Apparatus and Method of Forming Molds for a Building Foundation
A mold for the foundation of a building is constructed through the use of a plurality of forms. The forms having first and second connectors providing connection of the forms to create the mold when the connectors are aligned. One of the plurality of forms having a bend allowing the form to various angles. The mold may form a variety of shapes, such as squares and circles. The forms are connected together by a releasable locking mechanism that passes through openings located in the connectors on the form when the connectors are aligned. The release locking mechanism connects the forms and provides stability to the mold to resist the pressure exerted when the foundation is formed.
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The present invention relates in general to construction materials and, more particularly, to molds for constructing the foundation of residential, commercial, and industrial buildings.
BACKGROUND OF THE INVENTIONThe construction of a building is a time-consuming process. While building techniques have improved and become more efficient, the process for constructing a building requires a substantial amount of time. The construction of a building includes the process of combining multiple dependent features with each other to form one complete building. The possibility of error is constant because of the assorted parts necessary to be assembled to create a building; and, the errors cause substantial time delays.
Errors result from manufacturing error or human error. Manufacturing errors occur when components are not constructed according to the dimensions or specifications provided. Another major mistake is human error. An incorrect measurement of any component of the building causes major delays. Because the components are dependent on each other, a miscue in the measurement of one component will have an impact on the entire construction of the building.
Another problem is the considerable amount of time taken to make accurate measurements of every component in the building. Because of the intricate relationship between all of the parts of the building, an accurate measurement is required. If a measurement is not correct by even the smallest of margins, the resulting mistake can be large and costly. Further, the mistake causes an increase in time for correction. The workers may be forced to re-cut a new component or make changes to other parts to accommodate the mistake. Either method results in the waste of goods and workers' time.
Even accurate measurements of the component parts cause problems in construction. It takes time to make accurate measurements. Further, the measurements are taken more than once for the same components used in different areas of the building. This repetitive action requires time for the construction worker to verify the accuracy of the measurement. Though the measurement will be accurate, significant amount of time is required to achieve the accuracy.
Accurate measurements may still result in inaccurate cuts or fabrication of the component. The time committed to make the accurate measurement is wasted when the cut is executed incorrectly. The mistake requires a construction worker to repair the error. Time and money are wasted on the correction of the mistake, even one based on an accurate measurement.
The first part of the building created is the foundation. The foundation provides the footprint and base of the building being constructed. A building needs a foundation to shoulder its considerable weight, provide a flat and level base for construction and to separate wood-based materials from contact with the ground, which may cause rot and allow termite infestation of the wood materials. If the foundation is not properly created, then the building will not be built correctly. A proper, accurate foundation is required for the construction of any building. The foundation may be created by poured concrete, stone, brick, or concrete block.
The building's footprint can be created using wood forms outlining the dimension of the foundation. The wood pieces are fastened together and supported into the ground. Concrete is poured into the wood form and allowed to harden. While the concrete is hardening, the construction workers attempt to keep the surface as flat as possible to prevent waving or uneven surfaces from forming in the concrete.
After the concrete has hardened, the wood forms are removed and destroyed as they can not be reused. The wood forms are not able to be reused because of the stress placed on the wood forms while the concrete is hardening. Further, if the wood forms resulted in an inaccurate foundation, the construction worker has no use for the form.
SUMMARY OF THE INVENTIONIn one embodiment, the present invention is a mold for constructing a foundation of a building with hardenable material comprising a plurality of forms surrounding an area for the foundation, each having first and second ends with first and second connectors, respectively, and a releasable locking mechanism for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms.
In another embodiment, the present invention is a form for constructing a foundation of a building comprising a set of castings surrounding an area for the foundation, each casting having first and second ends, and a releasable locking mechanism coupled to the first and second ends of each of the set of castings, the releasable locking mechanism providing for the first and second ends of adjacent ones of the set of castings to be connected and disconnected.
In another embodiment, the present invention is a method of forming a foundation of a building comprising of providing a plurality of forms surrounding an area for the foundation, each having first and second ends with first and second connectors, respectively, and providing a releasable locking mechanism for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms.
In another embodiment, the present invention is a building structure having a foundation formed by a process comprising the steps of providing a plurality of forms surrounding an area for the foundation, each having first and second ends with first and second connectors, respectively, and providing a releasable locking mechanism for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms
In another embodiment, the present invention is a mold for constructing a foundation upon ground, comprising a plurality of forms surrounding a perimeter for the foundation, each having first and second ends with first and second connectors respectively, one of the plurality of forms having a bend for providing a change of direction, one of the plurality of forms is made of material selected from the group consisting of metal, plastic, graphite, stone, concrete, composite, and wood, and a member for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms, the member having length to be inserted into the ground.
