Note: Descriptions are shown in the official language in which they were submitted.
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FRAME FOR A WALL OPENING
AND METHODS OF ASSEMBLY AND USE
TECHNICAL FIELD
The present invention relates to frames used for forming an opening in a
structure wall such as a poured concrete wall and a structure wall formed with
an
insulated concrete form.
BACKGROUND ART
When constructing a building, it is frequently desirable to position a window,
door, garage door, or other opening, in a structure wall such as a poured
concrete wall
or in a wall made from concrete using an insulated concrete form. Procedures
for
forming an opening have included manufacturing a frame from wood and
positioning
the frame within a pair of forms used for forming a concrete wall or insulated
concrete
forms used for forming an insulated concrete wall. Typically, the frame is
positioned
between the pair of forms after which the concrete is poured into the form and
about the
frame. Therefore, the desired opening is defined in the wall when the concrete
hardens
or cures. Thereafter, the window form has been removed and replaced with
structure
that is used to size the opening and to provide structure for receiving and
attaching the
window unit itself.
U.S. Patent 4,430,831 discloses a window buck formed of a series of sides or
channels joined together with nails in an end-to-end relationship to define a
rectangular
opening. The window buck is a window form which is assembled and positioned so
that concrete may be poured around it. U.S. Patent 4,589,624 (Jones) also
shows a
window buck which is provided for forming a window opening in a cast concrete
wall.
The buck is removable after the concrete wall is formed in order to proceed
with further
installation of a window.
U.S. Patent 5,169,544 (Stanfill et al.) also describes a buck for use in
construction. The buck has internal bracing so that it does not deform or
change
dimension when the concrete wall is poured about it.
In order to facilitate construction, it would be desirable to have a frame
such as
and including a window buck which can be easily assembled on site and which
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thereafter can be installed and remain in place. The frame would preferably be
one that
is easily sized and shaped and also which is formed to receive a finished
insert such as a
door or window after the concrete wall has been poured and cured. It would
also be
desirable to have a frame that could be used with insulated concrete forms.
DISCLOSURE OF INVENTION
A frame for forming an opening in a structure wall includes side member means
assembled to define the opening. The side member means is formed to have a
perimeter and a width. The width is substantially the width of the structure
wall into
which the frame is to be placed. That is, when the assembly is complete and
the wall
formed, the frame is approximately coextensive with the wall in width. In a
preferred
arrangement the frame has flanges that embrace or contain the wall there
between.
The side member means has an inner wall facing toward the interior of the
opening and an outer wall spaced away from the interior wall and the opening.
A
plurality of internal channels are formed between the inner wall and the outer
wall.
Retention means is mechanically associated with the outer wall and formed to
extend
away therefrom for mechanical association with the structure wall. The
retention
means is one or more extensions associated with and desirably unitarily formed
with
the the exterior wall. In a selected arrangement the retention means is a rib
formed
unitarily therewith. The retention means also more preferably has a securement
member proximate an outer end which may be a lip formed to be normal to the
rib.
The side member means has two ends that are formed for positioning proximate
each other for interconnection to each other by connector means. In one
embodiment
the connector means has a locking member with a first member sized and shaped
for
insertion into a selected one of the plurality of channels in one of the two
ends. The
locking member has a second member sized and shaped for frictional insertion
into and
engagement with a corresponding selected one of the plurality of channels in
the other
of the two ends.
In an alternate arrangement, the side member means includes a female side
member and a male side member. The connector means is structure formed at the
ends
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of the female side member and the male side member to effect a male-female
connection between the ends of the female member and said male member.
The side member means may be formed to define a circular shaped perimeter
or a perimeter in a plurality of geometric shapes.
The side member means preferably includes a plurality of separate sides, each
of
which is formed to have two ends. Even more preferably each side member is
each
secured to its adjacent side member proximate one end of the adjacent side
member.
The connector means includes a connector configured for joining the two ends
of each
of said four separate sides.
The opening formed by the frame may be a door opening in which the side
members are formed to define at least the top and the two sides of the door
opening.
The opening may be a garage door opening, a window or any other opening to be
formed in a structural wall.
In one preferred embodiment, the side member means is four separate sides
assembled to define a rectilinearly shaped window buck. The window opening has
a
top and a bottom; and the four separate sides include a bottom side oriented
toward the
bottom of the window opening. The bottom side preferably includes aperture
means
formed therein and sized to receive concrete therethrough.
Each of the side members includes a plurality of channels extending lengthwise
between said inner wall and said outer wall. The channels are desirably side
by side
and hollow and formed to extend the length of each side member. The channels
may be
selectively filled with insulating material if desired.
In a desired embodiment, the first side member has one channel of its
plurality
of channels formed to define a first opening at both of its ends. A second
side member
is similarly formed. The connector means is locking member which has a first
member sized and shaped for insertion into and engagement with the first
opening in
the first end of both the first side member and a second member similarly
sized and
shaped for insertion into a second opening in the second member. The first
member
and the second member are in a desired configuration a male structure formed
for
engagement with said first opening of said first side member and a male
structure for
engagement with the second opening of the second side member.
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In alternate and preferred arrangements, each channel of the plurality of
channels has a longitudinal axis The longitudinal axis of each channel of the
plurality of
channels are in alignment.
The structure wall has an interior surface and an exterior surface. In
selected
configurations, the first side member and the second side member each have an
interior
flange connected to its respective outer wall. The flanges are positioned to
extend
away from the respective side member and along the interior surface of the
structure
wall. Similarly the first side member and the second side member each have an
exterior flange mechanically associated with its respective outer wall. The
exterior
flange is formed to extend away therefrom and substantially along the exterior
surface
of the structure wall.
In use, side members may be cut such as by sawing on site to achieve a desired
size. As a result end pieces or remnants may be available so that a side
member may be
formed therefrom. That is, a side member alternately is formed from a first
section and
a second section joined to each other. Each of the first section and the
second section
have a first end and a second end having at least one aperture formed therein.
fastener
is sized to snugly insert into the selected apertures of said first section
and said second
section to secure said first section to said second section preferably in an
abutting
relationship and in axial alignment..
Methods of forming the frame including a window frame include forming at
least three side members from stock to a desired size. One side member will be
formed
to be the top of the frame. Two side members are also formed from the stock to
a
desired dimension. A bottom member is desired for a window frame. If the
opening is
a door or door-like opening in the structure wall, a bottom may not be
required or
desired. If the opening is a window opening or a window-like opening, it may
be
formed from bottom stock in which the inner wall and the outer wall have
apertures
formed therein to receive cement therethrough. The side members are assembled
together by securing each to its adjacent side member or members with the
connectors.
The connectors have male ends sized for frictional engagement in a selected
channel
formed in the side members.
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Once the frame is assembled, it may be installed in the forms for the
concrete.
The forms may be standard concrete wall forms or insulated concrete wall
forms. Once
installed, it typically is braced by attaching an angle brace at one or more
selected
corners of the assembled frame based on the size of the frame. In addition,
other metal
or wooden braces may be used to extend between the top and bottom side members
and/or the opposite vertical side members. Bracing is provided using in a
conventional
manner with one metal or wooden brace being provided for approximately every
0.9
meters (three feet) of opening.
