Frangible concrete insert clip

Abstract

A frangible clip and method for embedding a concrete insert into a concrete structure. The clip may include at least one frangible member which shears from a base member when a sufficient shearing force is applied. The clip may be formed of plastic as an integrally formed, single unit.

Description

This application claims the benefit of U.S. provisional application U.S. Ser. No. 60/519,739, entitled “Frangible Concrete Insert Clip” and filed Nov. 13, 2003, the entire contents of which are hereby expressly incorporated by this reference.

RELATED FIELDS

The present invention relates to frangible clips and methods for embedding concrete inserts into concrete structures.

BACKGROUND

When forming concrete slabs, including floors, walls and ceilings, it is often desirable to embed one or more inserts in the concrete. The concrete inserts may be various shapes and sizes useful for a variety of purposes.

Concrete inserts may be formed from a variety of materials, such as steel, iron, fiberglass, fiberglass reinforced plastics or other suitable materials. The inserts may also include various finishes. Suitable concrete inserts are available from Unistrut Corporation of Wayne, Mich. and Anvil International, Inc. of Portsmouth, N.H. These inserts may be “continuous” inserts, “spot” inserts or any other desired type of insert.

Continuous inserts may include one or more channels that, when properly installed, create recesses in the surface of the poured concrete. The channels may be used for any desired and/or suitable application, including securing other structures to the insert through the use of a channel nut or other appropriate device. The channels may also be useful for running wire or other similar items along the length of the channel.

Spot inserts may be used as an anchor or attachment point for a variety of structures. Spot inserts may include threaded rods extending from the concrete slab such that a suitable and/or desired structure can be bolted or otherwise secured to the concrete slab. Spot inserts may also be used as anchor points for structures such as sprinkler systems or hangers for pipes, wires or other items.

Continuous and spot inserts may be installed in any desired location, including concrete floors, ceilings and walls. Typically, concrete structures, such as walls, are formed by first erecting a concrete form. Then concrete is poured into the form and allowed to cure. After the concrete has sufficiently cured, the form is removed, exposing the concrete wall. The concrete forms used in this process are preferably suited for quick erection and removal. Typically, concrete forms are constructed from steel or wood.

Installation of concrete inserts into a wall is generally done by securing the insert to the concrete form such that the concrete envelops and surrounds the insert as it is poured into the form. Removable foam filler, or other appropriate materials, may be included in portions of the insert to prevent concrete from seeping into certain portions of the insert, such as a channel. The foam filler may be removed after removal of the concrete form.

There are a number of methods for securing the concrete insert to the form. Some previous inserts are secured directly to the concrete form. These inserts include apertures allowing them to be directly secured to the form by nails, screws or other appropriate fasteners. However, because the insert is secured directly to the form, it is difficult and time consuming to remove the concrete form. Alternatively, metal clips may be used to secure the concrete insert to the form. These clips include frangible portions that secure the insert to the form prior to and during concrete pouring. During removal of the form, the frangible portions of the clip shear off, leaving the remainder of the clip, along with the insert, embedded in the concrete wall. These metal clips may be undesirable. First, the metal clips may be relatively expensive and complicated to manufacture. The frangible portions of these clips are formed from separate components, increasing the complexity and expense associated with producing the clips. Second, because the previous clips are metal, the various components of the clips must be welded, formed and/or bent, also increasing the complexity and expense of production.

SUMMARY

Various embodiments of the present invention include a single piece plastic clip adapted to secure a concrete insert to a form wall prior to and during concrete pouring and curing. The plastic clip may include frangible portions, allowing the concrete form to be easily removed from the concrete wall. In some embodiments, the clip, because it is made of plastic, may be inexpensively and easily manufactured as a one-piece unit.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a concrete insert clip according to a first embodiment of the present invention in perspective view.

FIG. 2 shows a front view of the concrete insert clip shown in FIG. 1, the rear view being the same.

