Brace for retaining panels during cement distribution

Abstract

A brace for temporarily retaining a first panel and a second panel in abutting contact with a respective support member for each panel has two brace members, breakable end portions, removable brackets connectable to the end portions thereof, and a retaining members engageable in retaining apertures proximal disposed between the end portions and proximal thereto. The brace members are extended between the opposing panels, with the support members being placed in the brackets. The retaining member is inserted into each retaining member until each panel is held with the inner face abutting the retaining member and the outer face abutting the support member in the bracket. After application of the cementitious material, the breakable portions, brackets, and support member may be removed by breaking off the breakable end portions by application of a force thereto.

Description

FIELD OF THE INVENTION

The present invention is related to braces for retaining panels, and is more particularly directed to a brace for retaining panels while a cementitious material is distributed therebetween.

BACKGROUND OF THE INVENTION

It is well known in the art to use to use braces for retaining panels while a liquid cementitious structure is distributed therebetween to bond the panels together to form a single structure or to form a cementitious structure between the panels which are then removed when the cementitious material has solidified. For example, U.S. Pat. No. 4,085,495 issued to Hebert on Apr. 25, 1978 and U.S. Pat. No. 3,730,476 issued to Prichard Jr. on May 1, 1973 teach braces and methods therefor in which braces are used to maintain panels spaced apart against support members, held in brackets of the braces, while the cementitious material is distributed therebetween. The panels typically have a plurality of apertures where braces are extended between the panels and are attached to the support members extending across the outer surfaces of the panels which are retained in abutment thereagainst by retaining members wedged against inner faces of the panels, nails, or the like, and by the brackets, disposed on the outer face of the panels. As the panels are retained against the support members, which are spaced part from one another, the panels are retained spaced a part allowing the cementitious material to be distributed therethrough. After the cementitious material has solidified, the support members may be removed, often by breaking parts of the brace connecting the support member to the panel or by removing such parts.

Unfortunately, such braces often require large numbers of holes to be placed in the panels, which must often be covered after removal of the support members. Further, placement of the support members in brackets and removal of the brackets can be cumbersome. Additionally, parts of the brace may remain protruding from the outer face of the panels after removal of the supporting members.

Accordingly, there is a need for an improved brace for retaining panels on support members while a cementitious material is distributed therebetween.

SUMMARY OF THE INVENTION

It is therefore a general object of the present invention to provide an improved for an improved brace for retaining panels on support members while a cementitious material is distributed therebetween.

An advantage of the present invention is that the braces may be easily installed against the panels and support members.

Another advantage of the present invention is that brackets of the brace, which retain the support members and the panels against one another, are easily connected and removed from the remainder of the braces.

A further advantage of the present invention is that, after distribution of the cementitious material, the support members and brackets may be easily removed without leaving a portion of the brace extending outside of the panels.

Still another advantage of the present invention is that the braces may retain support members against adjacent sets of panels.

Another advantage of the present invention is that the brace extends completely around the support member.

Still another advantage is that the invention permits mounting and forming of cement filled architectural structures.

According to a first aspect of the present invention, there is provided a brace for temporarily retaining a first panel and a second panel in abutting contact with a respective support member for each panel on an outer face of the panel while a cementitious material is distributed between respective inner faces of the panels, the brace comprising:

• • first and second brace members each having respective longitudinally opposed first and second ends, first and second respective breakable portions disposed respectively proximal the first and second ends, the breakable portions being breakable by application of a force thereto, first and second respective end portions extending respectively from the first and second breakable portions to the first and second ends, and first and second retaining members disposed respectively between the first and second breakable portions and proximal thereto;
  • first and second brackets connected to, respectively, the first and the second ends, wherein the brace members extend between the panels with the first and second ends thereof disposed respectively proximal the first and second panels with the retaining members abutting against the respective inner faces of the brackets and the support members abutting against the brackets and the outer faces of the panels with each breakable portion disposed between the respective inner face and outer face of the panel for breakage thereat and subsequent removal of the end portion, bracket, and support member after the cementitious material has been distributed.

Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, in which similar references used in different Figures denote similar components, wherein:

FIG. 1 is a front perspective view showing an embodiment for retaining panels spaced apart for distribution of a cementitious material therebetween, in accordance with an embodiment of the invention.

FIG. 2 is an enlarged view of the brace shown in FIG. 1;

FIG. 3 is a top plan view of the brace shown in FIG. 1; and

FIG. 4 is a side plan view of the brace shown in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the annexed drawings the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.

Referring now to FIGS. 1 to 4, there is schematically shown an embodiment of a brace, shown generally as 10, for retaining first and second opposing panels 12a, 12b spaced apart and with outer faces 20 thereof against, e.g. in abutting contact with, respective support members 14 therefor while a cementitious material 16 is distributed between respective inner faces 18 of the panels 12. As best shown in FIG. 1, a plurality of braces 10 may also be deployed to retain sets 22a, 22b of vertically superposed or stacked opposing panels 12a, 12b against support members 12. In such case, the opposing panels 12a, 12b of the sets 22a, 22b are, preferably but not compulsorily, aligned with horizontal ends 24 thereof generally in vertical alignment with one another and vertical ends 26 thereof in horizontal alignment with one another and each support member 14 and braces 10 are positioned extending over the adjacent vertical ends 26 of horizontally adjacent panels 12. In such configurations, opposing panels 12a, 12b disposed vertically intermediate have a brace 10 extending therebetween. The panels 12 may be of any material conventionally used for forming structures with cementitious material, including wood, metal, brick, plastic, ceramic, cement or the like. The cementitious material 16 may be cement, concrete, or any other material typically used for distribution, for example pouring, in liquid from and then solidifying to form a hardened structure. The panels 12 are, preferably, bonded to one another with the cementitious material 16 to form a unitary structure therewith, such as a wall, panel or the like. Alternatively, the panels 12 may be removed after the cementitious material has solidified, in which case the panels 12 serve as a temporary mould for the cementitious material 16.

As shown, each brace 10 has two, i.e. first and second, longitudinal brace members, respectively 30a, 30b which are configured, i.e. sized and shaped, to longitudinally extend or traverse across a predetermined space D between the panels 12a, 12b, and specifically between the opposing respective inner faces 18 thereof. Each brace member 30 has respective longitudinally opposed first and second ends, respectively 32a, 32b, between which respective first and second side edges 40 extend, with first and second, preferably planar and flat member surfaces 42a, 42b extending longitudinally between the first and second side edges 40 and first and second ends. Accordingly, the brace members 30 are, preferably, substantially flat.

First and second ends breakable portions 34a, 34b are situated proximal to, respectively, the first and second ends 32a, 32b, each breakable portion 34 being formed and defined by pairs of break indentations 44 which extending inwardly toward one another from, respectively the first and second longitudinal side edges 40 at a common, i.e. identical, predetermined longitudinal position relative the ends 32. The first and second breakable portions 34a, 34b and the first and second ends 32a, 32b, respectively define first and second removable end portions 36a, 36b extending therebetween for each brace member 30 and which may be removed by breaking the breakable portion 34. For each brace 10, the brace members 30 are preferably identical. Each brace member 30 also has first and second longitudinal retaining member apertures or slots 54a, 54b disposed between the breakable portions 34a, 34b situated, respectively, proximal the first and second breakable portions 34a, 34b. The retaining slots 54 receive generally triangularly wedge shaped retaining members 54, which are inserted therein for abutment against the inner faces 18 of the panels 12. The break indentations 44, preferably triangular in shape, are defined by respective first and second tapered portions 46 in the side edges 40 tapering inwardly towards each other and intersecting each other at a common longitudinal position, along which optional perforations, not shown, may be disposed. The break indentations 44 weaken the brace members 30 and enable breakage of the brace members 30 at the breakable portions 34, notably at the common longitudinal position, by application of a force thereto, for example by striking the brace 10 in proximity to the ends 32 with a mallet or hammer.

