Note: Descriptions are shown in the official language in which they were submitted.
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WALL OPENING FORM
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates generally to forming openings and in particular
to providing a frame, frame members and framing kits for forming openings in
insulating concrete form construction.
2. Description of Related Art
In the construction industry, a method known as insulating concrete form
construction is well known. Insulating concrete form construction utilizes
walls
having a central cast in place concrete layer bounded by a pair of insulating
forms. In insulating form construction, the insulating forms are typically
comprised of forming panels which are positioned as a pair of spaced apart
walls so as to form a wall cavity therebetween. The wall cavity may then be
filled with concrete to form the completed wall. In this type of construction
the
forming panels may be left in place to provide additional insulating qualities
to
the wall.
As is common with most forms of construction, it is frequently necessary to
construct walls with openings for windows and doors for example. In
insulating concrete construction, such openings are typically formed in the
form blocks prior to filling the cavity with concrete. To form such an
opening,
the pair of opposed forms may have openings cut or formed into them
corresponding to the desired opening. The cavity between the opposed forms
may then be bridged about the perimeter of the opening by a framing member
or buck.
Traditionally, bucks were constructed of dimensioned lumber cut to an
appropriate size to substantially bridge the wall cavity between the two wall
forms. The buck may then be screwed to the wall forms to secure it in place.
A buck constructed from dimensioned lumber requires a significant amount of
work to position within a wall cavity to form an opening therethrough. The
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size of the lumber must firstly be cut to the appropriate dimensions and
nailed
or screwed together to form the buck. Secondly, the assembled buck must be
screwed to the forms within the opening to secure it in place. Also, as a
traditional dimensioned lumber buck has only flat smooth sides oriented
towards the concrete, there is no positive engagement of the window or door
buck with the concrete. This results in the opening not being as secure as is
possible were the lumber to include a surface that positively engages the
concrete. In addition, dimensioned lumber may be prone to rotting and water
damage should water permeate the wall thereby damaging the structure to
which the window or door is secured.
Natural fiber-plastic composite material is a well-known material comprising a
composition of natural fibers set in a plastic matrix. The natural fibers may
be
provided as wood chips, sawdust or rice husks. The plastic matrix may
comprise polyethylene, polyvinyl chloride, polypropylene, or any other
suitable
plastic material. Natural fiber-plastic composite material is often used as a
decking material as it is able to be nailed or screwed in place and is also
water and rot resistant. Natural fiber-plastic composite material is typically
extruded into shapes resembling the cross-sections of traditional dimensioned
lumber. The use of natural fiber-plastic composite material having such
cross-sections, however, would not address some of the aforementioned
difficulties with dimensioned lumber, namely, lack of positive engagement with
the concrete.
In U.S. Patent No. 6,070,375 to Anderson et al., a frame for a wall opening is
disclosed. The frame of Anderson et al. may be constructed of a plurality of
extruded box sections, which may be cut to length and assembled into a buck
by inserting a corner insert into adjacent boxes of the members. The frame
members of Anderson et al. consist of extruded vinyl. Windows and doors are
not as easily securable to the frame of Anderson et al. due to the material
properties of the vinyl used in this construction. In addition, the relatively
thin
cross-section partitions of the frame of Anderson et al. provide a relatively
small surface for a nail, screw or other fastener to engage with.
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Also, the use of a plastic-only extrusion in the frame of Anderson et al.
results
in a weaker structure than is possible by using a composite material of wood
and plastic, for example. The frame of Anderson et al. therefore requires
extensive internal bracing when forming the wall so as to prevent deflection
of
the frame members of Anderson et al. However, it would be difficult to form
the frame members of Anderson et al. from a wood and plastic composite
material due to the complexity and thinness of the shape of the frame
members. It is known to be difficult to extrude wood and plastic composite
materials through small die openings.
What is needed is an insulating concrete form window or door buck that is
constructed of frame members that are water and rot resistant while
maintaining the strength and fastening characteristics of wood bucks. It would
also be desirable to have a buck that offers improved engagement of the buck
with the concrete.
SUMMARY OF THE INVENTION
The present invention provides a window buck that is resistant to water and
rot
and provides a surface that is easily securable to using nails, screws or
other
suitable fasteners. In addition, the present invention has a shape that
retains
the strength characteristics of wooden bucks thereby reducing required bracing
and engages the surrounding concrete.
According to a first embodiment of the present invention there is provided a
frame member for forming an opening through an insulating concrete form
wall having opposed first and second forms. The frame member comprises
an elongate member dimensioned to extend between the opposed forms.
The elongate member is composed of a natural fiber plastic composite
material having an opening forming surface and a wall forming surface and a
pair of longitudinal retention fins extending from the wall forming surface.
Each of the retention fins has a distal lip portion wherein the lip portions
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cooperate to form a hollow between the lip portions and the wall forming
surface.
