Insulated Concrete Form Connector

Abstract

A connector has an attachment plate for overlying the exterior of an insulated form to provide an attachment for a structural member to the connector. A plurality of anchoring plates extend from the attachment plate into the interior of the insulated form to anchor the connector.

Description

BACKGROUND OF THE INVENTION

[0001] The present invention is directed to a connection between a foam-insulated concrete wall and a ledger board or beam attached to the wall by a connector.

[0002] A foam-insulated concrete wall is built with foam insulating blocks. The foam insulating blocks are stacked, often in an interconnecting manner, to create a hollow form into which the concrete is poured and sets. The foam blocks typically have two or more side walls which are spaced apart by thin bridging members, usually made of plastic or metal. When the concrete hardens, rather than stripping off the side walls of the foam insulating blocks as is done with typical wood or metal forms, the insulating blocks are left in place. The walls of the insulating blocks are generally formed of expanded polystyrene and plastic. Structural members such as building walls and floors and roofs are attached the foam-insulated concrete wall, and the foam-insulated concrete wall is covered with finishing materials. Examples of such insulated, concrete formwork assemblies are illustrated in U.S. Pat. Nos. 4,655,014, 4,706,429, 4,731,968, 4,884,382, 4,889,310, 5,390,459 and 5,809,728. While each of these designs utilizes the basic setup of the two foam panels or side walls of polystyrene tied together with metal or plastic bridging members, each of the designs has certain variations. A number of the designs are provided with interlocking means along the edges of the polystyrene blocks to interlock the blocks together. In addition, the attachment of the bridging members to the polystyrene blocks varies from design to design. In some of the designs the bridging members are provided with exterior plates which overlay the exterior wall of the polystyrene panels of the blocks. Other designs utilize structures which are held within the polystyrene panel itself such that the bridging member is not exposed to the exterior of the wall. Some of the specialized forms utilize bridging members having recesses or hooked structures which facilitate attaching reinforcing bars to the bridging members. This can make construction of the wall easier.

[0003] The present invention is concerned with attaching a structural member to the side of the wall. U.S. Pat. No. 7,024,833 teaches a connector that is added to the form before the cement is poured that will provide a strong means of attachment of structural members to the wall, such as ledger boards. The connector has one or more leg members that will be anchored in the cementitious member once the cementitious member has hardened and a face plate that interfaces with the outer surface of the form member to which fasteners can be easily attached for making structural connections.

[0004] The current invention improves upon the prior art, allowing for for use of blocks with thicker side walls that provide greater insulation, while being amenable to current methods of installation.SUMMARY OF THE INVENTION

[0005] The present invention provides a connector for use with insulated forms for concrete walls for attaching a beam or ledger board to the wall. The bracket has an attachment plate for overlying the exterior of the insulated form. The ledger board or beam is attached to the bracket at the attachment plate. The bracket is also provided with a plurality of anchoring legs extending from the attachment plate that are inserted into the interior of the insulated form to anchor the bracket in the concrete.

[0006] According to one embodiment of the present invention, first and second strengthening flanges are connected to each anchoring leg of the plurality of anchoring legs, and preferably the strengthening flanges extend toward the center region of the connector. Preferably, the first and second strengthening flanges connected to each anchoring leg of the plurality of anchoring legs extend orthogonally to the anchoring leg to which they are connected.

[0007] According to another embodiment of the present invention, the anchor plate is formed with a top portion and a bottom portion, with a vertical axis of the connector running from the top portion to the bottom portion, and the anchor plate is formed with a first side edge and a second side edge, with the first side edge being parallel with and generally opposed to the first side edge and offset from the first side edge along the vertical axis of the anchor plate; and first and second anchoring legs of the plurality of anchoring legs attached to the face place are disposed parallel to each other, with the first anchoring leg being attached to the first side edge and the second anchoring leg being attached to the second side edge, and with the first anchoring leg being offset from the second anchoring leg such that one of the first and second anchoring legs is disposed closer to the top edge and the other of the first and second anchoring legs is disposed closer to the bottom edge.

