US20080048093A1

US20080048093A1 - Concrete form

Info

Publication number: US20080048093A1
Application number: US11/878,920
Authority: US
Inventors: Scott Peterson; Kevin Snyder
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-08-22
Filing date: 2007-07-27
Publication date: 2008-02-28

Abstract

The concrete form is a structure having a user-selectable shape allowing for the creation of an opening in a concrete surface, such as a concrete patio, with the opening having the user-selectable shape. The form includes a plurality of wall members, which are joined together to form a closed continuous wall having the user-selectable shape. The wall members are each secured to the ground, and the user pours liquid concrete on the ground exterior to the closed continuous wall. The closed continuous wall defines the opening and prevents flow of the liquid concrete within the opening. Following hardening of the concrete, the form may be removed, leaving an opening in the concrete surface, having the user-selectable shape, in which the user may plant flora and the like.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/839,127, filed Aug. 22, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention
The present invention relates to construction molds and forms, and particularly to various embodiments of a concrete form for forming decorative cutouts and shapes in concrete surfaces and structures.
2. Description of the Related Art
In the formation of concrete surfaces, such as concrete patios, users often wish to create openings for centrally formed gardens, pools and the like. Typically, such openings are created during the liquid-pouring phase of the concrete surface formation, rather than cutting the opening following the hardening of the concrete. Typically, a form, in the shape of the desired opening, is provided and placed in the location of the desired opening, and acts as a barrier to the liquid concrete. The concrete hardens about the barrier and, following hardening, the form is removed, leaving the opening of desired shape and size.
Such forms are typically formed from a continuous wall of material shaped in simple geometric patterns, such as a circle, ellipse or rectangle. Such forms are pre-constructed and transported to the appropriate site. However, since gardens, pools and the like are typically relatively large, it is inconvenient to store or transport such a form to the appropriate site.
Further, such forms typically come in a relatively small variety of set shapes and sizes, and are not customizable. Also, such forms are designed to be removed following the pouring of the concrete. Should the user wish to surround the opening with a decorative wall or the like, the form must first be removed and the decorative wall must be constructed in its place. It would be desirable to provide a form which may be utilized both during the pouring of the concrete, and which could further be used as a decorative wall, requiring no further construction. Such a form should, additionally, be easily transportable and storable, and further should be customizable in size and shape.
Thus, a concrete form solving the aforementioned problems is desired.

SUMMARY OF THE INVENTION

The concrete form is a structure having a user-selectable shape, allowing for the creation of an opening in a concrete surface, such as a concrete patio, with the opening having the user-selectable shape. The form includes a plurality of wall members, which are joined together to form a closed continuous wall having the user-selectable shape.
A plurality of connectors may be provided for joining adjacent wall members. One such connector includes a connector plate having a pair of openings formed therethrough. Each end of each one of the plurality of wall members also has an opening formed therethrough. A connector plate is mounted to a pair of adjacent wall members, with the respective openings being aligned, and a pair of threaded bolts or the like secures the connector plate to the pair of wall members, and secures the pair of adjacent wall members to one another. Alternatively, each wall member may have a threaded stud integrally molded with the wall member projecting from each end of the wall member, the connector plate being placed over the studs of adjacent wall members and fastened thereto by wing nuts or the like. In another alternative, each wall member may have a projecting member formed on a first end thereof, and a corresponding recess formed in a second end thereof, the projecting member forming a snap fit or friction fit with the recess to join adjacent wall members.
The wall members are further each secured to the ground. Each wall member preferably has at least one grade stake loop mounted to an inner surface thereof (with the terms “inner” and “outer” referring to the interior and exterior of the closed continuous wall formed by joining of the plurality of wall members together). Each loop receives a corresponding grade stake, which is adapted for being driven into the ground to secure each wall member to the ground. Preferably, each loop has a transverse pin opening formed therethrough, which is aligned with a corresponding one of a plurality of axially aligned openings formed through the stake. A pin is inserted through the pin opening and a selected axial opening in the stake, thus securing the stake to the loop, and allowing the user to adjust the height of the stake (and the corresponding wall member) with respect to the ground.
Following attachment of the closed continuous wall to the ground, the user pours liquid concrete on the ground outside the concrete form. The closed continuous wall defines the opening and prevents flow of the liquid concrete within the opening. Following hardening of the concrete, the form may be removed, leaving an opening in the concrete surface having the user-selectable shape, in which the user may plant flora and the like, for example.
Alternatively, the closed continuous wall may be left in place, forming a permanent decorative wall about the perimeter of the opening. A channel may be formed in an upper edge of the closed continuous wall for reception of a decorative light string, or the like. A cap or plug member may be snapped into the channel if the user does not wish to use the decorative light string.
Further, the closed continuous wall may be alternatively mounted on a pre-existing concrete surface; i.e., rather than forming an opening in a new concrete surface with the opening being partially defined by the ground, the opening may be partially defined by the pre-existing layer of concrete with the new concrete surface being formed on top of the pre-existing layer of concrete.
These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an environmental, perspective view of an exemplary concrete form according to the present invention.