According to a further embodiment of the present invention there is provided a
frame for forming an opening through an insulating concrete form wall having
opposed first and second forms. The frame comprises at least three frame
members each comprising an elongate member dimensioned to extend
between the opposed forms. The elongate member are composed of a
natural fiber plastic composite material and have an opening forming surface
and a wall forming surface and a pair of longitudinal retention fins extending
from the wall forming surface. Each of the retention fins have a distal lip
portion wherein the lip portions cooperate to form a hollow between the lip
portions and the wall forming surface. The frame further comprises at least
two corner connectors for connecting said frame members. The corner
connectors comprise a bracket insertable into the hollows.
According to a further embodiment of the present invention there is provided a
frame kit for forming an opening through an insulating concrete form wall
having opposed first and second forms. The frame kit comprises at least
three frame members, each comprising an elongate member dimensioned to
extend between the opposed forms. The elongate member are composed of
a natural fiber plastic composite material having an opening forming surface
and a wall forming surface and a pair of longitudinal retention fins extending
from said wall forming surface. Each of the retention fins have a distal lip
portion wherein the lip portions cooperate to form a hollow between the lip
portions and the wall forming surface. The frame kit further comprises at
least
two corner connectors for connecting the frame members. The corner
connectors comprising a bracket insertable into the hollow.
Other aspects and features of the present invention will become apparent to
those ordinarily skilled in the art upon review of the following description
of
specific embodiments of the invention in conjunction with the accompanying
figures.
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BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate embodiments of the invention,
Figure 1 is a perspective view of a wall section having an opening formed
by a window buck according to the present invention.
Figure 2 is a perspective view of the window buck of Figure 1.
Figure 3 is a cross-sectional view of a window buck frame member of
Figure 2 taken along line 3-3.
Figure 4 is a cross-sectional view of a window buck frame member
mounted on a pair of wall forms.
Figure 5 is a cross-sectional view of a window buck frame member
mounted on a pair of wall forms according to an alternative embodiment of the
present invention.
Figure 6 is a cross-sectional view of a window buck frame member
mounted on a pair of wall forms according to an alternative embodiment of the
present invention which includes a raised nailing strip.
Figure 7 is a perspective exploded view of one corner of the window buck
of Figure 1.
DETAILED DESCRIPTION
Referring to Figure 1, an insulating concrete form wall is shown generally at
2.
The insulating concrete wall comprises a pair of opposed first and second wall
forms 4 and 6, respectively constructed of forming panels 7 and ties 9 forming
a wall cavity 8 therebetween. The insulating concrete wall may include an
opening 10 bounded by a wall-opening frame 12 according to a first
embodiment of the invention. A window or a door may then be located within
the opening 10 and secured to the wall-opening frame 12.
As shown in Figure 2, the wall-opening frame 12 comprises a plurality of
frame members 20 connected at adjacent ends to form a completed frame.
The frame members 20 may be arranged in a rectangle as shown in Figure 2
or in an inverted U-shape to form an opening for a door (not shown).
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Now referring to Figure 3, a cross sectional view of a frame member 20 of
Figure 2 is shown taken along the line 3-3. Each frame member 20
comprises a substantially elongate member as shown in Figures 1 and 2. The
frame member as shown in Figure 2 has an opening forming surface 22 and a
wall forming surface 24, and first and second longitudinal edges 26 and 28
respectively. The frame member also includes retention fins 30 and 32,
respectively, extending from wall forming surface 24 for engaging the
concrete as well as assisting in locating adjacent frame members relative to
each other as will be further explained below. As shown in Figure 2, retention
fins 30 and 32 extend normal to the wall forming surface 24, however, it will
be appreciated that other orientations will also be useful as well. The first
and
second retention fins 30 and 32 are parallel to and spaced apart from each
other and include lip portions 34 and 36 at distal ends 38 and 40
respectively,
thereof. The lip portions 34 and 36 extend from said distal ends 38 and 40
normal to the first and second retention fins 30 and 32 and are oriented
towards each other. The wall forming surface 24, first and second retention
fins 30 and 32 and first and second lip portions 34 and 36 form a hollow 42
therebetween. The frame member 20 that is located at the bottom of a frame
may also include relief openings 14 as shown in Figures 1 and 2 to provide for
venting of any entrapped air beneath the wall-opening frame 12 when
concrete is poured into the wall cavity 8.
The frame member as shown in Figure 3 may also include first and second
edge flanges 44 and 46, respectively extending from said first and second
longitudinal edges 26 and 28 normal to said frame member 20. At each edge
of the frame member, the edge flange 44 or 46 and retention fins 30 or 32
form panel receptacles 48 and 50 for receiving the forming panels 7 as shown
in Figure 4. As show in Figure 3, the frame member may be thicker adjacent
to the hollow 42 than it is adjacent to the panel receptacles 48 and 50. It
will
be appreciated that the distance between the respective edge flange 44 or 46
and the retention fin 30 or 32 will be selected so as to securely receive the
form panel. The first and second edge flanges 44 and 46 also provide an
integral drip ledge around the periphery of an opening so as to prevent water
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from leaking through the opening and between the concrete and the forming
panels.