[0008] According to one embodiment of the present invention, each of the plurality of anchoring legs are formed with one or more embossments, and preferably each of the plurality of anchoring legs is formed with four embossments, and at least one of the one or more embossments in each of the plurality of anchoring legs extends substantially the entire length of the anchoring leg of the plurality of anchoring legs in which it is formed.

[0009] According to one embodiment of the present invention, each of the plurality of anchoring legs are formed with one or more openings, and preferably, at least one of the one or more openings in each of the plurality of anchoring legs is formed near the rear end of the anchoring leg of the plurality of anchoring legs in which it is formed, such that the opening is distal from the anchor plate.

[0010] According to one embodiment of the present invention, the first anchoring leg extends from a first side edge of the anchor plate and the second anchoring leg extends from an opposed, second side edge of the anchor plate, with the second side edge being disposed parallel to and slightly offset from the first side edge; and a first upper edge extends from an upper end of the first side edge towards the opposed, second side edge, and a second upper edge extends from a terminating end of the first upper edge to the opposed, second side edge in a direction that is downwardly from the first upper edge, and the second upper edge is preferably longer than the first upper edge, and the second upper edge connects with the second side edge at an upper end of the second side edge.

[0011] According to one embodiment of the present invention, a first lower edge extends downwardly from a lower end of the first side edge towards the opposed, second side edge, and a second lower edge extends from a terminating end of the first lower edge to the opposed, second side edge, and the second lower edge is preferably shorter than the first lower edge, and the second lower edge connects with the second side edge at a lower end of the second side edge, and preferably, the first upper edge and the second lower edge are disposed generally horitzontally.

[0012] According to one embodiment of the present invention, the first anchoring leg extends from a first side edge of the anchor plate, and the second anchoring leg extends from an opposed, second side edge of the anchor plate, with the second side edge being disposed parallel to and slightly offset from the first side edge; and a first upper edge extends at an angle from an upper end of the first side edge towards the opposed, second side edge, and a middle upper edge extends from a terminal end of the first upper edge toward the opposed, second side edge in a direction that is generally orthogonal to the first and second side edges and, and a second upper edge connects the middle upper edge to the opposed, second side edge, extending downwardly from a terminating end of the middle upper edge that is distal from the first side edge of the anchor plate, and the second upper edge is preferably longer than the first upper edge.

[0013] According to one embodiment of the present invention, a first lower edge extends downwardly and at an angle from a lower end of the first side edge towards the opposed, second side edge, a middle lower edge extends from a lower end of the first lower edge toward the opposed, second side edge, and a second lower edge connects the middle lower edge to the opposed, second side edge, extending upwardly from a terminating end of the middle lower edge that is distal from the first side edge of the anchor plate, and the second lower edge is preferably shorter than the first lower edgeBRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a front perspective view of the connector of the present invention.

[0015] FIG. 2 is a back perspective view of the connector of the present invention.

[0016] FIG. 3 is a right side view of the connector of the present invention.

[0017] FIG. 4 is a left side view of the connector of the present invention.

[0018] FIG. 5 is a top plan view of the connector of the present invention.

[0019] FIG. 6 is a bottom plan view of the connector of the present invention.

[0020] FIG. 7 is a back end view of the connector of the present invention.

[0021] FIG. 8 is a front end view of the connector of the present invention.

[0022] FIG. 9 is a perspective view of a block of a concrete form with the connector attached to the block by inserting the anchoring legs of the connector through slots in the front panel of the block.

[0023] FIG. 10 is a perspective view of a block of a concrete form with the connector attached to the block by inserting the anchoring legs of the connector through slots in the front panel of the block and the cement has been poured into the form in the space between the panels of the block.

[0024] FIG. 11 is a front perspective view of another embodiment of the connector of the present invention.

[0025] FIG. 12 is a back perspective view of the connector of FIG. 11.

[0026] FIG. 13 is right side view of the connector of FIG. 11.