BRIEF DESCRIPTION OF DRAWINGS
In the drawings which illustrate what are presently regarded to be the best
modes of carrying out the invention,
FIG. 1 is a window buck of the present invention with a proposed window frame
for insertion therein depicted in phantom;
FIG. 2 is a cross-section of a side member for use with the window buck of the
present invention;
FIG. 3 is a cross section of an alternative side member for use with the
window
buck of the present invention;
FIG. 4 is a perspective view of a locking member for use in connecting side
member means of a window buck of the present invention;
FIG. 5 is an exploded, partial side view of separate side members of the side
member means of a window buck of the present invention with a locking member
positioned for interconnecting the illustrated separate side members;
FIG. 6 is a top view of a circular shaped window buck of the present
invention;
FIG. 7 is a locking member for use with a window buck of FIG. 6;
FIG. 8 is a partial perspective view of an female side member of an alternate
embodiment of the present invention;
FIG. 9 is a partial perspective view of a male side member of an alternate
embodiment of the present invention;
FIG. 10 is a partial front view of an assembled female side member and male
side member of an alternative embodiment of the present invention;
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FIG. 11 is a partial side view of an alternative male member of an alternate
embodiment of the present invention;
FIG. 12 is a partial side view of alternative tongues of a male member of the
alternative embodiment of FIG. 9 of the present invention;
FIG. 13 is a partial perspective view of an alternative configuration of a
female
side member of an alternative embodiment of the present invention;
FIG. 14 is perspective view of side members suitable for use in forming a
window buck of the present invention;
FIG. 15 is a perspective view of the side members of FIG.14 positioned for
assembly into a window buck of the present invention;
FIG. 16 is a perspective view of the side members of FIG. 24 assembled into a
window buck of the present invention;
FIG. 17 is a simplified illustration of a saw used in the formation of side
members used with window bucks of the present invention;
FIG. 18 is a simplified perspective illustration depicting the steps for
assembling
a window buck of the present invention;
FIG. 19 is a perspective illustration of a window buck of the present
invention
with cross braces;
FIG. 20 is a perspective illustration of the window buck of FIG. 19 with a
window frame positioned for insertion and a window well cover positioned for
attachment to the widow buck;
FIG. 21 is an exploded perspective of a preferred alternate embodiment of a
frame for use in openings in a structural wall with a window and with a
partial view of
an insulated concrete form;
FIGS. 22 and 23 are perspective views of a bottom side member;
FIG. 24 is a cross section of a side member for use with and in the present
invention;
FIG. 25 is a partial perspective exploded view of two adjacent side members
and a connector of the present invention;
FIG. 26 is a partial perspective view of two adjacent side members connected
together and a side member in section;
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FIG. 27 is a perspective view of a connector for use with the present
invention;
FIG. 28 is a perspective view of a connector for use in connecting sections of
a
side member for use with the present invention;
FIG. 29 is a perspective view of a window buck with corner braces;
FIG. 30 is a perspective view of a corner brace for use with the present
invention; and
FIGS. 31-33 are perspective views of frames for use with the present invention
with braces and corner braces.
BEST MODES FOR CARRYING OUT THE INVENTION
In FIG. 1, one embodiment of a window buck 10 has side member means which
may include one (FIG. 6) or a plurality of side members. In FIG. 1, the window
buck
10 is rectilinear in projection with a left side member 12, a top side member
14, a
bottom side member 16 and a right side member 18. A window 20 is shown in
phantom sized for positioning within the window buck 10 after construction of
a wall
as more fully discussed hereinafter. The window 20, as shown, has a left
window pane
unit 22 and a right window pane unit 24, both of which slide in a track 21
attached to
the frame 26.
The left side member 12, the top side member 14, the bottom side member 16
and the right side member 18 are each formed to have a length 28 and a width
30. The
length 28 and width 30 is selected to define a window opening of the desired
size and
configuration and more particularly of a height 29 and a width 31 that is for
a standard
sized or commercially available window 20. The width 30 is selected to be
substantially the width of the wall into which the window buck 10 is to be
placed. That
is, the width 30 is selected so that the internal flanges 12A, 14A, 16A and
18A are
exposed and extend along the inner surface 137 of the wall 136 (FIG. 3).
Similarly,
external flanges 12B, 14B, 16B and 18B are exposed and extend along the outer
surface
135 of wall 136.
The left side member 12, the top side member 14, the bottom side member 16
and the left side member 18 are each formed preferably of a vinyl material
that is
extruded. However, they may be formed from other materials including
fiberglass,
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Teflon, aluminum, aluminum alloys, and other similar materials. The preferred
material is low cost and resistant to corrosion while having sufficient
structural
strength to support, for example, the cement when the wall is formed. The
preferred
material is also one that may be made readily cut such as by a hand saw or
hand held
power saw. The preferred material is also one that can be formed in different
colors if
desired.
FIG. 2 shows a side member 32 which has a top wall 34 and a bottom wall 36.
It also has a first outside wall 38 and a second outside wall 40. The top wall
34 defines
an interior surface 42 of the window buck and, in turn, provides a surface
that faces
toward the interior of the buck which is the opening 19 defined by the buck
and the
window (e.g., window 20) installed therein. The inwardly facing surface 16C of
the
bottom side member 16 acts as a window sill.
Between the top wall 34 and the bottom wall 36 is a plurality of channels 44,
46,
48 and 50. Each of the channels 44, 46, 48 and 50 is sized and shaped to be
substantially the same in height 52 and width 54. Separating walls 56, 58, 60
and 64
are formed in-between the top wall 34 and the bottom wall 36 to define the
channels 44,
46, 48 and 50 and to strengthen the side member 32 so that it is structurally
strong and
has sufficient rigidity to maintain dimensional integrity when in use. That
is, each
channel 44, 46, 48 and 50 has a plurality of sidewalk each of which is
preferably
rectangular in projection with four sidewalls such as sidewalls 56 and 58 as
well as
sidewalls SS and 57. The sidewalls 55 and 57 are also part of the interior
surface 42
and the bottom wall 36.
As can be seen in FIG. 2, the top wall 34 steps down to a ledge 62 defined by
the separating wall 64 and a ledge wall 66 as well as the second outside wall
40. The
ledge 62, second outside wall 40 and ledge wall 66 as well as the bottom wall
36
together define a smaller channel 68 as shown.
The frame 26 of the window 20 is sized so it can be slid into position on the
ledge 62 and for abutment against the separating wall 64 to, in turn, provide
for
installation of the window 20 within the window buck 10 defined by the left
side
member 12, the top side member 14, the bottom side member 16 and the right
side
member 18. It may be noted that the ledge 62 is spaced a distance 70 below the
top
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wall 34. The distance 70 is selected to provide for some dimensional
variations in the
window frame 26 while still providing an appropriately sufficient amount of
surface of
the separating wall 64 to facilitate installation using screws, nails, glue or
the like. The
distance 70 is also preferably selected to be less than the height 67 of the
lower element
69 of the frame 26. The ledge 62 has a width 63 that is preferably at least
the width 65
of the separate members of the frame 26 such as members 69 and 71.