FIG. 2 is a top view of the concrete form of FIG. 1.

FIG. 3 is a partially exploded top view of the concrete form of FIG. 1.

FIG. 4 is an exploded end view of a section of a concrete form according to the present invention, showing attachment of a grade stake and adjustment of the height of the form.

FIG. 5 is a partial top view of a concrete form according to the present invention, showing a connector for joining a pair of adjacent wall members.

FIG. 6 is a partial top view of an alternative embodiment of a concrete form according to the present invention, showing an alternative method for joining of a pair of adjacent wall members.

FIG. 7 is an exploded partial perspective view of an alternative embodiment of a concrete form according to the present invention, showing a channel formed in an upper edge of a wall member for receiving a light string.

FIG. 8 is a top view of the concrete form of FIG. 7.

Similar reference characters denote corresponding features consistently throughout the attached drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is directed towards a concrete form 10 for forming a decorative opening in a concrete surface. The concrete form 10 is a structure having a user-selectable shape, such as the exemplary dolphin shown in FIGS. 1, 2 and 3. It should be understood that the dolphin illustrated in the drawings is for exemplary purposes only, and the concrete form 10 may have any desired user-selectable or customizable shape. For example, the form 10 may be contoured like a star, a butterfly, a seashell, a basic geometric shape, or any desired shape.
As best illustrated in FIG. 1, usage of the form 10 allows for the creation of an opening in a concrete surface 14, such as a concrete patio, for example, with the opening having the user-selectable shape. The opening is defined by a lower surface, which is the ground 12 in the example of FIG. 1. In the example of FIG. 1, the user may wish to plant flora 16 within the ground 12, creating a dolphin-shaped garden in the center of concrete patio 14. Alternatively, the lower surface may be in the form of pre-formed and hardened concrete, or may be any other surface upon which a new layer of concrete 14 is formed.
The form 10 includes a plurality of wall members, which are joined together to form a closed continuous wall having the user-selectable shape. In the example of FIGS. 2 and 3, the dolphin-shaped form 10 includes eight separate wall members; namely, wall members 22, 24, 26, 28, 30, 32, 34 and 36. It should be understood that form 10 may be constructed from any desired number of wall members according to the size and shape of the completed form 10. Wall members 22, 24, 26, 28, 30, 32, 34 and 36 may be formed from any suitable material capable of withstanding the pressure of poured liquid concrete. For example, the wall members may be formed from ¼ inch-thick fiberglass, ⅛ of an inch-thick stainless steel, rigid plastic, recycled hardened plastic or any other suitable material. The wall members may be approximately four inches in height, or may have any other desired dimensions. The plurality of wall members allows for ease in transportation and storage of concrete form 10.
A plurality of connectors 20 may be provided for joining adjacent wall members 22, 24, 26, 28, 30, 32, 34 and 36. One such connector 20, illustrated in FIG. 5, includes a connector plate 42 having a pair of openings 46 formed therethrough. Each end of each one of the plurality of wall members 22, 24, 26, 28, 30, 32, 34 and 36 also has an opening 48 formed therethrough. The connector plate 42 is mounted to a pair of adjacent wall members (34 and 36 in the example of FIG. 5), with the respective openings being aligned (i.e., each opening 46 of connector plate 42 is aligned with a corresponding opening 48 of one of the respective wall members 34, 36), and a pair of threaded bolts 44 or the like secures the connector plate 42 to the pair of wall members 34, 36, and secures the pair of adjacent wall members 34, 36 to one another.
In FIG. 5, a pair of wing nuts 50, or the like, are provided for releasably securing the threaded bolts 44. Alternatively, the wall members 34 and 36 may have threaded studs molded therewith or permanently attached thereto extending from each end of the wall member 34 and 36, so that connector plate 42 may be placed over the studs of adjacent wall members and fastened thereto by wing nuts 50.
In another alternative, shown in FIG. 6, each wall member (as in FIG. 5, the two wall members 34, 36 are being used for exemplary purposes) may have a male snap member or projecting member 54 formed on a first end thereof, and a corresponding female snap member or recess 56 formed in a second end thereof, so that the projecting member 54 of one wall member (wall member 36 in the example of FIG. 6) forms a snap fit or friction fit with a corresponding recess 56 of adjacent wall member 34 to secure the pair of wall members 34, 36 together. It should be understood that the embodiments illustrated in FIGS. 5 and 6 are shown for exemplary purposes only, and that adjacent pairs of wall members may be joined in any suitable manner, dependent upon the particular needs and desires of the user.