[0027] FIG. 14 is front side view of the connector of FIG. 11.

[0028] FIG. 15 is a top plan view of the connector of FIG. 11.

[0029] FIG. 16 is a bottom plan view of the connector FIG. 11.

[0030] FIG. 17 is a back end view of the connector of FIG. 11.

[0031] FIG. 18 is a front end view of the connector of FIG. 11.

[0032] FIG. 19 is a perspective view of a block of a concrete form with the connector attached to the block by inserting the anchoring legs of the connector through slots in the front panel of the block and the cement has been poured into the form in the space between the panels of the block.DETAILED DESCRIPTION OF THE INVENTION

[0033] As shown in FIG. 1, the connection of the present invention is made with a connector 1 that can be used for attaching a structural member to wall 3. The wall 3 is made up of a cementitious member 5 and an insulated concrete form 6. The form 6 can be constructed by stacking hollow insulated form blocks 7 upon each other. The blocks 7 typically have two main panels 8 of expanded foam facing each other which are spaced apart the appropriate distance so that the cementitious member 5 will have the desired thickness. The blocks 7 may have additional end panels or openings in the main panels 8 to form corners in the wall 3, or special corner blocks may be used. Typically, the panels 8 are connected to each other and spaced apart the appropriate distance by bridging members 9. In the preferred embodiment, the main panels 8 of the blocks 7 are either three and one-quarter inches or four and one-half inches thick.

[0034] As shown in FIG. 1, the connector 1 is provided with an anchoring plate 10 and first and second anchoring legs 11 and 12. The anchoring plate is a substantially planar member, and the first and second anchoring legs 11 and 12 are also substantially planer members. Preferably the connector is U-shaped with the anchoring plate forming the base or web of the “U” and the anchoring legs 11 and 12, preferably, extending perpendicular from opposed edges of the anchoring plate 10. The connector 1 is preferably formed by cutting and bending a blank of sheet steel of suitable strength. The sheet steel may be galvanized to improve its resistance to rusting. In the preferred embodiment the connector 1 is made from 14 gauge, galvanized steel.

[0035] The anchoring legs 11 and 12 preferably have openings 13 into which the concrete can flow to help anchor the connector 1. Reinforcing bars may also be installed through the openings 13 in the anchoring legs 11 and 12.

[0036] The connector 1 can also be attached to the bridging members 9 in the form with separate fasteners.

[0037] The connector 1 of the present invention is preferably attached to the concrete form 6 before the cementitious member is poured. Slots are cut in the foam panels 8 of the form 6, and the one or more anchoring legs 11 and 12 are inserted through the slots in the panels 8 of the form 6 and into the cavity that will receive the uncured cementitious member. Preferably, the anchor plate 10 interfaces with the outer surface 16 of one or more panels 8 of the form though which the anchoring legs 11 and 12 of the connector 1 are inserted.

[0038] As shown in FIG. 1, preferably a plurality of embossments 17 are formed in and extend substantially along the length of the anchoring legs 11 and 12, except where the openings 13 are formed in the anchoring legs 11 and 12. The embossments 17 are preferably disposed parallel to each other and extend from the anchor plate 10 toward the rear ends 18 of the anchoring legs 11 and 12. Preferably, the openings 13 in the anchoring legs 11 and 12 are formed near the rear ends 17 of the anchoring legs 11 and 12. Preferably, the anchoring legs 11 or 12 are each formed with four embossments 17 extending parallel to each other along the anchoring legs 11 and 12.

[0039] As shown in FIG. 1, the anchoring legs 11 and 12 are preferably formed with strengthening flanges 19 at the upper and lower edges 20 and 21 of the anchoring legs 11 and 12. Preferably, each of the strengthening flanges 18 attached to either the first or second anchoring legs 11 or 12 extends orthogonally and inwardly from either the first or second anchoring leg 11 and 12 to which it is attached and toward the other of the opposed first and second anchoring legs 11 and 12.