Turning now to Figure 5, a frame member 20 may be provided in which the
spacing between one or both of the respective edge flanges 44 or 46 and the
retention fin 30 or 32 is increased. This enables the placement of a pluraiity
of form panels in the corresponding panel receptacle 48 or 50. As shown in
Figure 5, panel receptacle 48 may be enlarged by increasing the distance
between edge flange 44 and first retention fin 30 enabling the placement of a
thicker form panel 11 therebetween. As shown in Figure 5, panel receptacle
50 is sized so as to receive a first thinner panel 7. It will be appreciated,
however, that it is also possible to increase the distance between edge flange
46 and second retention fin 32 so as to enable the placement of a thicker form
panel 11 therebetween as well. It will also be appreciated that panel
receptacles 48 and 50 may be sized so as to allow for the placement of more
than one panel or a different sized panel therein. By allowing the use of
multiple width forming panels or multiple panels on each side of the wall,
walls
of different insulating or "R" values may be achieved. This is particularly
useful in colder climates where better insulating walls increase the energy
efficiency of the structure.
Now referring to Figure 6, the frame member 20 may also include a securing
strip 54 extending from the opening forming surface 22. The securing strip
comprises an elongate raised portion from the opening forming surface, which
may include interior and exterior securing surfaces 56 and 58 and a top
surface 59. The interior surface 56 faces towards the interior of the wall
while
the exterior surface 58 faces towards the exterior of the wall. A door or
window frame (not shown) may be inserted into the wall-opening frame 12
into abutment with the securing strip 54 and secured thereto by means of
nails, screws or other fasteners. It will be appreciated that a window or
doorframe may be secured to either side of the securing strip, although the
exterior surface will be most commonly used. As shown in Figure 6, the
frame member 20 may also includes a tapered portion 68 between the
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exterior surface 58 and the second edge 28 which advantageously assists
with water drainage away from the wall opening or to the exterior of the
building.
The securing strip 54 may be located such that the distance between the
exterior surface 58 and the first edge 28 of the frame member 20 corresponds
to the thickness of the window or door frame intended to be secured at that
location. In addition, the height of the securing strip 54 will typically be
chosen to adequately secure the window or doorframe while not hindering
access thereto.
The frame members 20 are composed of a natural fiber-plastic composite
material. In such a material, natural fibers are set into a matrix of a
plastic
material. The natrual fibers may be provided by wood chips, saw dust or
other small wood elements. It will also be understood that although wood
fibers are used in the above description, other natural fibers such as for
example, rice husks, bamboo, straw, and peanut shells may also be used.
The plastic matrix natural fiber-plastic composite material may be any
suitable
plastic material such as, for example, polyethylene, polypropylene or
polyvinyl
chloride.
Now referring to Figure 7, an exploded perspective view of two frame
members 20 and a corner bracket 60 are shown according to a further
embodiment of the present invention. The corner bracket 60 comprises first
and second orthogonal members 62 and 64, respectively adapted to be
received within the hollow 42 of two adjacent frame members 20. As shown
in Figure 7, the first and second members may have a rectangular cross-
section, however it will be appreciated that other cross-sections will be
useful
as well so as to correspond to the cross-section of the hollow 42 of the frame
member 20. The corner bracket may also include external stiffening ribs 66,
which are locatable between the lip portions 34 and 36 of the frame members.
The corner bracket shown in Figure 7 includes two stiffening ribs 66, however
it will be appreciated that other multiples of stiffening ribs will also be
useful as
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well. The corner bracket may also include pre-drilled securing holes 70 which
may receive a nail, screw or other fastener therein for securing the corner
bracket 60 to the frame members 20.
To form a frame for insertion into a wall opening, first and second members
62 and 64 of the corner bracket may be inserted into the hollows 42 of two
adjacent frame members 20 and secured therein with a fastener. Once
connected in this fashion, the two frame members 20 will form a corner. An
additional frame member 20 and corner bracket 60 may be located at a distal
end of one of the frame members so as to form a U-shaped frame. Such a U-
shaped frame may be useful for forming an opening for a door. A further
frame member and two additional corner brackets may be used to close the
open end of the U-shaped frame so as to form a rectangular frame that is
useful for forming an opening for a window. It will be appreciated that the
lengths of the frame members used may be adjusted to the desired length so
as to provide any desired opening size and shape. In addition to securing
with corner bracket 60, the frame members may be secured to each other by
nails, screws or other suitable fasteners.
While specific embodiments of the invention have been described and
illustrated, such embodiments should be considered illustrative of the
invention only and not as limiting the invention as construed in accordance
with the accompanying claims.
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