The present invention is described in one or more embodiments in the following description with reference to the Figures, in which like numerals represent the same or similar elements. While the invention is described in terms of the best mode for achieving the invention's objectives, it will be appreciated by those skilled in the art that it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims and their equivalents as supported by the following disclosure and drawings.
The construction of a building can be made more efficient by the use of pre-manufactured pieces that are assembled on the job site. The pieces can be made in a controlled environment that will ensure the piece is constructed to the desired dimensions and materials that are desired by the builder. The ability to reuse forms or castings in the construction of buildings allows the buildings to be created faster and more efficiently. The castings will have exact and correct dimensions because the casting was created in a controlled environment and successive buildings can be constructed more efficiently because the castings can be reused to construct the successive building.
To construct a building with the forms for the foundation of the building as described herein, an architect or builder designs the layout of the building structure. The building may be a home, office, industrial, hotel, or commercial structure of any size and shape and as tall as the local building codes permit. The building designer creates a blueprint of the building, including dimensions for the footprint of the building, usually called the foundation. The designer selects the desired dimension of the building. The foundation of a building provides a stable base for the building to be constructed. Further, the foundation provides a smooth or flat surface for the building. The foundation can be any shape that is desired, such as square, circle, oval, polygon, L-shaped, or U-shaped.
The material used to create foundation 12 is usually one that is a hardenable material. A hardenable material can be one that forms a hardened structure when dry. One such material is concrete. Different climates and other factors require the use of certain mixture or formula of concrete. Some environments require a thicker concrete formula while other environments require a thinner concrete mixture. Also, the intended building to be constructed on foundation 12 will have an impact on the formula or mixture that is chosen.
Forms 22 and 24 are formed as having a front surface 32 exposed to the concrete and a top surface 34. Forms 22 and 24 can be any desired length, e.g., 4-10 feet. The length of forms 22 and 24 are selected according to the perimeter of foundation 12 of building 10. Forms 22 and 24 may be constructed to have a length equal to a length of building 10 or a side of building 10. Depending on the shape of building 10, forms 22 and 24 can be created to have a length to minimize the number of forms needed to construct foundation 12. Forms 22 and 24 may have a short length to create a bend or turn in the mold. The length of forms 22 and 24 may be 4 inches.
Forms 22 and 24 may have an adjustable length. Forms 22 and 24 may be constructed to provide a variable length for instances when foundation 12 has an odd length. In one embodiment, the form is made in two sections so that the front surface of a first section can slide with respect to a front surface of a second section of the form. Having an adjustable length, forms 22 and 24 are able to be used in a variety of situations and allow for corrections of any errors that may arise on the job site. A builder is able to create the mold through the utilization of a lesser number of forms 22 and 24 on a job site.
Forms 22 and 24 have a height dependent on the desired height of foundation 12. Foundations may have a height of about 6 inches to 36 inches. The height of forms 22 and 24 are greater than the height of foundation 12 to prevent any of the material creating foundation 12 from spilling over or escaping the mold.
Forms 22 and 24 may be constructed of material such as metal, plastic, graphite, stone, concrete, composite, and wood. The material chosen to create forms 22 and 24 is dependent on the force exerted by the hardenable material. Additionally, the length of forms 22 and 24 may affect the choice of material. A longer form has more weight than a shorter form made of the same material. Practical limitations may affect the choice of material used for forms 22 and 24 as some materials may create a form that is too heavy to be carried or moved on the job site.
Forms 22 and 24 have a surface 34 protruding from the form at an angle, such as at ninety degrees. Surface 34 has a length which may be equal to the length of form 22 or 24. Surface 34 has a width that may be about 2 to 4 inches. Surface 34 has a thickness which may be about 0.5 inches to 4 inches. Surface 34 is located at the first end of forms 22 and 24. Surface 34 may be a continuous component of surface 32. Surface 34 may be connected to surface 32 by welding or use of nails, adhesive, or screws.
Surface 34 is located at a height on forms 22 and 24. Surface 34 may be located at the top of forms 22 and 24 to create a ridge at the top of forms 22 and 24. Surface 34 is located at a height greater than second connector 42 to create a releasable locking mechanism.