[0040] As shown in FIGS. 1, the anchor plate 10 can have an octagonal shape. Preferably, the anchor plate 10 is asymmetrical. As shown in FIG. 11, the anchor plate can have an irregular, hexagonal shape, and again preferably, the anchor plate is asymmetrical.

[0041] As shown in FIGS. 1, 9 and 10, in one embodiment of the present invention, the first and second anchoring legs 11 and 12 can be vertically disposed when installed in the concrete form 6 for a typical vertical wall. The first anchoring leg 11 extends from a first side edge 22 of the anchor plate 10, and the second anchoring leg 12 extends from an opposed, second side edge 23 of the anchor plate 10. The second side edge 23 is preferably disposed parallel to and slightly offset from the first side edge 22. Along the upper portion of the anchor plate 10, a first upper edge 24 extends upwardly and at an angle from an upper end 25 of the first side edge 22 towards the opposed, second side edge 23. A middle upper edge 26 extends from an upper end 27 of the first upper edge 24 toward the opposed, second side edge 23 in a direction that is generally orthogonal to the first and second side edges 22 and 23. A second upper edge 28 connects the middle upper edge 26 to the opposed, second side edge 22, extending downwardly from a terminating end 29 of the middle upper edge 26 that is distal from the first side edge 23 of the anchor plate 10. The second upper edge 28 is preferably longer than the first upper edge 24. The second upper edge 28 also preferably extends from the middle upper edge 26 at a similar, but opposed angle as the first upper edge 24 extends from an initiating end 30 of the middle upper edge 26, such that the second side edge 23 is disposed lower in the concrete form 6 than the first side edge 22, when the middle upper edge 26 is set generally horizontally with respect to the concrete form 6. This results in the second anchoring leg 12 being disposed lower in the concrete form 6 than the first anchoring leg 11, when the middle upper edge 26 is set generally horizontally with respect to the concrete form 6.

[0042] As shown in FIG. 1, along the lower portion of the anchor plate 10, a first lower edge 34 extends downwardly and at an angle from a lower end 35 of the first side edge 22 towards the opposed, second side edge 23. A middle lower edge 36 extends from a lower end 37 of the first lower edge 24 toward the opposed, second side edge 23 in a direction that is generally orthogonal to the first and second side edges 22 and 23. A second lower edge 38 connects the middle lower edge 36 to the opposed, second side edge 22, extending upwardly from a terminating end 39 of the middle lower edge 36 that is distal from the first side edge 23 of the anchor plate 10. The second lower edge 38 is preferably shorter than the first lower edge 34. The second lower edge 38 also preferably extends from the middle lower edge 36 at a similar, but opposed angle as the first angled lower edge 34 extends from an initiating end 40 of the middle lower edge 36, such that the second side edge 23 is disposed lower in the concrete form 6 than the first side edge 22, when the middle lower edge 36 is set generally horizontally with respect to the concrete form 6. This results in the second anchoring leg 12 being disposed lower in the concrete form 6 than the first anchoring leg 11, when the middle lower edge 36 is set generally horizontally with respect to the concrete form 6.

[0043] As shown in FIG. 19, in another embodiment of the present invention, preferably the first and second anchoring legs 11 and 12 are generally disposed offset from a vertical line when installed in a typical concrete form 6 for a vertical wall. The first anchoring leg 11 extends from a first side edge 52 of the anchor plate 10 and the second anchoring leg 12 extends from an opposed, second side edge 53 of the anchor plate 10. The second side edge 53 is preferably disposed parallel to and slightly offset from the first side edge 52. When installed in typical concrete form 6 for a vertical wall, preferably the first and second anchoring legs 11 and 12 are disposed slightly offset from the vertical. When installed as described, along the upper portion of the anchor plate 10, a first upper edge 54 extends horizontally from an upper end 55 of the first side edge 52 towards the opposed, second side edge 53. A second upper edge 56 extends from a terminating end 57 of the first upper edge 54 to the opposed, second side edge 53 in a direction that is downwardly from the first upper edge 54 when the connector 1 is installed in a concrete form 6 as described. The second upper edge 56 extends downwardly from the terminating end 57 of the first upper edge 54 that is distal from the first side edge 53 of the anchor plate 10, such that the second side edge 53 is disposed lower in the concrete form 6 than the first side edge 52, when the connector 1 is installed as described. The second upper edge 56 is preferably longer than the first upper edge 54. The second upper edge 56 connects with the second side edge 53 at the upper end 58 of the second side edge 53.