As best shown in FIG. 4, the plurality of wall members 22, 24, 26, 28, 30, 32, 34 and 36 are each secured to the ground 12. Each wall member preferably has at least one grade stake loop 18 formed on an inner surface 40 thereof (with the terms “inner” and “outer” referring to the interior and exterior of the closed continuous wall formed by joining of the plurality of wall members together). In FIG. 4, single wall member 36 is shown for exemplary purposes, although it should be understood that each of wall members 22, 24, 26, 28, 30, 32, 34 and 36 is secured to the ground 12 in a similar manner.
Each loop 18 receives a corresponding grade stake 42, which is adapted for penetrating the ground 12 to secure each wall member 22, 24, 26, 28, 30, 32, 34 and 36 to the ground 12. Preferably, each loop 18 has a transverse opening 52 formed therethrough, which is aligned with a corresponding one of a plurality of axially aligned openings 54 formed through the stake 42. A pin 56 is inserted through the transverse opening 52 and a selected opening 54 formed through the stake 42, thus securing the stake 42 to the loop 18 and allowing the user to adjust the height of the stake 42 (and the corresponding wall member 36) with respect to the ground 12, the pin 56 lying across the surface of the ground. It should be understood that concrete form 10 may be secured to the ground in any suitable manner, and the height of form 10 with respect to the ground may be adjusted in any suitable manner. It will further be understood that the form 10 may be embedded in the ground with its top edge at ground level.
In FIG. 4, stake 42 is preferably between approximately twenty-four and thirty-six inches in length, and is formed from any suitable rigid material. Openings 54 are preferably spaced apart by approximately ½ inches. Pin 56 may be formed from metal, plastic or any other suitable material.
Following attachment of the closed continuous wall of form 10 to the ground 12, the user pours liquid concrete on the ground exterior to the form 10. The closed continuous wall of the form 10 defines the opening and prevents flow of the liquid concrete within the opening. Following hardening of the concrete, the form may be removed, leaving an opening in the concrete surface 14 having the user-selectable shape, in which the user may plant flora 16 and the like, as illustrated in FIG. 1. Further, conventional expansion joints or one-inch-deep saw cuts may be formed in concrete surface 14 to allow for thermal expansion and contraction of the concrete.
Alternatively, the form 10 may be left in place, forming a permanent decorative wall about the perimeter of the opening. Preferably, the user removes stakes 42, but leaves the decorative closed continuous wall in place, bonded to the concrete. A channel 60 may be formed in a top edge 58 of the closed continuous wall for reception of a decorative light string 62, fiber optic cable, or the like, as illustrated in the embodiment of FIGS. 7 and 8. Preferably, for a wall member having exemplary dimensions of approximately four inches in height and one inch in thickness, channel 60 has a depth of approximately ½ inches, and a width of ½ inches.
In FIGS. 7 and 8, single wall member 36 is shown for exemplary purposes. However it should be understood that a similar channel 60 is formed in the upper surface of each wall member 22, 24, 26, 28, 30, 32, 34 and 36, allowing the light string 62 to extend about the entire perimeter of form 10.
Further, a cap or plug member 63 may be provided for sealing, covering or concealing the channel 60 if the user does not wish to use the decorative light string 62. The cap or plug member 63 may be releasably joined to the respective wall member by any suitable releasable fastener. One method is shown in FIG. 7, in which a pair of slots or grooves 61 are formed in upper surface 58, each extending parallel to channel 60, and each being formed on either side of channel 60.
The cap or plug member 63 includes an elongated, flat cover surface 67 with a pair of parallel flanges 65 depending therefrom. The flanges 65 frictionally and releasably engage the grooves 61 to attach the cap 63 to upper surface 58.
As shown in the top view of FIG. 8, another channel 64 is formed in the outer surface 38 of wall member 36 and extends in a substantially vertical direction. Channel 64 communicates with channel 60 via channel 68, which extends substantially orthogonal to channel 60 and is formed in top edge 58 of wall member 36. Thus, a power cord associated with light string 62 may be received within channels 68 and 64 for connection to an external power supply.
As noted above, the closed continuous wall of concrete form 10 may be alternatively mounted on a pre-existing concrete surface; i.e., rather than forming an opening in a new concrete surface, the opening may be partially defined by the pre-existing layer of concrete, with the new concrete surface 14 being formed on top of the pre-existing layer of concrete.
Concrete form 10 may be used by swimming pool companies, concrete companies, home builders, private homeowners or any other person or people laying a concrete surface to form a decorative opening in that concrete surface. Form 10 may be provided in a wide variety of shapes, such as the exemplary dolphin of FIGS. 1-3, with the user selecting a particular desired shape, or may be provided to the user as a variety of wall members, such as wall members 22, 24, 26, 28, 30, 32, 34 and 36, having a variety of differing contours (linear, arcuate, etc.), with the user assembling the wall members into a closed shape having a customized desired contour.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.