Surface 34 has a first connector 36. First connector 36 may include an opening for the passage of a rod. First connector 36 has a width to allow the passage of a rod. The rod functions as a releasable locking mechanism or member. The releasable locking mechanism allows for the connection and disconnection of the adjacent forms. The width of first connector 36 is less than the width of surface 34 because first connector 36 allows the rod to pass through surface 34. First connector 36 may have a width of about 1 to 4 inches. First connector 36 is located on surface 34 at the first end of forms 22 and 24. First connector 36 may be a bracket that connects to forms 22 and 24. The bracket functions as a releasable locking mechanism.
Second connector 42 is located at the second end of forms 22 and 24. Second connector 42 may extend beyond the end of forms 22 and 24. Second connector 42 has a height less than the height of forms 22 and 24 allowing second connector 42 to slide into another form 22 or 24. Second connector 42 may have a height of about 12 to 24 inches. Second connector 42 is fastened to forms 22 and 24 by such methods as welding or the use of adhesive, nails, or screws. Second connector 42 is connected to forms 22 and 24 on a surface opposite of surface 32 to allow a continuous flat surface 32 to be formed when form 22 is associated with form 24. Second connector 42 has a length that provides additional stability to the mold. The length of second connector 42 may be about 12 to 24 inches.
Second connector 42 may include a surface 40. Surface 40 may be located along the height of second connector 42, and may be located at the top of second connector 42. Surface 40 has a length which may be equal to the length of second connector 42. The width of surface 40 provides space for second bracket 38. The width of surface 40 may be about 2 to 6 inches.
Second bracket 38 has a width to allow passage of a member or rod through the opening. Second bracket 38 may have an opening of about 1 to 3 inches. The opening may have a small circumference to allow increased connection with a rod that is passed through second bracket 38. The increased connection provides increased rigidity to forms 22 and 24 because of the tight connection between the rod and second bracket 38. Second bracket 38 is located on second connector 42 to allow a rod or member to pass through the opening of second bracket 38.
To allow form 22 to connect to form 24, second connector 42 on second end of form 22 aligns with first connector 36 on the first end of form 24. When first connector 36 is aligned with second connector 42, a rod is placed into the connectors to fasten forms 22 and 24 together. The rod may be removed after foundation 12 is formed so that forms 22 and 24 may be removed and taken to another job site. Also, the alignment allows for the forms to be connected together and form a mold that is able to withstand the pressure and force exerted by the hardenable material that will form foundation 12. In an embodiment, second connector 42 is located 4 inches from the second end of form 22 and first connector 36 is located 4 inches from first end of form 24. The openings are to be at the same respective distance from the ends of forms 22 and 24 to allow the forms to be connected and disconnected.
Form 26 may be connected to adjacent forms 22 and 24. Form 22 may be connected to adjacent forms 24 and 26. Form 24 may be connected to adjacent forms 22 and 26. The plurality of forms 20 is created when adjacent forms are connected by a releasable locking mechanism. The mechanism of connecting forms together may be a different mechanism to connect forms in the plurality of forms 20. Additionally, the same mechanism may be used to connect adjacent forms in the plurality of forms 20. Any mechanism illustrated to connect and disconnect two forms, e.g, forms 22 and 24, may be implemented to connect adjacent forms of any combination of forms 22, 24, and 26.
The releasable locking mechanism may be coupled to the first and second end of forms 22 and 24 to allow the forms to be connected and disconnected. When forms 22 and 24 are adjacent and aligned, the releasable locking mechanism connects the forms by member 50 sliding through an opening on forms 22 and 24. Coupling the releasable locking mechanism to the first and second ends of forms 22 and 24 permits the mold to make use of the entire length of forms 22 and 24. Then, a lesser number of forms 22 and 24 may be utilized to create the mold.
While one or more embodiments of the present invention have been illustrated in detail, the skilled artisan will appreciate that modifications and adaptations to those embodiments may be made without departing from the scope of the present invention as set forth in the following claims.
Claims
1. A mold for constructing a foundation of a building with hardenable material, comprising:
- a plurality of forms surrounding an area for the foundation, each having first and second ends with first and second connectors respectively; and
- a releasable locking mechanism for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms.
2. The mold of claim 1, wherein the first connector includes a first bracket attached to the first end of each of the plurality of forms.
3. The mold of claim 2, wherein the second connector includes a second bracket attached to the second end of each of the plurality of forms.