FIG. 3 shows a left side view of the concrete insert clip shown in FIG. 1, the right side view being the same.

FIG. 4 shows a top view of the concrete insert clip shown in FIG. 1.

FIG. 5 shows a cross-section front view of the concrete insert clip shown in FIG. 1, the cross-section rear view being the same.

FIG. 6 shows the concrete insert clip of FIG. 1, a concrete insert and a concrete form wall prior to securing the insert onto the wall.

FIG. 7 shows the insert of FIG. 6 secured to the form wall by the clip.

FIG. 8 shows a second form wall in addition to the clip, insert and wall of FIG. 7.

FIG. 9 shows the clip, insert and form walls of FIG. 8 after concrete has been poured into the form.

FIG. 10 shows the form walls of FIG. 9 partially removed from the poured concrete.

FIG. 11 shows the insert as well as the remaining portion of the clip embedded in the poured concrete.

DETAILED DESCRIPTION

FIG. 1 shows a concrete insert clip 10 according to a first embodiment of the present invention. In the embodiment shown in FIG. 1, clip 10 is formed from plastic in any suitable and/or desirable manner. For instance, clip 10 may be formed from injection molded polystyrene. Because clip 10 is formed from plastic, it can be manufactured as an integrally formed, single unit, rather than having multiple parts.

The clip 10 shown in FIG. 1 includes a base member 12 and two frangible members 14. Base member 12 may be formed with a recess 16 adapted to receive at least a portion of a concrete insert (such as the concrete insert 18 shown in FIGS. 6-11). Recess 16 may be formed in any suitable and/or desirable shape and size to receive and secure a wide variety of concrete inserts. Recess 16, however, is not limited to the size and shape illustrated in the figures.

Base member 12 may be formed with flange portions 30 on either side of the base member 12. Frangible members 14 may extend from flange portions 30.

Preferably, clip 10 includes at least two frangible members 14, although only one frangible member 14 is necessary. Clip 10 can also include more frangible members 14 secured to base member 12 if desired. Frangible members 14 may be separated from based member 12 by applying a shearing force.

As shown in FIG. 5, the proximal ends of frangible members 14 may be approximately co-planar with the mouth of recess 16. Because they are co-planar, in embodiments where clip 10 is used with an appropriately sized concrete insert, mounting the concrete insert and clip 10 to a concrete form may secure the insert flush against the form wall, such that there is not a gap between the insert and the wall.

Clip 10 may be formed in any desired and/or appropriate shape and size. In the embodiment shown in FIG. 1, clip 10 is approximately 2.4 inches (6.096 centimeters) in length, 3.75 inches (9.525 centimeters) in width, and 1.125 inches (2.8575 centimeters) in depth. The recess 16 shown in FIG. 1 is approximately 0.75 inches (1.905 centimeters) in length, 1.75 inches (4.445 centimeters) in width, and 1.125 inches (2.8575 centimeters) in depth. The recess 16 shown in FIG. 1 is of an appropriate size and shape to receive portions of a continuous strut concrete insert, such as the concrete insert 18 shown in FIGS. 6-11. The frangible members 14 shown in FIG. 1 are circular tubes that are approximately 1.5 inches (3.81 centimeters) in length and 0.3 inches (0.762 centimeters) in outer diameter.

In the embodiment shown in FIG. 5, frangible members 14 are hollow tubes. The hollow structures of frangible members 14 facilitate shearing from the remainder of clip 10 when sufficient shearing force is applied. The frangible members 14 may also be thinner than the other portions of clip 10 to facilitate shearing the frangible members 14. In the embodiment shown in FIG. 5, the frangible members 14 are approximately 0.1 inches (0.254 centimeters) thick while the other portions of clip 10 are approximately 0.125 inches (0.3175 centimeters) thick. However, it is not necessary that frangible members 14 be thinner that other portions of clip 10. In other embodiments, the thickness of the frangible members 14 and other portions of clip 10 are similar. In still other embodiments, points or lines of weakness may be included in frangible members 14 to aid in shearing.