The first and second end portions 36a, 36b have, respectively, longitudinal first and second bracket apertures or slots 58a, 58b for the brace member 30 disposed thereon and are configured, e.g. sized and shaped, for connecting preferably identical brackets 50a, 50b to the brace members 30. The bracket first bracket slot 58a and second bracket slot 58b of the first brace member 30a are preferably aligned with the first bracket slot 58a, 58b of the second brace member 30b, i.e. at the same position on relative the ends 32a, 32b. The retaining slots 54a, 54b are the brace member 30a, 30b are, preferably, aligned with one another in the same way. The brackets 50a, 50b are of similar shape to the support member 12 and are configured for receiving the support members 14 and retaining them in abutment against the respective outer faces 20 of the panels 12, i.e. with at least a portion of a proximal surface 62 of the support member 14 positioned proximally adjacent the outer face 20 and abutting therewith. The remaining portion of the support member, extending away from the adjacent surface 62 is embraced, preferably abuttingly, by the bracket 50.

More specifically, and as shown, each bracket 50 is preferably U-shaped and has a bracket plate 66 extending between first and second bracket side arms, respectively 68a and 68b, connected thereto and extending radially therefrom to first and second bracket ends, respectively 74a, 74b. The bracket arms 68a, 68b have, respectively, first and second bracket fingers 60a, 60b at bracket ends 74a, 74b for releasable insertion into the bracket slots 58a, 58b to removably connect the brackets 50 to the brace members 30 at the end portions 36a, 36b. When the panels 12 are held in place, spaced apart from each other at distance D, by the braces 10, the bracket plate 66 of each bracket 30 abuts against a distal portion or surface 64 of the support member 14, situated distal the outer face 20 and generally opposite the proximal surface 62, and the proximal surface 62 abuts the outer face 20, with the arms 68 extending from the bracket plate 68 to the end portions 36 and connected thereto by the bracket fingers 60 in the bracket slots 58. Thus, the first bracket 30a is connected to the first end portions 34a of the brace members 30, with the fingers 60 thereof engaged in the first bracket slots 54a. Similarly, the second bracket 30b is connected to the second end portions 34b of the brace members 30, with the fingers 60 thereof engaged in the second bracket slots 54b. At the same time, each panel 12 is held against the proximal surface 62 by the retaining members 52 inserted into the retaining slots 54 and in abutment against inner faces 18. Thus, the panels 12 are retained spaced apart from each other, at distance D for distribution of the cementitious material 16 therebetween. When the cementitious material 16 has hardened or solidified, a force may be applied to the brackets 50, for example by striking the brackets 50 with a hammer or the like, which causes the breakable portions 34a, 34b to break, thus allowing the end portions 36, brackets 50, and support members 14 to be easily removed.

The brace members 30 are further configured, i.e. sized in terms of the distance between the breakable portions 34, such that the breakable portions 34 are disposed between the inner and outer faces 18, 20 when the panels 12 are retained by brackets 50 and retaining members 52 as described above. Thus, when the brackets 50 and end portions 36 are removed, the breakable portions 34 are disposed between the inner and outer faces 18, 20, which allows for application of the cementitious material or grout between the panel 12 and a structure vertically adjacent thereto, such as a vertically adjacent panel 12, to cover the breakable portion 34.

To provide additional support and stabilization of the support member 14, each bracket 50 is provided with a retaining screw 76 and screw aperture 78 therefor, preferably disposed on the bracket plate 66. The retaining screw 76, preferably threaded, is screwed through the screw aperture 78, also preferably threaded, into the support member to facilitate retention of the support member 14 in abutment with the bracket 50, notably the plate thereof. Further, the retaining screw 76, when screwed through the aperture 78 into the support member 14 prevents axial displacement, for example sliding or slippage, of the support member 14 in the bracket 50.