In FIG. 2 it can also be seen that the side member 32 has a lower portion 72
of
the first outside wall 38 which functions as an outside flange and which
extends below
the bottom wall 36 a distance 74, which is comparable to the height 52 of the
channels
44, 46, 48 and 50. The distance 74 may vary as desired by the user to provide
for
sufficient connection to the cement wall 76 when the concrete (or the like)
used to form
the wall 76 dries after being poured. That is, the distance 74 of the portion
72 is
selected to provide for a rigid attachment to the cement wall 76. It is also
selected so
that fasteners such as nail 77 may be used to secure the window buck to a
fiberglass
external cement form 79 used to define, with internal cement form 81, a cavity
or void
into which cement is poured to form the wall 76. The finger 78 associated with
the
lower portion 72 of the first outside wall 38 and the forger 80 associated
with lower
portion 82 of the second outside wall 40 extend inwardly in order to rigidly
secure the
side member 32 and, more particularly, the window buck 10 in place after the
concrete
hardens or solidifies to form wall 76.
It may be noted that side member 32 may be formed of an extruded vinyl
material. When extruded, it may have rounded corners such as the left corner
84 and
the right corner 86. The rounding of corners is not necessary. They may be
formed in
any manner desired to facilitate assembly and construction and an appearance
desired
by the user.
Referring now to FIG. 3, an alternative side member 90 is illustrated in cross-
section. The side member 90 has a top wall 92 and a bottom wall 94. It also
has a left
wall 96 and a right wall 98. In the space between the left wall 96 and the
right wall 98
is a plurality of channels 100, 102, 104 and 106, each sized and shaped to
have
essentially the same height 108 and essentially the same width 110. Each of
the
channels 100, 102, 104 and 106 is separated by a separating wall such as walls
112,
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114, and 116 as shown. Extending above the top wall 92 is abutment member 118.
The abutment member 118 has a top wall 120 and opposite side walls 122 and 124
positioned to define a channel 126, which may be dimensioned in height 125 and
width
127 the same as the height 108 and width 110 of the other channels 100, 102,
104 and
106.
The abutment member 118 is positioned spaced a distance 128 from the right
wall 98 so that the frame 26 of a window 20 can be received with the outer
wall 130 of
the frame 26 being in general alignment with the right wall 98. Similarly, the
abutment
member 118 is sized to have a height 132 to provide for dimensional variances
in the
frame 26 of the window 20.
It may also be noted that the right wall 98 has an interior flange or
extension 134
which extends below the bottom wall 94 a distance 135 selected to provide for
secure
attachment of the side member 90 to the cement wall 136. It may be noted that
the
extension 134 also has a bead or node 138 formed at its distal end 140 to
facilitate
secure attachment of the side member 90 to the cement wall 136. The left wall
96 has a
similar flange or extension 142 sized in length comparable to the extension
134 of the
right side wall 98. Even though the extensions 134 and 142 are noted to be
substantially the same in length, they may differ if desired.
FIG. 4 shows a locking member 150 which may be used to interconnect
adjoining side members as illustrated in FIG. 5. More specifically, FIG. 4
shows a
locking member 150 for use in assembling two side members 162 and 166 as
illustrated
in FIG. S. The locking member 150 is formed to have a first member or leg 152
and a
second member or leg 154 oriented at a right angle to each other. The legs 152
and 154
are sized in height 156 and in width 158 to be comparable to the height 52 and
width 54
of the channels 44, 46, 48 and 50 of the side member 32 of FIG. 2 or the
height 108 and
width 110 of channels 100, 102, 104 and 106 of side member 90. The legs 152
and 154
are similarly dimensioned in height 108 and width 110 so that the legs 152 and
154 may
frictionally engage and be inserted into one selected channel 100, 102, 104
and 106, or
a selected one of channels 44, 46, 48 and 50.
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As can be seen in FIG. 4, the leg 152 has a raised portion 160 which
fractionally
engages the interior surface of the selected one of channels 44, 46, 48 and
50, or
channels 100, 102, 104 and 106, to provide for a more rigid, secure
connection.
As best seen in FIG. 5, the leg 152 is inserted into a selected channel of the
side
member 162. The leg 152, with the raised portion 160, fractionally engages the
interior
of the selected channel. Similarly, leg 154, with a raised portion 164,
fractionally
engages a channel in an adjoining side member 166. The side members 162 and
166
are urged toward each other and into abutment 168 and 170 with corresponding
abutting edges 172 and 174 formed at an angle 173 and 175 selected to provide
for
abutment. The angle 173 and 175 presently preferred is 45°. Inasmuch as
multiple
channels are provided in the side member 32 and the side member 90, it can be
seen
that one or more locking members 150 may be inserted into two or more of the
channels, such as channels 44, 46, 48 and 50, or channels 100, 102, 104 and
106, to
provide for a rigid connection between multiple channels of adjoining side
members of
a particular window buck.
More specifically, locking members, such as locking member 150, are
positioned in-between to connect, for example, the left side member 12 with
the top
side member 14, and the top side member 14 to the right side member 18.
Similar
locking members 150 are used to interconnect the bottom side member 16 with
the left
side member 12 and the right side member 18 at their respective corners.
Obviously, the window buck 10 may be shaped and sized in height 177 and in
width 179 (FIG. 1 ) as desired. That is, height 177 and width 179 may be
selected to
receive conventional or preassembled windows such as window 20. In selected
circumstances, the user may take a length of side wall and cut it to a desired
dimension
to form a window of desired dimensions and assemble it using a locking member,
such
as locking member 150 of FIG. 4 or other suitably formed locking members.
After the
concrete wall 76 (136) is formed, a window 20 can be constructed and installed
in any
available opening with extensions such as extensions 134 and 142 (FIG. 3)
fractionally
engaging the wall 136. A window buck 10 may also be used in wooden, block and
brick walls as well as walls of other materials.
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Preferably, the left side member 12, the top side member 14, the bottom side
member 16 and the right side member 18 (FIG. 1 ) may all be precut and
assembled in a
carton with the necessary locking members 150 so that a user may simply
assemble the
window buck 10 on site prior to installation. Therefore, the window buck 10
may be
easily stored before use because it is disassembled, reducing the amount of
space
necessary for shipment and minimizing the amount of damage occurring during
transportation to and minimizing storage requirements on the construction site
prior to
installation.
FIG. 6 shows a side member 180 which is shaped to be circular in projection.
It
has an interior wall 182 with a ledge 184 so that in cross-section it is
similar to the
cross-section shown in FIG. 2. The locking member 186, shown in FIG. 7, also
is sized
and shaped to fit within an interior channel formed in the side member 180.
The
locking member 186 has a left raised portion 188 and a right raised portion
190 to
provide for frictional engagement within the selected channel of the side
member 180.
As can be seen, the side member 180 has a first end 192 configured to abut the
other
end 194 when assembled with the locking member 186 interiorly positioned
within a
selected channel. A plurality of locking members 186 may be used if desired
with a
plurality of channels formed within the side member 180.
It should also be recognized that the side members such as left side member
12,
top side member 14, bottom side member 16 and right side member 18 may be cut
and
assembled into shapes other than the rectilinear shape shown in FIG. 1. That
is, locking
members having an angle 159 other than 90° may be used to develop
geometric shapes
that may be triangular, diamond shaped, octagonal, or some other polygon with
a
perimeter. That is, the perimeter of the window buck 10 of FIG. 1 includes the
length
28 and the height 177, as well as height 181 and width 183 for a rectilinear
window
buck 10 and window 20. Alternatively, side members may be formed in half
circle
sections or other geometric forms and used with curvilinear or straight
sections in-
between to develop a substantially elliptical window buck or window buck of
any
desired shape.
