Masonry and concrete forming scheme and apparatuses

Abstract

Novel methods of in situ forming masonry and concrete structures at least include providing stock lumber to serve as frame members, removably joining at least two frame members by at least one manufactured frame member joiner, placing masonry elements and/or concrete (or cement) between said joined frame members, separating the joined frame members from the resultant structure of masonry elements and/or concrete created, and removing the joined frame members from said frame member joiners. The frame member joiner includes at least two sleeve members, each sleeve member adapted to receive and hold in place during masonry element and/or concrete (or cement) placement, a frame member.

Description

FIELD OF THE INVENTION

The present invention generally relates to improved methods and apparatuses for the on-site forming of masonry and concrete structures. More particularly, the present invention relates to improving the formation and removing of frames used in on-site masonry and concrete projects.

BACKGROUND OF RELATED ART

Many prior art on-site masonry and concrete projects require the use of frames to serve as molds or boundaries. The typical approach to frames is to either use a completely pre-fabricated frame that can be expensive, bulky and not easily portable or maneuverable, or construct makeshift frames by nailing or screwing stock lumber together. The pre-fabricated approach typically uses expensive steel frame members. Additionally, such frames are usually only assembled in one configuration, which may not give a contractor/mason the flexibility needed at a work site.

The latter approach solves some of the problems associated with the pre-fabricated frame approach, but introduces other limitations. In a simple example, a contractor/mason desiring to construct a driveway out of brick or concrete might form a long frame member by nailing two or more boards (such as two-by-fours and two-by-sixes) end-to-end. Boards are then nailed to each other forming other angles (such as perpendicular orientations) as needed until the makeshift frame encloses the target area.

Subsequently, the contractor/mason can pour concrete or cement as appropriate, and install masonry elements such as bricks as desired. Upon sufficient drying of the work the frame can be dismantled and removed.

The latter approach to on-sight frame formation can lead to frame members that are not sufficiently aligned, introducing an unacceptable variance from the desired dimensions at times. Further, the joining of frames can be unnecessarily time-consuming. Additionally, this approach often damages the ends of the lumber to an extent that it is not reusable in future frames.

What is therefore needed but absent in the prior art, is a flexible frame approach for on-site masonry and concrete projects in which the frame can be quickly, inexpensively and accurately formed and removed at the work site, and in which greater flexibility of the orientation of the frame members is also possible.

SUMMARY

In view of the above-identified limitations of the prior art, the present invention provides an improved method of in situ forming masonry structures. The method at least includes providing stock lumber to serve as frame members, removably joining at least two frame members by at least one manufactured frame member joiner, placing masonry elements and cement between the joined frame members, separating the joined frame members from the resultant structure of cement and masonry elements created, and removing the joined frame members from the frame member joiners. The frame member joiner includes at least two sleeve members, each sleeve member adapted to receive and hold in place during masonry element and cement placement, a frame member.

The present invention also provides an improved method of in situ forming concrete structures. The method at least includes providing stock lumber to serve as frame members, removably joining at least two frame members by at least one manufactured frame member joiner, pouring concrete between joined frame members, separating the joined frame members from the resultant concrete structure created, and removing the joined frame members from the frame member joiners. The frame member joiner includes at least two sleeve members, each sleeve member adapted to receive and hold in place during concrete pouring, a frame member.

The present invention further provides an article of manufacture adapted to form at least a portion of a frame for the in situ forming of masonry structures. The article of manufacture includes at least two joined sleeve members, wherein each sleeve member is adapted to receive and hold in place during masonry element and cement dispensing, a frame member.

BRIEF DESCRIPTION OF THE DRAWINGS

Features of the present invention will become apparent to those skilled in the art from the following description with reference to the drawings, in which:

FIG. 1 is a plan view of a frame formed using the present-inventive articles of manufacture and the present-inventive method of frame formation;

FIG. 2 is a more detailed version of FIG. 1 showing masonry elements placed in the mold formed by the frame of FIG. 1;

FIG. 3 is a top view of one version of the present-inventive article of manufacture for joining frame members, which also shows frame member securing means;

FIG. 4 is a front view of the article of manufacture introduced in FIG. 3;

FIG. 5 is a top version of a second version of the present-inventive article of manufacture for joining frame members;

FIG. 6 is a top version of a third version of the present-inventive article of manufacture for joining frame members;

FIG. 7 is a top version of a fourth version of the present-inventive article of manufacture for joining frame members;

FIG. 8 is a top view of a fifth version of the present-inventive article of manufacture for joining frame members, which also shows a pivotal sleeve member; and

FIG. 9 is a side view of the article of manufacture introduced in FIG. 8.

DETAILED DESCRIPTION

The present invention is a novel approach to forming frames on site for masonry and concrete projects such as sidewalks, driveways, roads, floors, patios, etc. As introduced in the “Summary,” supra, frame members consisting of stock lumber (in the preferred embodiment) are inserted into special articles of manufacture here labeled as frame member joiners.

A simple frame 100 formed using the present-inventive articles of manufacture and method is shown in FIG. 1. In the illustration, four inventive frame member joiners 110 are shown with four frame members 120, 130, 140 and 150 inserted therein to form a frame for the boundary of a masonry or concrete project. While the frame is in a rectangular form, other non-rectangular frames can be formed using the present-inventive frame joiners 110.

FIG. 2 shows a near completed masonry project, where a frame surrounds a workspace 160 filled with cement 164 and masonry elements such as bricks, stones or blocks 168. After the molding is complete, the frame can either be removed from the project as a unit, or it can be dismantled as will be explained infra.