To further stabilize the support member 14, the bracket arms 68 are configured, e.g. sized and shaped, to extend abuttingly against abut against at least a portion of member side surfaces 72 which extend between proximal and distal surfaces 62, 64 when the support member 14 is seated in the bracket 30, as described above, with the bracket fingers 60 inserted into the slots 58. To provide space for the ends 32 when the fingers 60 are inserted into the bracket slots 58, each side arm 68 is formed of a side plate 80 extending from a respective intersecting edge 82, a recessed portion 84 extending from the side plate 82, and a finger portion 86 extending from the recessed portion 84 to the bracket end 74, i.e. a free side arm end 74 for each side arm 68. The recessed portion 84 is recessed relative the finger portion 86 and the side plate 80 and forms a side arm recess 88 for receiving the end 32 therein when the finger 84 is inserted into the bracket slot 58. As the recessed portion 84 is recessed relative the finger portion 86 and the bracket end 74, the finger portion 86 protrudes therefrom and forms the finger 60. More specifically, each finger 60 has a preferably straight end, i.e. the free end 74, and an inwardly tapering edge 90, adjacent the plate recess 88, tapering inwardly towards the side plate 80. Advantageously, the tapering finger edge 90 allows vertical sliding or wedging of the finger 60 into the bracket slot 58 for facilitating connection of the bracket 50 to the brace members 30. Optionally, the bracket arms 68 may be resilient or resiliently connected to the bracket plates 66 at the intersecting edges 82. In such case, the arms 68 may be resiliently bent or biased inwardly when the bracket 50 during connection to the end portions 36, by insertion of the fingers 60 into the slots 58, to bring the bracket arms 68 into abutment with at least a portion, e.g. the member side surface 72, of the supporting member 14.

Each retaining member 52 is, preferably triangularly, wedge shaped with an angled inner side 91 which extends angularly away from a, preferably straight, outer side 92, with planar member surfaces 94 extending therebetween. The retaining slots 54 are defined by longitudinally opposed inner and outer slot ends, respectively 96a, 96b, and slot side edges 98 of the end portion 36 extending therebetween. The retaining members 52 and slots 54 are configured, e.g. sized, for insertion of the retaining member 52 therein with the angled side 91 facing towards the inner slot ends 96a and the outer side 92 facing towards the inner face 20 of the panel 12, with the member surfaces 94 in abutting contact with the slot side edges 98. Once introduced, i.e. initially inserted into the slot 54, the retaining member 52 is forced, by application of a force thereto, further into the slot 54 to force the angled side 91 into sliding abutting contact with the inner slot end 96a and the straight outer side 92 into abutting contact with the inner face 18.

As one skilled in the art will readily understand, the outwardly angled inner side 91 will force the outer straight side 92 further and further towards the inner face 18 as the member 52 is forced further into the retaining slot 54 until at least a portion of outer side 92 abuts against the inner face 18 and the inner side abuts against the inner slot end 96a. In turn, as the retaining member 52 is forced still further into the retaining slot 54, the retaining member 52, abutting against the inner face 18 and inner slot end 96a forces the panel 12 towards the support member 14 and the support member 14 further into the bracket 18 until the support member 14 is seated in the bracket 30 with the proximal surface 62 abutting against the outer face 20 and the distal surface 64 abutting against the bracket plate 66, at which point the panel 12 is abuttingly retained against with support member 14. By repeating this process with both panels 12a, 12b, the panels 12 are retained spaced apart from one another and the cementitious material 16 may be applied.

To ensure that the retaining member 52 is retained in the retaining slot 54, one or more of the member surfaces 94 may have spaced apart teeth or ridges 100 disposed thereon, preferably extending proximally adjacently the outer side 92. The teeth 100 grippingly and abuttingly engage the side edge 98 as the retaining member 52 is inserted into the retaining slot 54 for retaining the member 52 therein. Typically, the member 52 is left in the slot 54 once the cementitious material 16 is applied. To facilitate deployment of reinforcement members 102, well known in the art, between the panels 12, the brace members 30 have indented notches 104 disposed between the breakable portions 34 for receiving cables 106 which are used for tying or otherwise securing the reinforcement members 102 in place. The cable 106 is typically pulled tight through the indented notches 104 during securing of the reinforcement members 102 therewith. As the cable 106 is pulled tightly through the notches 104, slippage or other displacement of the cable 106 and reinforcement member 102, relative the brace members 30, is impeded.