Although the window buck is herein stated to be formed of an extruded vinyl,
other materials may be used including, in some cases, aluminum if desired.
However,
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the preferred material is vinyl or vinyl-type material or vinyl-like material.
Vinyl is
preferred because it is strong yet not brittle. It can be cleaned, does not
need to be
pointed or preserved and can be nailed or glued. Also, it can be cut with a
saw or
similar cutting tool.
It may be also noted that the channels 44, 46, 48 and 50, as well as the
channels
100, 102, 104, 106 as well as channels 68 and 126, may each be filled with an
insulation material if desired. Appropriate insulation materials include, for
example, an
expanded polyurethane foam as well as fiberglass materials or any other
similar
material that would increase the thermal resistivity to reduce heat loss
through the
window buck after construction of the window is complete.
In an alternative and more preferred arrangement, the window buck 10 of the
invention has at least two side wall members. The sidewall members each have a
first
end and a second end. One of the first ends and one of the second ends are
formed to
connect with the other. One end of the side wall member is a female member 200
shown in perspective in FIG. 8. The female member 200 is formed comparable to
the
side member 32 of FIG. 2 with a substantially similar length 202, height 204
and width
206. It has channels 210, 212, 214 and 216 formed in it along with a side
portion 218
and 220 sized to embrace the concrete wall in a manner similar to side member
32.
The female member 200 also has a ledge 222 formed as shown to receive the
window
after the concrete wall is poured and hardened.
The female member 200 has a surface 224 facing to the interior of the window
buck. The surface has three slots 226, 228 and 230 formed in a line as shown.
Each slot
226, 228, 230 has a width 232 and a length 234 substantially the same and
selected to
snugly receive corresponding tongues from the male member 240 shown in FIG. 9
as
discussed hereinafter. Each slot 226, 228 and 230 extends through the surface
224.
The slots 226, 228 and 230 are each spaced a distance 236 selected to
correspond to the
width of channels formed in the male member as discussed hereinafter.
The female side member 200 has two ends, which are the same except for their
orientation. The female side member 200 may come in a length 202 larger than
needed
for a desired window buck and in turn may be cut to form an essentially
straight end
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238. That is, the end 238 is substantially planar and presents what could be
said to be
an effectively flat surface.
The female side member 200 may be formed with the slots 226, 228 and 230
preformed and spaced in a plurality of rows such as rows 237 and 239 along the
entire
length 202 of the female side member. Alternatively, the slots 226, 228 and
230 may
be formed on site by cutting using an appropriate tool (e.g. a chisel or
drill) or by
pressing out fillers that are formed by making scribe marks during formation
of the
female side member 200 so that upon application of a force (e.g., pressing
with a punch
or screw driver tip) the filler breaks along the scribed lines to thereby form
the desired
slots such as slots 226, 228 and 230 or other slots in other rows such as rows
237 and
239. The scribed lines shown by dotted line for the slots of rows 237 and 239
such as
slot 235 are weakened portions of the surface so that application of pressure
causes the
filler such as filler 233 to easily separate and cause the desired slot to
appear.
Referring now to FIG. 9, a side member has one end formed to connect to one
other end of an adjoining member. The side member is a male side member 240
shown
in partial perspective with a length 242, height 244 and width 246 comparable
to
member 32 of FIG. 2. It is formed with channels 248, 250, 252 and 254
comparable to
the channels formed in the side member 32 of FIG. 2. The male side member 240
also
has side portions 256 and 258 to embrace the concrete wall when it is formed.
The male side member 240 also has three tongues 260, 262 and 264 extending
upwardly from and along the interior surface 266. The tongues 260, 262 and 264
are
each substantially the same in dimension and have a length 268 and a width 270
selected to snugly register with the corresponding slots 226, 228 and 230 of
the female
side member 200. The tongues 260, 262 and 264 are sized in height 272 to
extend into
the respective channels 210, 212 and 214 of the female member and to either
contact
the interior surface 276 of those channels or be short of it. That is, the
channels 210,
212 and 214 have a depth 278; and the height 272 of the tongues is the same as
the
depth 278 or slightly less so the end 280 of the male member can snugly abut
the
surface 224 of the female member. That is, the end 280 of the male side member
240 is
planar or flat in section and therefore can snugly abut the interior facing
surface 224 of
CA 02255256 1998-12-04
-15-
the female side member 200 when the male side member 240 and the female side
member 200 are assembled.
As shown in FIG. 10, the female side member 200 and the male side member
240 are joined at their ends. T'he tongues 260, 262 and 264 together with the
corresponding slots 226, 228 and 230 constitute connection means for attaching
one
end of the female side member 200 to one end of the male side member 240. More
specifically, the tongues 260, 262 and 264 are inserted into the slots 226,
228 and 230.
The tongues 260, 262 and 264 are urged into the slots 226, 228 and 230 until
the
surface 280 abuts the surface 224. The sides of the channels 248, 250 and 252
all abut
the surface 224 and function as part of the connection means to mechanically
limit
angular rotation and twisting of the female side member 200 relative to the
male side
member 240 and vice versa.
As can be seen in FIGS. 9 and 10, the male side member 240 also has a ledge
282 which can be said to be defined and formed by the channel member 254 and
the
side wall of the channel 252. In order to have a smooth corner in the window
buck
formed of two male side members and two female side members, the channel 254
is cut
to extend a height 284 which is selected to abut the side surface 286 of the
ledge 222
and in turn form a clean and snug corner.
In order to form the tongues such as tongues 260, 262 and 264, the male side
member may be cut on site to create them. Alternatively they may be formed by
removing filler pieces 288 and 290 and separating them from associated
structure such
as the side portion 256 and the side surface 292 along scribes or perforations
indicated
by dotted lines.
Although reference has been made to a male member having both ends formed
as shown in FIG. 9 and a female member with both of its ends formed as shown
in FIG.
8, it may be understood that a side member may be so arranged or may have one
female
end and one male end.
As can be seen in FIG. 11, a tongue 300 may be preformed in the channels and
may be simply rotated 302 from the channel in the side member 304. The tongue
300 is
formed to be tapered in width. It has a smaller width 301 near the top in
relation to the
CA 02255256 1998-12-04
-16-
width 303 near the bottom. The width 303 is selected to form a snug friction
fit with a
corresponding slot in a female member.
As depicted in FIG. 12, a tongue can be formed in a variety of shapes
including
triangular, rounded 308 or to be two spaced apart fingers or pins 310 and 312.
The
spaced apart fingers or pins 310 and 312 are spaced apart a distance so that
the pins
may snugly fit into one corresponding slot in the female side member.
Referring now to FIG. 13, an alternative female side member 320 is shown. It
is
comparable to the female side member of FIG. 8 but for the slots 322, 324 and
326
which are all oriented lengthwise or along the length of the female side
member. Of
course the orientation of the tongues of the male members would necessarily
need to be
reconfigured to register with the slots 323, 324 and 326.
In FIGS. 14-16, four side members 350, 352, 354 and 356 are shown. Each side
member such as side member 350 has a plurality of side-by-side channels such
as
channels 358, 359, 360, 361 and 362 for side members 350. The channels 358-362
are
similar to those described in more detail in FIGS. 2, 3, 8 and 9. Each side
member such
as side member 350 also has an exterior flange 364 and an interior flange 366
comparable to the flanges or extensions 72 and 82 in FIG. 2, extensions 134
and 132 in
FIG. 3 and extensions 220 and 238 shown in FIG. 8.