FIGS. 3 through 9 all illustrate various embodiments of the present-inventive frame member joiners. The frame member joiners are articles of manufacture that can be made of any suitable material such as plastic or metal. However, the preferred embodiment frame member joiners are molded plastic, and can be discarded after a single use if desired. What each embodiment for a frame member joiner has in common is at least two sleeve members dimensioned to accept and hold in place, a frame member. Therefore, when stock lumber is used, the sleeve members are dimensioned to accept the end cross-section of particular boards (i.e., a different frame joiner may be used to join “two-by-fours” as opposed to “two-by sixes,” for example) in a reasonably, but not overly snug fit.

The frame member joiner 110 in Figure has three sleeve members 312, 314 and 316, for receiving two or more stock lumber frame member boards. The top view of FIG. 3 is further augmented by the front view of FIG. 4. In this example, the frame member joiner 110 also has securing devices 320 and 330 to providing extra holding of the lumber during the completion of the construction job. The securing devices are optional, however. The securing device 330 is merely a hole, through which lumber can be temporarily nailed or engaged by a screw. The securing device 320 is a flange member biased toward the center of the sleeve member, the flange member holding the lumber in place when the lumber is inserted in the sleeve. Prior to removing lumber from a sleeve member, a tab 322 is used to pull the flange member 320 away (e.g., using a flathead screwdriver or the like) from the lumber to disengage it.

Examples of many variations on the present-inventive frame member joiner are shown in the remaining drawing figures. Given the teachings in this Letters Patent, many other variations are possible. The frame member joiner 510 in FIG. 5 acts as an extender, and accepts two frame members to form a longer boundary. The frame member joiner 610 in FIG. 6 joins two frame members at right angles. Meanwhile, the frame member joiner 710 in FIG. 7 not only illustrates that frame member joiner of the present invention can have three or more sleeve members, but that the sleeve members can also be oriented at relative angles other than 90° and 180°.

FIGS. 8 and 9 show the top and side views, respectively, of a frame member joiner 810 where at least one of the sleeve members 890 can be moved to an arbitrary angle relative to one or more of the other sleeve members (870 and 880). The sleeve member 890 contains two rigid flanges 894 that pivot about a pin 898.

Variations and modifications of the present invention are possible, given the above description. However, all variations and modifications which are obvious to those skilled in the art to which the present invention pertains are considered to be within the scope of the protection granted by this Letters Patent.

Claims

1. A method of in situ forming masonry structures comprising: providing stock lumber to serve as frame members;

removably joining at least two frame members by at least one manufactured frame member joiner;

placing masonry elements and cement between said joined frame members;

separating the joined frame members from the resultant structure of cement and masonry elements created; and

removing the joined frame members from said frame member joiners;

wherein said frame member joiner comprises at least two sleeve members, each sleeve member adapted to receive and hold in place during masonry element and cement placement, a frame member.

2. A method of in situ forming concrete structures comprising: providing stock lumber to serve as frame members;

removably joining at least two frame members by at least one manufactured frame member joiner;

pouring concrete between joined frame members;

separating the joined frame members from the resultant concrete structure created; and

removing the joined frame members from said frame member joiners;

wherein said frame member joiner comprises at least two sleeve members, each sleeve member adapted to receive and hold in place during concrete pouring, a frame member.

3. An article of manufacture adapted to form at least a portion of a frame for the in situ forming of masonry structures, said article of manufacture comprising:

at least two joined sleeve members;

wherein each sleeve member is adapted to receive and hold in place during masonry element and cement dispensing, a frame member.

4. The method of claim 1, wherein said frame members are stock lumber.

5. The method of claim 1, further comprising at least three sleeve members.

6. The method of claim 1, wherein said sleeve members are oriented so that at least two joined frame members form parallel or perpendicular angles.

7. The method of claim 1, wherein said sleeve members are oriented so that at least two joined frame members form non-parallel and non-perpendicular angles.

8. The method of claim 1, wherein said sleeve members are pivotally attached so that frame members form an angle adjustable by a user.

9. The method of claim 1, wherein said sleeve members comprise securing devices adapted to secure engaged frame members during masonry element and cement placement.

10. The method of claim 1, wherein said frame member joiners are adapted to be disposable after a single use.

11. The method of claim 2, wherein said frame members are stock lumber.

12. The method of claim 2, wherein said sleeve members are pivotally attached so that frame members form an angle adjustable by a user.

13. The method of claim 2, wherein said sleeve members comprise securing devices adapted to secure engaged frame members during masonry element and cement placement.

14. The method of claim 2, wherein said frame member joiners are adapted to be disposable after a single use.

15. The article of manufacture of claim 3, wherein said sleeve members are pivotally attached so that frame members form an angle adjustable by a user.

16. The article of manufacture of claim 3, wherein said sleeve members comprise securing devices adapted to secure engaged frame members during masonry element and cement placement.

17. The article of manufacture of claim 3, further adapted to be disposable after a single use.

18. The article of manufacture of claim 16, wherein said securing devices comprise flange members biased to the centerline of the sleeve member to which said securing device is attached, said flange member being adapted to hold said frame members in place while said frame members are inserted into said sleeve members, and said flange members are adapted to be pried away from said frame members for removal of said frame members.

19. The article of manufacture of claim 16, wherein said securing devices comprise a region of said sleeve members having a hole adapted to receive a nail or screw through said hole into said frame members to hold said frame members in place while said frame members are inserted into said sleeve members.

20. The article of manufacture of claim 3, further comprising at least three sleeve members.