30
which may extend upwardly from the base 40 and acts as a support
structure for keeping the molded liner 20 in the proper position.
Also, the coping support wall 50 should be of sufficient thickness
(or width) to support the pressure due to the concrete prior to
setting. Such thickness may be determined by those skilled in the
art and will vary according to the material of which the form board
30 is made and the height of the molded liner 20 to be supported
when concrete is poured. The support surface 52 of the coping
support wall 50 abuts the outer surface 22 of the molded liner 20.
The support surface 52 and the outer surface 22 may be generally
smooth, for making solid contact and a secure hold on the molded
liner 20. In one embodiment, the outer surface 22 and the support
surface 52 are planar, but other embodiments may have alternate
shapes, including curved, ridged, segmented, etc.
[0028] In this embodiment, the base 40 may include one or more
mounting surfaces 42 for mounting the base 40 to the vertical
structure 12 (shown in FIG. 3). The mounting surfaces 42 may be
separated by one or more lateral kerfs 46. The mounting surfaces 42
may include an adhesive layer 44 for mounting the base 40 to the
vertical structure 12. Any kind of bonding agent known to those
skilled in the art may be used, including epoxy, glue, or other
tacky substance which may form a strong, but preferably removable,
bond between the form board 30 and the vertical structure 12.
Additionally, peel-removable tape 45 (e.g., wax paper or other
removable layer) may be used to cover the adhesive layer 44 to
protect it, and removed prior to mounting the form board 30 on the
vertical structure 12.
[0029] In the present embodiment, three of the adhesive layers 44
are included on three of the mounting surfaces 42, rather than the
usual two. The inclusion of a third mounting surface 42 provides
additional adhesive strength so that it is possible to mount the
form board 30 without the use of tie-wires. It is preferred to
avoid the use of tie wires when using the molded liner 20, because
the molded liner 20 interferes with the positioning of the tie wire
therethrough. This is an improvement over the prior art, which had
previously considered the inclusion of tie wires to be important to
properly supporting the form board 30, so that the form board 30
was able to support the weight of the concrete.
[0030] The lateral kerfs 46 are slots where material has been
removed from the base 40 for the purpose of adding flexibility to
the form board 30, so that the form board 30 can fit around curves
in the shape of the pool or other structure. The number of the
lateral kerfs 46 and the mounting surfaces 42 are variable and
depend on the strength needed to hold the base 40 in place on the
vertical structure 12 and also the structural limitations of the
vertical structure 12, for instance if there was an obstruction
that limited the overall height of the combination of the mounting
surfaces 42 and the lateral kerfs 46. In one embodiment, there may
be three of the mounting surfaces 42, with two of the lateral kerfs
46 separating them. In other embodiments, there may be more or
fewer of the mounting surfaces 42 and the lateral kerfs 46. The
number, placement, and shape or depth of the lateral kerfs 46 may
be determined by those skilled in the art and should be considered
equivalent and within the scope of the present invention.
[0031] Also, as shown in FIGS. 1-2, the form board 30 may also
include a receiving recess 80 for receiving an elongate protective
strip 90 (shown in FIG. 3). In one embodiment, the receiving recess
80 may be formed at the intersection of the uppermost of the
mounting surfaces 42 and the top surface 48. The receiving recess
80 is discussed in greater detail below. In other embodiments,
there may be no need for the elongate protective strip 90. In this
case, the form board 30 may not have the receiving recess 80, but
may be as described above in all other respects.
[0032] In one embodiment, the height of the mounting surfaces 42
may be about 1.9 cm. (0.75 inches), and the height of the lateral
kerfs 46 may be about 1.3 cm. (0.5 inches). In another embodiment
the height of the mounting surfaces 42 may be between 4.0 cm. (1.6
inches) and 1.0 cm. (0.4 inches) and the height of the lateral
kerfs 46 may be between 3.0 cm (1.18 inches) and 0.5 cm. (0.2
inches). In another embodiment the height of the mounting surfaces
42 may be between 10.0 cm. (4 inches) and 5.0 cm. (2 inches) and
the height of the lateral kerfs 46 may be between 7.0 cm (2.75
inches) and 3.0 cm. (1.18 inches). The term "about" as used in
describing dimensions or ranges indicates an uncertainty of 10%.
Other sizes of the lateral kerfs 46 and the mounting surfaces 42
may be used by those skilled in the art, depending the support
needed, the number and placement of the lateral kerfs 46 and the
mounting surfaces 42, etc. and should be considered equivalent and
within the scope of the present invention.
[0033] FIG. 3 is a rear perspective view of the edge form system 10
operatively installed on a bond beam of a swimming pool forming the
simulated stone coping 18 of the swimming pool. Here we discuss one
possible method of use of the present embodiment of the edge form
system 10. Other methods of use known to those skilled in the art
may also be employed and considered equivalent to the description
below. As shown in FIG. 3, the swimming pool forms the vertical
structure 12, which also includes a tile layer 14.
[0034] As illustrated in FIG. 3, the method of assembly of the edge
form system 10 begins with mounting the form boards 30 on the
vertical structure 12, in this case completely around the pool. In
this embodiment, the form boards 30 are mounted via the adhesive
layers 44 on each of the mounting surfaces 42. The peel-removable
tape 45 (shown in FIG. 2) is removed from the mounting surfaces 42
to expose the adhesive layers 44 on each of the mounting surfaces
42, and this is then used to mount the form board 30 on the
vertical structure 12. Other mounting mechanisms or systems may
also be used, as discussed in greater detail below, and any
alternative methods or systems should be considered within the
scope of the present invention.