4. The mold of claim 3, wherein the releasable locking mechanism includes a rod inserted through an opening in the first bracket and through an opening in the second bracket.
5. The mold of claim 3, wherein the releasable locking mechanism includes a nut and bolt for connecting and disconnecting the first and second brackets.
6. The mold of claim 1, wherein the plurality of forms include one form selected from the group consisting of straight form, fixed angled form, adjustable angle form, adjustable length form, and curved form.
7. The mold of claim 1, wherein one of the plurality of forms is made of material selected from the group consisting of metal, plastic, graphite, stone, concrete, composite, and wood.
8. A form for constructing a foundation of a building, comprising:
- a set of castings surrounding an area for the foundation, each casting having first and second ends; and
- a releasable locking mechanism coupled to the first and second ends of each of the set of castings, the releasable locking mechanism providing for the first and second ends of adjacent ones of the set of castings to be connected and disconnected.
9. The form of claim 8, wherein the releasable locking member includes a first connector attached to the first end of each of the set of castings.
10. The form of claim 9, wherein the releasable locking member includes a second connector attached to the second end of each of the plurality of forms.
11. The form of claim 10, wherein the releasable locking mechanism includes a rod inserted through an opening in the first connector and through an opening in the second connector.
12. The form of claim 10, wherein the releasable locking mechanism includes a nut and bolt for connecting and disconnecting the first and second connectors.
13. The form of claim 8, wherein the plurality of forms include one form selected from the group consisting of straight form, fixed angled form, adjustable angle form, adjustable length form, and curved form.
14. The form of claim 8, wherein one of the plurality of forms is made of material selected from the group consisting of metal, plastic, graphite, stone, concrete, composite, and wood.
15. A method of forming a foundation of a building, comprising:
- providing a plurality of forms surrounding an area for the foundation, each having first and second ends with first and second connectors respectively; and
- providing a releasable locking mechanism for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms.
16. The method of claim 15, further including attaching a first bracket to the first connector of each of the plurality of forms.
17. The method of claim 16, further including attaching a second bracket to the second connector of each of the plurality of forms.
18. The method of claim 17, further including inserting a member through an opening in the first bracket and through an opening in the second bracket.
19. The method of claim 17, further including connecting and disconnecting a nut and bolt through an opening in the first and second brackets.
20. The method of claim 15, wherein the plurality of forms include one form selected from the group consisting of straight form, fixed angled form, adjustable angle form, adjustable length form, and curved form.
21. The method of claim 15, wherein one of the plurality of forms is made of material selected from the group consisting of metal, plastic, graphite, stone, concrete, composite, and wood.
22. A building structure having a foundation formed by a process comprising the steps of:
- providing a plurality of forms surrounding an area for the foundation, each having first and second ends with first and second connectors respectively; and
- providing a releasable locking mechanism for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms.
23. The process of claim 22, wherein the first connector includes a first bracket attached to the first end of each of the plurality of forms.
24. The process of claim 23, wherein the second connector includes a second bracket attached to the second end of each of the plurality of forms.
25. The process of claim 24, wherein the releasable locking mechanism includes a member inserted through an opening in the first bracket and through an opening in the second bracket.
26. The process of claim 24, wherein the releasable locking mechanism includes a nut and bolt for connecting and disconnecting the first and second brackets.
27. The process of claim 22, wherein the plurality of forms include one form selected from the group consisting of straight form, fixed angled form, adjustable angle form, adjustable length form, and curved form.
28. The process of claim 22, wherein one of the plurality of forms is made of material selected from the group consisting of metal, plastic, graphite, stone, concrete, composite, and wood.
29. A mold for constructing a foundation upon ground, comprising:
- a plurality of forms surrounding a perimeter for the foundation, each having first and second ends with first and second connectors respectively, one of the plurality of forms having a bend for providing a change of direction, one of the plurality of forms is made of material selected from the group consisting of metal, plastic, graphite, stone, concrete, composite, and wood; and
- a member for connecting and disconnecting the first and second connectors of adjacent ones of the plurality of forms, the member having length to be inserted into the ground.
Type: Application
Filed: Mar 30, 2007
Publication Date: Oct 2, 2008
Applicant: Sinclair ABT, LLC (Fort Myers, FL)
Inventor: J. Daniel Sinclair (Fort Myers, FL)
Application Number: 11/694,670
International Classification: E02D 27/01 (20060101);