Static structures (e.g. – buildings) – Module or panel having discrete edgewise or face-to-face... – Z- or u-strips – aligned flanges forming major faces
Reexamination Certificate
2002-04-01
2003-10-14
Ramirez, Ramon O. (Department: 3632)
Static structures (e.g., buildings)
Module or panel having discrete edgewise or face-to-face...
Z- or u-strips, aligned flanges forming major faces
C052S414000, C052S742140
Reexamination Certificate
active
06631599
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to cast-in features in concrete and related precast panels, and more particularly to an insert integrally-cast into a precast panel to allow decorative attachments to be affixed thereto, thereby improving the architectural attributes of the panel.
Precast construction of concrete wall panels for tilt-up and other types of construction is well-known in the art. In the tilt-up approach, forms, also known as form liners, are placed on a flat casting surface in the shape and dimension of the desired panel and filled with concrete. When the concrete cures, the forms may be removed, and the panel tilted up into a preferred, typically vertical, orientation, where it can be joined to structural frames or other panels. Additional structural reinforcements, such as rebar, can be placed within the form prior to pouring the concrete.
The present inventor has recognized a need for an insert that is inexpensive to manufacture and integrate into precast panels. An additional need exists for such an insert that can easily accept myriad attachments with minimal installation effort, yet secure enough to prevent the attachment from becoming decoupled once locked into place.
SUMMARY OF THE INVENTION
The need is met by the present invention, which comprises a panel insert used to provide connections in precast wall panels (generally) and tilt-up wall panels (specifically) such that attachments can be easily connected to the panel either prior to or once the panel is put in place. As used herein, a precast panel includes any panel that is formed from a cast material that upon curing hardens up, thereby allowing the panel to be subsequently placed in a desired location within a building structure. A tilt-up panel is a particular type of precast panel that is formed on a horizontal surface and tilted up into place upon curing of the cast material. The panel insert can take on many forms, including a long, continuous construction that can extend longitudinally substantially the entire length of a panel surface, or discrete, segmented pockets that can be easily integrated into a predetermined position within the panel. The degree of connection permanence between the insert and the attachment can be determined by the construction of the panel insert, specifically the attachment securing chamber portion of the insert. For example, a tapered attachment securing chamber geometry could permit a secure locking fit between the insert and the attachment, but still allow a slidable, non-permanent connection therebetween. Alternatively, a more permanent locking snap-fit could be effected by utilizing complementary engaging structures on the contacts between the attachment and the insert, and pressing the two of them together. The attachments, which are preferably used to present architectural and related decorative indicia, could also be utilitarian, as discussed below.
According to a first embodiment of the present invention, an insert configured to be integrally formed into a precast panel is disclosed. The insert defines a portion of the panel outer face, and serves as a place on the panel outer surface to which decorative and other attachments may be connected. The insert comprises a unitary structure made up of a pair of generally planar and laterally-spaced flanges defining an opening therebetween and an attachment securing chamber in connection with the flanges. In the present context, a structure is considered “unitary” when it is of one-piece construction. By way of example, a one-piece molded or extruded plastic component would be considered to exhibit unitary construction. In the present embodiment, the opening is disposed in the surface that is at least partially defined by the flanges such that the opening and the attachment securing chamber together define a channel in the outer face of the panel insert. This channel may possess a short, discrete longitudinal dimension, or may form the entire length of the insert. Attachments may subsequently be connected into one or more channels of the attachment securing chambers in the panel insert.
Optionally, the channel further comprises at least one attachment retention member. Additionally, the attachment securing chamber may comprise a pair of laterally-spaced sidewalls joined by a common base. In addition, the attachment retention member can be configured to form either a slidably engageable or frictional connection with the attachment. Thus, the insertion of an attachment into the channel of the attachment securing chamber could be effected by not only a frictional pressing into place of the former to the latter, such as by a snap-fit, but also by a longitudinally slidable engagement. Moreover, the attachment retention member, which is used to ensure that the attachment and channel will maintain their connectivity once they engage, can take on many forms. For example, it can be made up of numerous prismatic retention members disposed on at least one surface of the attachment securing chamber such that the plurality of prismatic retention members are configured to engage a complementary surface of the attachment. Prismatic retention members could be triangular, saw-tooth or trapezoidal in shape, for example. Preferably, but not necessarily, the relationship between the prismatic retention members and a complementary pattern in the decorative attachment is such that a permanent lock can be formed. In the present context, a locking arrangement is considered “permanent” where the connection between two members is such that they cannot be separated without severely curtailing or disabling their subsequent connective properties. In this configuration, a male-female connection could be effected by a snap-fit insertion of the prismatic retention members into the attachment securing chamber, where the prismatic retention members would resist separation from the complementary engaging surface of the attachment securing chamber once joined.
The attachment retention member can also be individual detents, or protrusions, emanating from one or more surfaces of the attachment securing chamber, or can be defined by a narrowness in the opening relative to the dimensions of the channel underneath. The latter can be achieved, for example, by a trapezoidal construction within the attachment securing chamber where the channel walls diverge in a direction going into the channel from the opening. This has the effect of having the sidewall of the inner surface of the attachment securing chamber being the retention member. Complementary shapes on an engaging member of the attachment (such as a detent) can then be slidably placed such that a secure connection is formed. The plurality of generally planar flanges can be configured such that they are substantially coplanar with each other, or where they are canted relative to each other. The insert may also include at least one inwardly-projecting spine extending from the attachment securing chamber or the generally planar flanges, in the latter case either by being laterally connected to the outer edge of the flange or somewhere off the inward-facing surface of the flange. This spine can be used to further engage the insert and the precast panel, and may further include a plurality of apertures therein to promote such engagement. Multiple such spines may be used to effect even more secure engagement.
According to another embodiment of the present invention, a panel insert is disclosed. The panel insert includes at least one each of an attachment securing chamber and a panel securing chamber, both defined by a pair of laterally-spaced sidewalls joined by a common base. The panel additionally includes a plurality of generally planar flanges laterally disposed relative to the chambers. The. panel securing chambers are coupled to the interior of the precast layer, as the panel material (such as concrete) can flow into the interstitial cavities defined by the panel securing chambers. Upon material hardening, a secure anchor is formed between them.
Optionally, the cham
Fukuvi USA, Inc.
Killworth, Gottman Hagan & Schaeff LLP
Ramirez Ramon O.
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