Claims

1. A concrete form, comprising:

a plurality of wall members;

means for joining the wall members together to form a closed continuous wall having a user-selectable shape; and

means for attaching the wall members to the ground;

whereby, following formation of the closed continuous wall, the user may pour concrete on the ground surrounding the closed continuous wall to form a concrete surface having an opening formed therethrough having the user-selectable shape.

2. The concrete form as recited in claim 1, wherein each of the wall members has a channel defined in a top edge thereof in order to form a continuous channel in the closed continuous wall, the continuous channel being adapted for receiving a light string.

3. The concrete form as recited in claim 1, wherein said means for joining the wall members together comprises:

a plurality of connector plates; and

means for joining each of the connector plates to a pair of adjoining ones of said plurality of wall members.

4. The concrete form as recited in claim 3, wherein said means for joining each of said connector plates to a pair of adjoining ones of said plurality of wall members comprises at least one pair of threaded connectors, the threaded connectors being received through at least one pair of openings formed through each of said connector plates and at least one pair of openings formed through adjacent ends of the pair of adjoining ones of said plurality of wall members.

5. The concrete form as recited in claim 3, wherein said means for joining each of said connector plates to a pair of adjoining ones of said plurality of wall members comprises a projecting member formed on one side edge of one of the pair of adjoining ones of said plurality of wall members, the projecting member being received within a recess formed in an adjacent side edge of the other of the pair of adjoining ones of said plurality of wall members.

6. The concrete form as recited in claim 1, wherein said means for attaching the wall members to the ground comprises:

at least one stake-receiving loop mounted to an interior surface of each of said plurality of wall members; and

a plurality of stakes, each of the stakes being received by a respective one of said stake-receiving loops, each of the stakes having a lower end adapted for insertion into the ground.

7. The concrete form as recited in claim 6, further comprising means for adjustably positioning each said stake with respect to a corresponding one of said stake-receiving loops.

8. The concrete form as recited in claim 7, wherein said means for adjustably positioning each of said stakes with respect to the corresponding one of said stake-receiving loops comprises a locking pin removably received through at least one aperture formed through each said stake and an opening formed through the corresponding one of said stake-receiving loops.

9. The concrete form as recited in claim 1, wherein each of the wall members has a channel defined in a top edge thereof in order to form a continuous channel in the closed continuous wall, the continuous channel being adapted for receiving a light string, the concrete form further comprising at least one cap member releasably and removably covering the channel formed in each said wall member.

10. The concrete form as recited in claim 9, wherein each said wall member has a pair of grooves formed therein, each of the grooves being formed on either side of the channel formed therein, each of the grooves extending in a direction substantially parallel to the channel.

11. The concrete form as recited in claim 10, wherein said at least one cap member includes a pair of downwardly-extending flanges releasably received within the pair of grooves of each of said wall members.

12. The concrete form as recited in claim 1, wherein each of the wall members has a channel defined in a top edge thereof in order to form a continuous channel in the closed continuous wall, the continuous channel being adapted for receiving a light string, wherein each of said wall members has a horizontal channel formed in the top edge thereof, the horizontal channel communicating with the continuous channel formed therein, the horizontal channel being adapted for receiving a power cord attached to the light string.

13. The concrete form as recited in claim 12, wherein each of said wall members has a vertical channel formed in a sidewall thereof, the vertical channel being in communication with the horizontal channel, the vertical channel being adapted for receiving the power cord attached to the light string.

14. A method of shaping concrete, comprising the steps of:

connecting a plurality of wall members together to form a closed continuous wall;

fastening the plurality of wall members to the ground;

pouring concrete on the ground surrounding the closed continuous wall to form a concrete surface about the closed continuous wall; and

hardening the concrete.

15. The method of shaping concrete as recited in claim 14, further comprising the step of removing the closed continuous wall following said step of hardening the concrete.

16. The method of shaping concrete as recited in claim 14, wherein said closed continuous wall has a top edge having a continuous channel defined therein, the method further comprising the step of placing a light string within the continuous channel.