In FIG. 14, it can be seen that side members 350 and 352 are virtually
identical
and are oriented and differ only in that they each have an interior surface
368 and 370
which are facing each other. As best seen with respect to the side member 352,
first
end 372 and the second end 374 are both formed to be substantially the same.
That is,
each are here shown to have connecting means which is female structure 376 and
378
configured to connect with male structure 380 and 382 positioned at the first
end 384
and the second end 386 of side member 354 or male structure 388 and 390
associated
with the first end 392 and the second end 394 of the side member 356. T'he
female
structure is associated with both ends 396 and 398 of the side member 350.
However,
the female structure of the side member 350 cannot readily been seen because
of the
orientation of the side member 350 in the illustration of FIG. 14.
The female structure 376 and 378 shown for the side member 352 includes a
first groove 400 and a second groove 402. Similarly, the other female
structure 378
CA 02255256 1998-12-04
-17-
contains a first groove 404 and a second groove 406. The grooves 400, 402, 404
and
406 each extend the complete width 408 of the interior surface 370 of the side
member
352. That is, they extend from the edge 410 to the edge 412.
In practice, the groove 400, 402, 404 and 406 are formed as seen in FIG. 17.
That is, a saw blade 414 is shown positioned to cut a groove in the interior
surface 370.
The associated drive mechanism for operating the saw blade in a conventional
manner
is not illustrated for purposes of simplicity. Any convenient table saw or
radial arm saw
will be suitable for achieving the purposes as hereinafter described.
Mechanisms other
than saws may be used including grinding wheels and friction discs to create a
groove
in a vinyl material or other material used to fabricate the side members 350,
352, 354
and 356.
In FIG. 17, the saw blade 414 is shown cutting a groove which is of a selected
depth 416. The depth 416 is selected to be more than the thickness 417 of the
interior
surface 370 of the member 352. Thus the groove 400 as well as other grooves
402, 404
and 406 can all be formed so that individual slots are defined by the channel
walls 418,
419, 420, 421 and 422 to provide access to the interior of each of the
plurality of
channels such as channels 423-426. The groove, such as grooves 400, 402, 404
and
406, is formed by moving the side member 352 on a saw table top 427 as the saw
blade
414 rotates to make the cut.
It can be seen that a saw can be devised in which two or four blades are
operating so two or four grooves 400, 402, 404 and 406 can be formed
simultaneously
with one movement of the side member 352.
The grooves such as groove 400 and 402 are spaced apart a distance 401 which
is the same as the distance 428 which in effect the height 432 of each of the
channels of
each of the side members such as channels 423-426 in side member 352.
In reference to the side members 354 and 356, it can be seen that each has
tongue structure which is a plurality of tabs or tongues 434, 435, 436, 437,
438, 439,
440 and 441. The tabs 434-441 are formed by using a saw blade such as saw
blade 414
and cutting grooves which coincide with the interior sidewalls such as
interior sidewalls
444, 445 and 446 shown for the channels 358-362 for side member 350. More
specifically, the tongues 434-441 are formed by making cuts which remove the
interior
CA 02255256 1998-12-04
-18-
sidewalls such as sidewall 444-446 as well as the sidewalls 447 and 448 down a
distance selected to form tongues 434-441. The saw blade creates a slot or
groove such
as slot 450, 451 and 452. The slots 450-452 have a width 454 which is defined
by the
width of the saw blade 414 which also coincides with and is slightly more than
the
width 456 of the interior sidewall 444-446 as well as sidewalls 448 and 447.
The tongues 434-441 each are cut to a depth 458 which is less than the depth
460 of each of the channels such as channels 358-361.
As seen in FIG. 15, the side member 350 is oriented with its slots in the
first end
396 (not shown) to register with the male structure 388 and more particularly
the
plurality of spaced-apart tongues 462 formed in the first end 392 of the
member 356.
Similarly the slots not shown in the second end 398 of the side member 350
register
with plurality of tongues 437-441 formed in the first end 384 of the side
member 354.
Similarly, the plurality of tongues 466 in the second end 394 of the side
member 356
are positioned to register with the slots 400 and 402 at the first end 372 of
side member
352. It may also be noted that the slot 453 (FIG. 14) creates an extension 468
so that a
snug fit of the extension 468 is effected in the window receiving groove 472
as better
seen in FIG. 16. A similar extension 469 is formed at the first end 390 of
side member
356. Similar extensions 467 and 465 are formed in side member 354 as
illustrated
In FIG. 15, the second end 374 of the side member 354 has male structure 382
in the form of tongue structure 474 that registers with the grooves 404 and
406. The
male structure 382 of the first end 384 registers with the female structure
(not shown) in
the first end 396 of the side member 350.
Since the saw blade 414 is selected to have substantially the same width as
the
thickness of the interior surface 370 of a side member and the interior
sidewalls such as
sidewalk 444-446 of the channels 358-361, it can be understood that a snug fit
is
effected between the tongues such as tongues 434-441 and the corresponding
slots such
as slots 400, 402, 404 and 406.
In some instances, a user may add a glue such as an epoxy resin or other
similar
material in order to enhance or strengthen the connection if desired.
As can be seen in FIG. 16, the side members 350, 352, 354 and 356 are
assembled to form a rectangular-shaped window buck. It can be seen that the
exterior
CA 02255256 1998-12-04
-19-
flanges 364, 476, 477 and 478 are shown with a plurality of dots 480 to
illustrate
scribes or apertures through which screws or nails may be inserted to secure
the
window buck shown in FIG. 16 to the wall of an associated form or one of a
pair of
forms used to define a cement wall. Nails such as a nail 482 may be driven
through one
or more of the apertures 480 or through the flanges 364, 476, 477 and 478 at
any
desired location. The window buck, though particularly useful and suitable for
use with
cement walls may also be used in wooden wall construction in selected, desired
applications.
To install a window buck such as that shown in FIG. 16, the cement forms such
as forms 79 and 81 in FIG. 2 are first provided. Preferably one form, such as
form 79,
is installed and positioned. The window buck such as that shown in FIG. 16 is
positioned on the wall at a desired location and secured in place by nails
such as nails
482. Alternately, other fasteners including glues or anything else to maintain
a secure
relationship may be employed. Alternately, the buck may be supported by a
rebar
structure positioned under it.
The other portion of the cement form 81 is then positioned in place and
secured.
Thereupon cement is poured into the form to define and create the cement wall.
The
cement is poured around and then over the window buck. Once the cement cures
or
dries, the form such as forms 79 and 81 are removed leaving an erect wall with
a
window buck defining a window opening. Thereupon a window such as window 20
may be inserted into the window groove 472 (FIG. 16).
It may be also noted that the use of two sets of tongues 434-437 and 438-441
to
associate with corresponding grooves such as grooves 400 and 402 effect a more
stable,
rigid relationship to facilitate installation. That is, one side such as side
member 356
could be associated and connected with side member 352. The double slot and
double
groove arrangement provide for more stable connections so that the assembly
remains
freestanding while the user continues to assemble the other sides such as side
350 and
354.
It may be noted with particularity that the window buck of FIG. 16 is formed
using two identical members 350 and 352 which have female structure such as
female
structure 376 and 378 formed at their opposite ends. Similarly the other side
members
CA 02255256 1998-12-04
-20-
354 and 356 are identical and have corresponding male structure 380 and 382 as
well as
388 and 390 formed at their respective opposite ends.