[0035] Once the form boards 30 have been installed, the molded
liner 20 is placed within the liner receiver 60 of the form boards
30, as illustrated in FIGS. 1-3. The first interlocking element 25
interlocks with the second interlocking element 70, to hold the
molded liner 20 in place on the form board 30. Release agents may
be added to the molded liner 20 to enable the later removal of the
molded liner 20, and it is helpful if the interlocking elements 25
and 70 enable interlocking without the use of any adhesives, tape,
etc.
[0036] In this embodiment, an elongate protective strip 90 may be
positioned in the receiving recess 80. The elongate protective
strip 90 may include an anchor 92 and a protective wall 94 that
extends downwardly from the anchor 92. The anchor 92 of the
elongate protective strip 90 is captured by the poured concrete,
such that the protective wall 94 extends downwardly to cover the
crack between the coping and the bond beam of the pool, and to also
cover a top edge of the tile layer 14. Such tile layer formations
are very common in forming attractive edging in a swimming pool,
Jacuzzi, decorative pond, or other similar constructions, where the
edge form system 10 is intended for use.
[0037] Concrete is then poured into the space defined on one side
by the molded liner 20, forming a concrete fill 16 that forms the
coping of the pool or other structure. When the concrete fill 16
cures, the molded liner 20 provides the texture of stone (or other
desirable texture) to the surface of the concrete. For purposes of
this application, the term "concrete" is hereby broadly defined to
include not only concrete but also any form of plastic, resin,
composite, or any other form of equivalent material or any
generally pourable and malleable material wherein after appropriate
curing, drying, or setting will form a rigid structure that retains
the desired molded pattern or texture.
[0038] After the concrete fill 16 has cured to the satisfaction of
the skilled user (though it may not be fully hardened should
additional sculpting need to occur) the form board 30 is stripped
from the vertical structure 12, breaking the contact at the
adhesive layer 44, and the form board 30 may be removed for
disposal (not shown). Afterwards, the molded liner 20 may be
removed.
[0039] FIG. 4 is a perspective view of the molded liner 20 being
peeled from the simulated stone coping 18 once it has cured. As
shown in FIG. 4, the textured imprinting 26 on the inner surface 21
of the molded liner 20 leaves its impression on the concrete fill
16, which in this case is shown as a rough-hewn stone appearance
with rounded corners, thus forming the simulated stone coping 18.
Also as shown in FIG. 4, the anchor 92 of the elongate protective
strip 90 is captured by the concrete fill, so that the elongate
protective strip 90 covers the crack between the coping and the
bond beam of the pool.
[0040] FIG. 5 is a perspective view of another embodiment of the
edge form system 10, illustrating the edge form system 10 being
held in place on the vertical structure 12 by a spring clamp 19. In
this embodiment, a pair of the form boards 30 may be clamped onto
the vertical structure 12, shown as a concrete block, with the
spring clamp 19. In this embodiment, each of the form boards 30 has
the molded liner 20 in place in the liner receiver 60. Once
clamped, the two edge form systems 10 create a space for pouring
the concrete fill 16 (shown in FIGS. 3 & 4). In this
embodiment, the base 40 includes a lip 100 which may extend past
the bottom edge 24 of the molded liner 20. The lip 100 has a top
lip surface 102 and a bottom lip surface 104. The lip 100 may
extend outwardly over a top surface 13 of the vertical structure 12
such that the bottom lip surface 104 abuts the top surface 13 of
the vertical structure 12. This serves to prevent vertical slippage
during setup, keep the edge form system 10 in place during pouring
of the concrete fill 16, and throughout the curing process. The top
lip surface 102, as shown in FIG. 5, has a generally rounded shape,
though other shapes are possible, such as rectangular, triangular,
or any other shape, as determined by those skilled in the art. The
bottom lip surface 104 may be generally planar, for making good
contact with the top surface 13, but texturing or other irregular
shapes may also be chosen according to those skilled in the art. As
shown in this embodiment, no adhesive layer is present, though in
other embodiments an adhesive layer may be present in addition to
the spring clamp 19. Similarly, no lateral kerfs are included in
this embodiment, though in other embodiments those may be present
as well.
[0041] One method of using the present embodiment for forming a
simulated stone coping 18, as illustrated in FIG. 5, may be to
begin by mounting the pair of edge form systems 10 on the vertical
structure 12 such that the lip 100 holds them in place. The spring
clamp 19 may them be applied to the form boards 30 to clamp them
together against the vertical structure 12.
[0042] The molded liners 20 are then placed within the liner
receiver 60 of the form board 30 for each of the pair of edge form
systems 10. The concrete fill 16 is then poured and allowed to
cure. When ready, the spring clamp 19 may be removed and the two
edge form systems 10 are pulled away, leaving the simulated stone
coping 18. While FIG. 5 illustrates one embodiment of the edge form
system 10, those skilled in the art may devise alternative
embodiments, and these alternative or equivalent are considered
within the scope of the present invention.
[0043] Furthermore, while this application discusses the specific
use of the system 10 for use in the construction of a swimming
pool, it may be likewise used to form a coping on any similar
structures. The term "vertical structure" is hereby defined to
include any part of the pool structure (e.g., wall, tile, etc.), as
well as similar structures (e.g., a concrete countertop, decorative
tops to walls or other structures, etc.).
[0044] As used in this application, the words "a," "an," and "one"
are defined to include one or more of the referenced item unless
specifically stated otherwise. Also, the terms "have," "include,"
"contain," and similar terms are defined to mean "comprising"
unless specifically stated otherwise. Furthermore, the terminology
used in the specification provided above is hereby defined to
include similar and/or equivalent terms, and/or alternative
embodiments that would be considered obvious to one skilled in the
art given the teachings of the present patent application.
* * * * *