In the embodiment shown in FIG. 5, frangible members 14 include pointed tips 20 that facilitate inserting clip 10 into concrete form walls or other desired structures. Tips 20, however, are not necessary. In other embodiments, clip 10 does not include tips 20. The ends of frangible members 14 may be formed in any desired shape and/or size. In some embodiments, the ends of frangible members 14 may include a number of resilient arms. During insertion of the frangible members 14 into holes formed in a form wall, the resilient arms may compress. However, once portions of resilient arms emerge on the other side of the form wall (or enter a suitable void), resilient arms may expand, locking clip 10 onto the form wall. Other structure may also be included on or used in conjunction with frangible members 14 to secure clip 10 to the form wall securely. In preferred embodiments, however, these structures are not necessary. Rather, the interaction of the frangible members 14 with the form wall is sufficient to secure clip 10, and consequently its associated concrete insert 18, to the concrete form.

FIGS. 6-11 show a clip 10 being used to embed a concrete insert 18 into a concrete wall 22. As shown in FIGS. 6-11, clip 10 is used to secure concrete insert 18 in a desired location on concrete form wall 24 prior to and during the pouring of concrete into the concrete form. In other embodiments of the present invention, clip 10 may be used to embed a concrete insert 18 into other concrete structures, not just walls.

FIG. 6 shows a concrete insert 18 positioned on a form 24. Form 24 includes an appropriate number of holes 26 in form wall 24, sized and located to receive the frangible members 14 of clip 10. Holes 26 may be of a size that snugly receive frangible members 14 to securely attach clip 10 to form 24. Holes 26 may be formed in any desired manner. In a preferred embodiment, holes 26 are formed by drilling into the form 24. In other embodiments, a plurality of holes 26 are pre-formed in the form 24, such that clip 10 may be installed in a number of different positions and/or orientations. In still other embodiments, holes 26 are not necessary. Rather, form wall 24 may be made of a material that allows frangible members 14 to penetrate as clip 10 is pressed against the form wall 24, securing clip 10 to the form wall 24.

As shown in FIG. 6, concrete insert 18 may be filled with a foam filler 28 or other suitable material before or after securing insert 18 to form wall 24. Foam filler 28 may prevent concrete from seeping into undesired portions of insert 18 during pouring and curing of the concrete. In other embodiments, foam filler 28 is not necessary. In some embodiments, end caps may be attached to concrete insert 18, before or after securing concrete insert 18 to form wall 24 to prevent undesired concrete seepage.

FIG. 7 shows the concrete insert 18 secured to the form wall 24 by clip 10. FIG. 8 shows the inclusion of a second form wall 24, the space between the form walls 24 defining a void for receiving concrete.

FIG. 9 shows poured concrete 22 surrounding and enveloping the clip 10 and associated concrete insert 18. Clip 10 may secure the concrete insert 18 in a desired location and orientation such that the pouring concrete does not dislodge or otherwise reposition insert 18 from the desired location and orientation.

FIG. 10 shows the form walls 24 partially removed from the sufficiently cured poured concrete 22. As shown in FIG. 10, the frangible members 14 of clip 10 are sheared from the remainder of clip 10 due to the application of shearing force by the removal of form wall 24.

FIG. 11 shows the concrete insert 18 as well as the remaining portions of clip 10 securely embedded in the poured concrete 22. As shown in FIG. 11, the foam filler 28 has been removed from the concrete insert 18 to allow the insert 18 to be used for its intended purpose.

Changes and modifications, additions and deletions may be made to the structures recited above and shown in the figures without departing from the scope or the spirit of the above description and below claims.