With regard to relative spacing and dimensions of the brace members 30 and brackets 50, the size of the brace 10 will vary based on the desired distance D between the panels 12, the thickness of the panels 12, and the size of the support members 14. Generally speaking, the retaining member slots 34a, 34b of each brace member are spaced apart relative one another such that the distance D extends between a portion of retaining slot 34a and a portion of retaining slot 34b. The bracket slots 58 are positioned on the brace member 30 and the brackets 50 are configured, i.e. sized and shaped, such that when the supporting member 14 is placed in the bracket 30 and the retaining members 32 are inserted against the inner faces 18 with the inner faces spaced apart at distance D, the adjacent support member 14 abuts against the outer face 20 and the bracket plate 66. The breakable portions 34a, 34b are spaced apart relative one another such that they are situated intermediate the inner and outer faces 20 when the support members 14 held in the brackets 30 abutting the outer faces 20 with the retaining members 52 in the retaining slots 54 and abutting against the inner faces 18. The brace members 30, brackets 50, and retaining members 52 are constructed of a rigid material, such as metal or rigid plastic. However, portions of the brackets 18, e.g. the bracket arms 68 may be constructed of a resilient material where desired.

In use, the brace 10 is typically deployed by placing panel 12 with the outer face 20 against the support member 14, which is preferably already anchored to a supporting base, such as the ground or cement structure, which maintains the supporting members 14 spaced apart from one another. The brace members 30 are then laid across the top horizontal ends 26 of the first and second panels 12, with the retaining aperture extending over the edge of the inner face 20. The brackets 30 are placed around the supporting members 14 and connected to the end portions 32, as described above. The retaining members 52 are then inserted into the retaining slots 54, as described above, until the panel 12 is held abuttingly against the support member 14 on the outer face and the retaining member 52 on the inner face 20 and the breakable portions 34 situated between the inner and outer faces 18, 20. Thus, the panel 12 is sandwiched in between the members 14, 52. The retaining screw is then screwed into the bracket 50 and retaining member. Once the panels 12 are connected by the brace 10, the cementitious material 16 is applied. When the cementitious material has solidified, a force is applied, for example by striking the brackets 30, to cause the breakable portions 34 to break and the brackets 50, end portions 36, and support members 14 are removed. Additional cementitious material 16 or grout may then be applied to cover the breakable portion 34.

Although the present invention has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed.

Claims

1. A brace for temporarily retaining a first panel and a second panel in abutting contact with a respective support member for each panel on an outer face of the panel while a cementitious material is distributed between respective inner faces of the panels, the brace comprising:

first and second brace members each having respective longitudinally opposed first and second ends, first and second respective breakable portions disposed respectively proximal said first and second ends, said breakable portions being breakable by application of a force thereto, first and second respective end portions extending respectively from said first and second breakable portions to said first and second ends, and first and second retaining members disposed respectively between said first and second breakable portions and proximal thereto;

first and second brackets connected to, respectively, said first and said second ends, wherein said brace members extend between the panels with the first and second ends thereof disposed respectively proximal the first and second panels with said retaining members abutting against the respective inner faces of the brackets and the support members abutting against the brackets and the outer faces of the panels with each breakable portion disposed between the respective inner face and outer face of the panel for breakage thereat and subsequent removal of the end portion, bracket, and support member after the cementitious material has been distributed.

2. The brace of claim 1, wherein said brace members have first and second longitudinal side edges extending from said first end to said second end and first and second planar surfaces extending longitudinally from said first and second ends and laterally between first and second side edges.

3. The brace of claim 1, wherein said brace members have first and second longitudinal side edges extending from said first end to said second end, each said breakable portion being defined by respective first and second indentations therefor extending inwardly toward another one from said first and second longitudinal side edges at a common predetermined longitudinal position therefor on said brace member.

4. The brace of claim 3, wherein said respective first and second indentations for each breakable portion are defined by respective first and second tapered portions tapering inwardly towards each other and intersecting each other.