In operation, a user may find it convenient to collect side members of
different
sizes in a single collection. That is, a collection of side members such as
side member
354 of a particular size may be stored next to a collection of side members
such as side
members 350 and 352. Next to that, another series of side members having
height or
length 480 that differs from the height or length of members 350, 352, 354 and
356 may
be provided. Similarly, additional side members having other lengths or
heights 482
(FIG. 14) may be provided in yet another adjoining storage location.
Thus, a user may be able to quickly assemble window bucks of different
dimensions by simply collecting a pair of side members having female structure
and a
pair of side members having male structure. Window bucks of different sizes
may be
quickly and easily assembled by simply assembling the desired side members to
effect
assembly of a window bucks having different desired heights and widths.
By way of example, one could assume that one desired window buck would
have a height 500 of 0.6 meters (two feet) and a width 502 of 0.6 meters (two
feet).
Another window buck would have a height 500 of 0.6 meters (two feet) and a
width
502 of 0.9 meters (three feet).
It can also be seen that side members which may be regarded as female side
members such as side member 350 and 352 may be separately collected (e.g., on
a
pallet or in a bin) having a width 502 of 0.6 meters (two feet). Another group
of side
members similar in shape and form to those 350 and 352 having a width of 0.9
meters
(three feet) may be separately assembled in an adjoining or nearby location.
Further, a
number of side members such as side members 354 and 356 having a height of 0.6
meters (two feet) may be in another nearby location. Thus, to assemble a
window buck
having a height of 0.6 meters (two feet) and a width of 0.6 meters (two feet),
one need
only assemble two female members having a width 502 of 0.6 meters (two feet)
and
two male members having a height 500 of 0.6 meters (two feet) in order to have
a
window buck that is 0.6 meters (two feet) by 0.6 meters (two feet).
To have a window buck that is 0.6 meters (two feet) by 0.9 meters (three
feet),
the user need assembly only two side members of 0.6 meters (two foot) height
and two
CA 02255256 1998-12-04
-21-
female members such as members 350 and 352 having a width of 0.9 meters (three
feet). Similarly, if a user desired a window having, for example, a width 502
of 0.9
meters (three feet) and a height 500 of 0.9 meters (three feet), a user could
then go to a
separate nearby location to acquire two side members such as side members 354
and
356 having a height of 0.9 meters (three feet) combining the side members that
are 0.9
meters (three feet) in height with the side members are 0.9 meters (three
feet) in width
502 produces a 0.9 meters (three foot) by 0.9 meters (three foot) window buck.
The above-referenced dimensions are purely theoretical and are not intended to
in fact reflect what the standardized size may be for given standardized
windows.
However, the sizes do illustrate the fact that different sizes of different
window bucks
may be assembled by simply assembling side members having the desired widths
and
heights to define the desired window openings. In turn, the number of overall
side
members that need to be inventoried can be reduced or controlled not only by
the
manufacturer, but also by the distributor as well as by the customer.
Turning now to FIG. 18, a preferred window buck 520 is depicted being formed
by the assembly of a pair of identical first side members 522 and 524 and a
pair of
identical second side members 526 and 528, the first side members 522 and 524
have
the same width 530 as well as the same lengths 532 and 534. The first side
members
522 and 524 also have slot structure 536 and 538 formed in their respective
first ends
540 and 542. Of course, they also have tongue structures 544 and 546 formed in
their
respective second ends 548 and 550.
The pair of second side members 526 and 528 also have the same width 552
which is the same as the width 530 of the pair of first side members 522 and
524. The
second side members also have the same lengths 554 and 556 which may be the
same
as or different from the lengths 532 and 534. The second side members 526 and
528
also have slot structures 558 and 560 formed in their first ends 562 and 564
as well as
tongue structures 566 and 568 formed in their respective second ends 570 and
572.
With the first side members 522 and 524 and the second side members 526 and
528 configured, as described, it can be seen that end-to-end assembly can be
effected as
depicted. End-to-end assembly results in the fully assembled window buck 520.
CA 02255256 1998-12-04
-22-
Because the first side members 522 and 524 are the same and because the
second side members 526 and 528 are the same, the user need only have two
stock piles
or bins rather than four. That is, the user need have only a first stock pile
or bin for first
side members and a second stock pile or bin for second side members. An
additional
stock pile or bin may contain third side members all of which are identical to
each other
so that window bucks of different dimensions may easily be assembled using
either the
first side members or second side members with the third side members.
FIG. 19 shows an assembled window buck 520 with a first brace 574 positioned
in the interior 576 defined by the first side members 522 and 524 and the
second side
members 526 and 528. The first brace 574 has a length 578 which is essentially
the
same as the height of the interior 576. The first brace 574 in place stiffens
or
strengthens the window buck 520 to inhibit collapse during assembly and to
inhibit
deformation during installation and during formation of the associated wall.
A second brace 580 is also shown extending the width 582 of the interior 576
to
stiffen or strengthen the window buck 520 during installation and during
formation of
the associated wall. A third brace 584 may also be provided. The third brace
584 is
sized the same as brace 580 and may be desired to strengthen the window buck
to assist
in resisting twisting forces that may evolve during installation and during
formation of
the associated wall. For example, cement may be poured unevenly and stress the
window buck 520 as the cement flows thereabout.
FIG. 19 also shows a shim 586 that may be placed between one interior surface
588 and the first brace 574. The first brace would necessarily be shorter in
length 578
to accommodate the thickness 590 of the shim 586.
After formation of the wall in which the window buck 520 is placed, the stress
or compression force on the first brace 574 may be quite high so that the
first brace may
need to be removed by use of force. In so doing, the surface 588 could become
scratched or otherwise damaged. The shim 586 limits or avoids such damage from
the
first brace 574. Of course, a similar shim may be used for the other braces
580 and 584.
FIG. 19 also shows the fasteners 592 spaced about the perimeter of the window
buck 520 for positioning through the exterior flanges, such as flanges 584,
586 (FIG.
18), 588 and 590, of the side members 522, 524, 526 and 528.
CA 02255256 1998-12-04
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In FIG. 19, a carpenter's level 592 is shown to illustrate that in the process
of
assembling the window buck 520, a level 592 is useful to ensure installation
of the
window buck 520 with a level or horizontal orientation of the interior surface
588 as
well as a vertical orientation of the side members 526 and 528. Of course, a
carpenter's
square 594 may be used in assembling the window buck 520 to ensure the
corners, such
as corner 596, are truly square or normal.
The embodiments of FIGS. 8 to 18 are preferred because they do not require use
of a separate locking member to form the corners of a rectilinear window buck
or to
connect the ends of a side member or side members to form a desired window
buck.
Thus in use, a window buck of desired dimensions may be packaged to contain
two
female side members and two male side members.
It should be recognized that the window buck of FIGS 1-18 provides for simple
transportation inasmuch as it need not be pre-assembled. Rather, it may be
shipped
disassembled with its components shrink-wrapped together or otherwise packaged
to
contain the various side members with or without locking members. Upon arrival
of
the package at the construction site, the window buck components may be
unpackaged
and easily assembled at the time of installation. Damage while in storage and
before
use at the site is thereby minimized. Thereafter, the window buck may be
easily placed
in between the forms that are then positioned to form the cement wall so that
upon
pouring the cement wall, the window buck is in position to make further window
construction simple and easy.