Claims

1. A clip for temporarily securing a concrete insert to a concrete form, comprising:

(a) a base member, the base member sized and shaped to receive at least one concrete insert;

(b) at least one frangible member extending from the base member;

(c) wherein the base member and the at least one frangible member are integrally formed;

(d) wherein applying a shearing force to at least one of the base member and the at least one frangible member separates the frangible member from the base member; and

(e) wherein the clip is plastic.

2. The clip for temporarily securing a concrete insert to a concrete form of claim 1, further comprising a second frangible member extending from the base member; wherein the base member and the second frangible member are integrally formed; and wherein applying a shearing force to at least one of the base member and the second frangible member separates the second frangible member from the base member.

3. The clip for temporarily securing a concrete insert to a concrete form of claim 2, wherein the base member comprises a recessed portion, the recessed portion sized and shaped to receive the at least one concrete insert.

4. The clip for temporarily securing a concrete insert to a concrete form of claim 3, wherein the base member further comprises flange portions disposed on sides of the recessed portion; wherein the frangible members extend from the flange portions.

5. The clip for temporarily securing a concrete insert to a concrete form of claim 4, wherein proximal ends of the frangible members are approximately co-planar with a mouth of the recessed portion.

6. The clip for temporarily securing a concrete insert to a concrete form of claim 3, wherein the recessed portion is sized and shaped to receive a portion of a continuous concrete insert.

7. The clip for temporarily securing a concrete insert to a concrete form of claim 3, wherein the recessed portion is sized and shaped to receive a portion of a spot concrete insert.

8. The clip for temporarily securing a concrete insert to a concrete form of claim 1, wherein the at least one frangible member is hollow.

9. The clip for temporarily securing a concrete insert to a concrete form of claim 8, wherein the at least one frangible member comprises walls that are thinner than the base member.

10. The clip for temporarily securing a concrete insert to a concrete form of claim 3, wherein the at least one frangible member includes a tapered tip at a distal end.

11. The clip for temporarily securing a concrete insert to a concrete form of claim 1, wherein the clip is polystyrene.

12. The clip for temporarily securing a concrete insert to a concrete form of claim 11, wherein the clip is injection molded polystyrene.

13. The clip for temporarily securing a concrete insert to a concrete form of claim 1, wherein a proximal end of the at least one frangible member comprises a line of weakness.

14. A method for locating a concrete insert in a concrete structure, comprising:

(a) assembling at least a portion of a concrete form;

(b) securing a concrete insert to the concrete form using a clip, the clip comprising: (i) a base member, the base member sized and shaped to receive at least one concrete insert; (ii) at least one frangible member extending from the base member; (iii) wherein the base member and the at least one frangible member are integrally formed; (iv) wherein applying a shearing force to at least one of the base member and the at least one frangible member separates the frangible member from the base member; and (v) wherein the clip is plastic;

(c) introducing concrete into the concrete form;

(d) allowing the concrete to cure; and

(e) removing at least a portion of the concrete form such that the at least one frangible member of the clip shears from the base member of the clip.

15. The method for locating a concrete insert in a concrete structure of claim 14, wherein securing the concrete insert to the concrete form using the clip comprises inserting the at least one frangible member into the concrete form.

16. The method for locating a concrete insert in a concrete structure of claim 15, wherein inserting the at least one frangible member into the concrete form comprises inserting the at least one frangible member into a pre-formed hole in the concrete form.

17. The method for locating a concrete insert in a concrete structure of claim 15, wherein inserting the at least one frangible member into the concrete form comprises pressing the at least one frangible member into the concrete form.

18. The method for locating a concrete insert in a concrete structure of claim 14, wherein securing the concrete insert to the concrete form using the clip comprises securing the concrete insert to the concrete form using a plurality of clips.

19. The method for locating a concrete insert in a concrete structure of claim 14, further comprising filling at least a portion of a void in the concrete insert with a filler.

20. The method for locating a concrete insert in a concrete structure of claim 14, further comprising securing at least one cap on at least one end of the concrete insert.