5. The brace of claim 1, wherein each respective bracket and the support member are of similar shape, said respective bracket being configured for retaining the support member in abutment against the respective outer face along at least a portion of an proximal surface of the support member extending proximally adjacent the respective outer face and abuttingly embracing a remaining portion of the supporting member extending away from the adjacent surface.

6. The brace of claim 1, wherein each respective bracket and the support member are of similar shape, said respective bracket being configured for abutting a distal surface of the supporting member situated distal the respective outer face with a proximal surface of the supporting member extending adjacently proximal the outer face in abutment therewith.

7. The brace of claim 1, wherein said brace comprises, for each bracket, a retaining screw and a respective screw aperture disposed on said bracket, said retaining screw being screwed through said retaining screw aperture and into the support member with the support member abutting against the outer face.

8. The brace of claim 7, wherein each bracket has a respective bracket plate, said respective bracket plate abutting against a distal surface of the support member with a proximal surface of the support member, situated opposite the distal surface and proximal the outer face, abutting against the outer face, the retaining aperture and said retaining screw being disposed on the bracket plate.

9. The brace of claim 1, wherein said first and second brackets each comprise a respective bracket plate and first and second respective bracket side arms connected thereto, the bracket plate extending between said side arms, said respective first and second side arms of said first bracket being connected to said first end portions and said respective first and second side arms of said second bracket being connectable to said second end portions with said bracket plate abutting against the support member and the support member abutting against the outer face.

10. The brace of claim 9, wherein said respective bracket plate abuts against a distal surface of the support member with a proximal surface of the support member, situated opposite the distal surface and proximal the outer face, abutting against the outer face, said side arms abutting against at least a portion of member side surfaces extending between said proximal surface and said distal surface.

11. The brace of claim 1, wherein said first and second brackets are releasably connectable to, respectively, said respective first and second end portions.

12. The brace of claim 11, wherein said first and second end portions each comprise respective bracket slots, said respective bracket slot of each first end being aligned with one another and said respective bracket slot of each second end being aligned with one another, and each bracket comprises bracket fingers sized and shaped for insertion into the bracket slots to removably connect the first and second brackets to, respectively, said first and second end portions.

13. The brace of claim 12, wherein said first and second brackets each comprise respective a respective bracket plate and first and second bracket side arms connected thereto and extending radially therefrom with the bracket plate extending therebetween, said side arms being connectable to said first and second end portions with said end plate abutting against the support member and the support member abutting against the outer face, said respective bracket fingers being disposed on said side arms, one said bracket finger for each side arm.

14. The brace of claim 13, wherein each side arm comprises a side plate extending from a respective intersecting edge of the end plate, a recessed portion extending from the side plate, and a finger portion extending from the recessed portion to a respective bracket end, the recessed portion being recessed relative the finger portion and the side plate and forming a side arm recess intermediate said finger portion and side plate for seating of the end of the brace member therein when the bracket finger is inserted into said bracket slot therefor.

15. The brace of claim 14, wherein each side arm is resiliently connected to said bracket plate such that said side arm may be bent inwardly during insertion of the bracket fingers into the bracket slots to bring the side arms into at least partial abutment with the supporting member.

16. The brace of claim 13, wherein said fingers have an inwardly tapering inner edge tapering inwardly towards said side plate.

17. The brace of claim 1, wherein said end portions comprise retaining apertures for receiving said retaining members, said retaining members being removably insertable into said retaining member apertures to abut with said inner faces.

18. The brace of claim 17, wherein said retaining member is wedge shaped with an angled inner side extending outwardly away from an outer side thereof, each retaining member and retaining member aperture being configured for insertion of said retaining member into said retaining member aperture with the outer side extending adjacent the inner face and the inner side extending angularly away therefrom, the inner side coming into contact with an inner slot end of the aperture as said retaining member is inserted and forcing the outer side into abutment with the inner face.

19. The brace of claim 17, wherein said retaining member is wedge shaped with an angled inner side extending outwardly away from an outer side thereof and member surfaces extending between the two sides, at least one member surface having ridges disposed thereon for grippingly abutting a side edge of the retaining slot when the retaining member is inserted therein to retain the retaining member in the retaining slot.