FIG. 20 is a perspective view of the window buck 520 of FIG. 19 having side
members 522, 524, 526 and 528 assembled as shown. A window frame 523 is show
positioned for insertion into the window buck 520 to complete formation of a
window.
A separate window well enclosure 525 is also show. It has a plurality of eye
shaped
openings such as openings 529A-D positioned to interconnect with headed
fasteners
(e.g., nails, screws, rivets, or the like) 527 !-D secured to the side member
528.
Corresponding fasteners 531 are associated with side member 526 to
interconnect with
openings (not shown) in the window well enclosure 525. Thus following assembly
of
the window 523 into the window buck 520, the window well enclosure 525 may be
attached for those windows that will be at or below ground level.
CA 02255256 1998-12-04
-24-
An alternate frame arrangement is shown in FIG. 21. A frame and more
particularly a window buck 600 is shown having a top side member 602, a right
side
member 604, a left side member 606 and a bottom side member. When assembled,
the
window buck 600 will have a height 610 and a width 612 which may be any
desired
height and width for an opening in a structural wall to be formed from
concrete.
The top side member 602, the right side member 604 and the left side member
606 are all formed from stock. That is, side member material may be provided
in
standard lengths as desired ranging from 1.8 meters (six foot) to 4.9 meters
(sixteen
feet). At present the 4.9 meters (sixteen foot) dimension appears to be
preferred and
because it is comparable in length to other building materials and in turn is
transportable by trucks sized to transport other building materials. The stock
also
comes in different widths 614 such as for example, 10 centimeters (four inch),
15
centimeters (six inch), 20 centimeters (eight inch), 25 centimeters (ten inch)
and 30
centimeters (twelve inch). Upon obtaining the desired stock, the user cuts the
tops side
member 602, the left side member 606 and the right side member 604 using any
suitable tool. A hand saw will work although it is expected that a hand held
portable
circular saw or other suitable saw will be used.
A bottom stock is separately provided. As can be seen the bottom side member
608 is formed with apertures 616 spaced along its length. The bottom stock is
provided
in lengths and widths comparable into the stock used to form the other side
members.
Upon selection of the proper stock for the bottom side member, it too is cut
to the
desired length in the same manner as the other side members 602,604, 606 to
form the
bottom of the window buck 600.
The each side member 602, 604, 606 and 608 of the window buck 600 is formed
with a plurality of channels 618-622 as seen more clearly in FIGS. 22, 23 and
24 and as
more fully discussed with respect thereto. Top side member 602 has opposite
ends
602A and 602 B. Similarly left side member 606 has opposite ends 606A and 606
B.
Right side member 604 has opposite ends 604 A and 604 B. Similarly the bottom
side
member 608 has opposite ends 608 A and 608 B. As can be seen in FIG. 21, an
opposite end of one side member is positioned for connection to an opposite
end of an
adjacent side member so that the widow buck may be formed. The opposite ends
are
CA 02255256 1998-12-04
-25-
connected by connection means such as connectors 628, 629, 630, 631, 632, 633,
634
and 635 not shown here.
The connectors each have a first finger or extension such as extensions 628 A
and 629A sized to fractionally and slidably engage the outer channels 618 and
620 in
the respective side members. A second finger or extension such as extensions
628B
and 629B are similarly sized to engage the outer channesl 618 and 622 of
adjacent side
members. Although two connectors such as connectors 628 and 629 are shown for
connecting one side member to the adjacent side member, it should be
understood that
one connector or more than two connectors can be used as desired. Two have
been
found to be suitable to reduce twisting and to maintain alignment of the
various inner
walls 636-639 of the side members 602-608
T'he connectors shown are mechanical to effect a frictional lock. It should be
understood that the connectors may be glued, welded, chemically adhered and
taped. In
other words, any fastening arrangement is acceptable so long is it results in
connection
of one side member to the adjacent sufficient to retain a fixed relationship
during the
pouring and curing of the concrete wall.
After the window buck 600 is assembled, it is placed so that a desired opening
is
formed when a concrete wall is formed. As shown in FIG 21, an insulated
concrete
form has two spaced apart wall members 642 and 643 assembled to define the
void 46.
Each side 642 and 643 is held in relationship to each other by conventional
means
including spacers 644. Rebar 645 may be placed in the wall to strengthen the
wall
when it is formed.
The window buck 600 is placed into an opening cut into the insulated concrete
form 640 and physically secured in the form by any acceptable means such as by
nails.
With the wall forms otherwise ready, concrete is poured into the void 646. In
the
vicinity of the window buck 600, concrete may be poured into the apertures 616
to
ensure the delivery of concrete to the void space under the window. The
apertures 616
also vent any air from under the window buck 600.
After installation, the window buck may be braced as more fully discussed
herein.
CA 02255256 1998-12-04
-26-
After the concrete is poured and cured, the bracing if any is removed and a
window such as window 648 is installed in the window buck 600. The window 648
may be secured in place by any acceptable means including an acceptable
adhesive,
nails, screws and the like.
FIG. 22 shows a bottom member 650 with its internal wall 652 facing upward.
FIG. 23 shows the bottom member 650 with its internal wall 652 facing downward
and
with the external wall 654 spaced from the internal wall 652 and facing into
the void
such as void 64. The channels 618-622 are also shown. Apertures 656-660 are
shown
spaced apart along the length 662 of the member 650. The apertures 656-660 are
sized
to be receive concrete therethrough. Any acceptable funnel, chute or the like
may be
aligned with the apertures 656-660 to direct concrete therethrough. In cases
where
concrete is being pumped, it has been noted that the output end of the house
is typically
less than about 11 centimeters (four and one half inches). Thus the apertures
656-660
are shown sized to be circular in cross section with a diameter of about 12.7
centimeters
(five inches).
The bottom member 650 also has concrete retention means which is here
shown as a fin 664 that extends along the length 662 of the bottom member 650.
The
fin 664 has a lip 665 oriented transversely to interconnect with the concrete
after the
wall is formed as more fully discussed hereinafter.
Referring now to FIG. 24, a side member 666 such as side members 602, 604,
606 and 608 is shown in cross section. The side member 666 has the plurality
of
channels 618-622 as hereinbefore discussed. The channels 618-622 are formed by
sidewalk 688-691 as well as the outer sides 692 and 693. The additional
sidewalls may
be used to from additional channels as desired. Fewer sidewalk may be used so
that
fewer channels are formed. However, at least one sidewall is regarded as
necessary to
provide desired structural rigidity in use. Further, the channels also
function to resist
heat transfer. Of course they may also be filled with insulating material if
desired.
As here shown the outer channels 618 and 622 are formed to have a height 694
and width 695 selected to fractionally receive a connector as more fully
discussed
hereinafter.
CA 02255256 1998-12-04
-27-
The outer sides 692 and 693 extend away from the inner wall 696 to form
flanges 697 and 698. The flanges 697 and 693 have the wall 699 thereinbetween.
More specifically, the sides 700 and 701 of an insulated concrete wall form is
shown
with the flanges 697 and 698 in alignment therewith. Prior to pouring of the
concrete,
flanges 697 and 698 act to retain the side members and in turn the frame with
which
they are associated in position. After the wall 699 hardens or cures, the
flanges 697 and
698 provide a surface to which one may attach other building elements and a
surface
that has an acceptable surface that does not require preservation or
decoration.
In FIG. 24, an additional flange 702 is shown in phantom. In some cases, it is
contemplated that multiple flanges will be provided so that one may cut (rip)
one
channel off to form a side members with a widths 703 and 705 that differ. In
FIG. 24, a
retention fin 706 is shown formed of an extension 707 and a lip 708. The
extension
707 has a height 709 selected so that the retention member is positioned
securely in the
poured concrete of the wall 699. In practice, it has been found that the
height may be
from about 1.3 centimeters to several centimeters (one half an inch to several
inches).
At present 1.4 centimeters (nine sixteenths of an inch) has been found to be
suitable.
However, any height will be suitable so long as the fin 706 is firmly anchored
int the
wall 699 when the concrete cures or hardens.
The lip 708 is shown to have a width 710. The width may be any desired width
to secure the or anchor the fin 706 in the wall 699. It may be from about 0.6
centimeters to several centimeters (one fourth of an inch to several inches).
At present
a width 710 of 1.1 centimeters (seven sixteenths of an inch) has been found to
be
suitable and adequate.
It should be noted that the fin 706 is shown to be "L" shaped in cross
section.
Other shapes or configurations may be used. That is, the lip 708 is simply one
means to
effect an anchoring of the related side member to the wall without the need to
use
fasteners such as nails, bolts, screws or the like. Upon curing of the
concrete, the side
members are secured quite firmly. Alternated shapes for the anchoring effected
by the
lip may be used. A separate fin 712 is shown with a hook like anchoring
arrangement.
Virtually any shape or configuration of anchoring may be used in lieu of the
lip 708 so
CA 02255256 1998-12-04
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long as the effect is to effectively preclude outward movement of the outer
wall 714
from the wall 699. It may also be noted that multiple fins may be used if
desired.
FIGS. 25 and 26 show adjacent side members 720 and 722 as well as side
member 724 and 726 comparable to side members 602, 604, 606, and 608 in FIG.
21.
The connectors 728, 730, 732 and 734 are comparable to the connectors 628-635
all of
which are comparable to connector 736 show in FIG. 27. As better seen in FIG.
27, a
connector 736 has first male structure such as finger 738 sized to
fractionally insert into
a selected channel such as outer channels 618 and 622. The finger 738 is here
shown to
be in the form of an "I" 740 in cross section to reduce the material and to
allow some
flexibility when inserting the finger 738 into a selected channel. The finger
738 has a
height 739 and a width 737 sized comparable to height 694 and width 695 (FIG.
24)to
effect a frictional but slidable engagement with a channel such as channel
618. In
some embodiments the finger 738 will have rounded or beveled corners 741, 742
and
743 as shown by dotted line. The rounded or beveled corners will facilitate
insertion of
the finger 738 into a channel such as channel 618.
In FIG. 27 the second male structure is a second finger 744 formed identically
to
the finger 738 and unitarily therewith to extend away at a 90 degree angle
745. A filler
plate 750 is attached to an outer surface of the fingers 738 and 744 by any
suitable
means including gluing. The filler plate 750 may also be unitarily be formed
with the
fingers 738 and 744. The filler plate 750 is sized in height 752 and in and
width 753 so
that when the connector 736 is installed between two adjacent side members
such as
side members 720 and 722 (FIG. 26). Thus the edges 754 and 755 of the
connector will
abut edges of the flanges such as flanges 697 and 698 (FIG. 24) to effect an
abutting
relationship and in turn a smooth connection as shown in FIG. 26. In other
words, the
filler plate 750 is sized so that upon installation of the connector 736, the
corner 758
will be formed to appear to be an extension of the flange edge 760 and the
flange edge
761.
FIG. 26 also shows that a side member 720 may be formed of a first section
720A and a second section 720 B. A connector 762 shown in FIG. 28 is "I"
shaped in
cross section and sized in height 764 and 766 comparable to height 694 and 695
of a
channel such as channel 618 so that the connector 762 fractionally engages a
channel
CA 02255256 1998-12-04
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such as channel 618 and 622 into which it is inserted. The connector 762 has a
length
768 selected to effect a secure connection in which the bending or relative
movement
between section 720A and 720B in the longitudinal direction or along the
longitudinal
axis 770 and transverse thereto 772 is limited. Thus pieces of the stock that
remain
after several frames have been formed can be joined together to form a side
member of
two or more sections. The amount of waste material is thereby reduced lowering
the
cost of waste removal from a building site and reducing the waste material
itself so that
less material need be purchased.
FIG. 29 shows a frame and more specifically window buck 780 installed in wall
782. The wall 782 is made with an insulated concrete form. The window buck 780
has
a height 784 which is less than 1.5 meters (S feet) and a width that is less
than 1.5
meters (5 feet). In turn the corner braces 788 and 790 are deemed to be
sufficient to
brace the window buck 780. An example of a brace 788 and 790 is shown in FIG.
30.
In FIG. 30, it can be seen that a corner brace 791 has a lip 792 formed along
one
side to create a surface 794 which is for positioning against the inner wall
of a side
member of a window buck or frame. Along another side a similar lip 800 is
formed
with a surface 801 for contact with the inner wall of a side member. Thus the
corner
brace in effect inserts into the inner area defined by the side members to
abut the inner
wall. Nails, screws or the like 808-811 are then inserted through appropriate
apertures
812-815 to secure the corner brace in the corner of the frame with which it is
being
used. The lip 792 and the lip 800 are normal to each other and form a ninety
degree
angle at the corner 816. The brace has a solid interior 818 which defines an
outer edge
820 that extends from the lip 792 at a 45 degree angle 806 and from the lip
800 at a 45
degree angle 804. The lip 792 and 800 are sized in length 796 and 798
respectively the
same. In use the lengths 796 and 798 should be sufficient to inhibit movement
of the
side members. For one brace now proposed, the length 796 and 798 has been
selected to
be about 46 centimeters (18 inches).
FIG. 31 shows a frame which is a window buck 830 installed with four corner
braces 832-835 and with cross braces 836 and 838. FIG. 31 is an example of
bracing
that may be used for windows in which a dimension is such that bracing every
0.9
meters (three feet) is recommended or typically employed. It may be noted that
the
CA 02255256 1998-12-04
-30-
corner braces 832 and 833 are positioned on opposite sides to provide bracing
on both
sides of the involved frame such as window buck 830. If the height 840
warrants it,
more cross braces 838 may be used. Similarly, if the width 842 warrants, it
more
vertical braces 836 may be used.
For example, the frame shown in FIG. 32 is a door frame 844 made of three side
members as shown. In view of the height, more vertical braces 845-847 are
typically
used
FIG. 32 shows a garage door frame 850 made of three adjacent side members
855, 856 and 857 in a manner similar to side members 602, 604 and 606 in FIG.
21.
The side members 855-857 are secured to each other the same as the side
members 602,
604 and 606. Horizontal braces 860, 861 and 862 are provided along with
vertical
braced 851-854 due to the extended width of the door and the opening. Corner
braces
858 and 859 are also provided to stabilize the side members 855-857 and
reinforce and
strengthen the corners of the frame 850.
Those skilled in the art will recognize that the embodiments herein described
are
for purposes of illustration and explanation and are not intended to limit the
scope of
the claims which themselves recite the features of the invention.