[0044] As shown in FIG. 19, when installed as described, along the lower portion of the anchor plate 10, a first lower edge 64 extends downwardly from a lower end 65 of the first side edge 52 towards the opposed, second side edge 53, such that the second side edge 53 is disposed lower in the concrete form 6 than the first side edge 52, when the connector 1 is installed as described. A second lower edge 66 extends from a terminating end 67 of the first lower edge 64 to the opposed, second side edge 53 in a direction that is horizontal from the first lower edge 64 when the connector 1 is installed in a concrete form 6 as described. The second lower edge 66 extends horizontally from the terminating end 67 of the first lower edge 64 that is distal from the first side edge 53 of the anchor plate 10. The second lower edge 66 is preferably shorter than the first lower edge 64. The second lower edge 66 connects with the second side edge 53 at the lower end 68 of the second side edge.

[0045] In the embodiment shown in FIGS. 11 and 19, the first upper edge 54 is preferably 1 and ⅜ inches long. The second upper edge 56 is preferably 5 and ⅝ inches long. The first and second anchoring legs are preferably either 6 inches or 8 inches long depending on the size of the panels 8 of the blocks 7. The angle between the first and second upper edges 54 and 56 is preferably 123 degrees. The angle between the first and second lower edges 64 and 66 is the same. The first and second side edges 52 and 53 are preferably 3 and ½ inches long. As is also shown in FIG. 19, the first lower edge 64 is preferably 5 and ⅝ inches long, and the second lower edge 66 is 1 and 3 / 8 inches long. The longest embossments are preferably 7 and ⅜ inches long, when the anchoring legs 11 and 12 are 8 inches long. The distance between the first and second anchoring legs 11 and 12 is preferably 6 and 25 / 32 inches. The distance between the first upper edge 54 and the second lower edge 64 is preferably 6 and 9 / 16 inches. Preferably a central axis for the part shown in FIGS. 11 and 19 can be drawn from the intersection between the first and second upper edges 54 and 56 and the first and second lower edges 64 and 66, and preferably a plurality of openings are provided on the center line of the part 1 for assisting with alignment and the installation of the part on the panel 8 of the block 7. The connector 1 can be attached to the panel 8 of the block 7 with fasteners provided through the anchor plate 10 to hold the connector 1 in place while the concrete is poured, if needed.

[0046] Once the cementitious member 5 has been poured and set, such that the connector 1 is anchored to the wall 3, the structural member is held against the wall 3 in the proper position and fasteners are driven through the structural member and into the anchor plate 10 of the connector 1. The preferred fasteners are self-drilling and self-tapping screws.

[0047] In certain installations, it may be desirable to use an additional connector to make the connection as when the structural member is a wood ledger board. A J-shaped bracket interfaces with the structural member or ledger board with the extending bottom flange of the bracket interfacing with the bottom of the ledger board. An upwardly extending flange of the additional bracket interfaces with the outer facing surface of the ledger board 2. Fasteners are driven through the upwardly extending flange of the additional bracketing, through the ledger board and into the anchor plate 10 of the connector 1.

Claims

1. A connection utilizing a connector to attach a structural member to a generally vertical cementitious member having one or more panels diposed on one or more vertical faces of the cementitious member, the connection comprising:a. the one or more panels, each having a front face, a back face opposite the front face, the one or more panels having negligible dowel bearing strength compared to the generally vertical cementitious member;b. the generally vertical cementitious member having significant dowel bearing strength compared to the one or more vertical panels;c. the connector, the connector comprising:i. an anchor plate in parallel registration or in close association with the front face of a first vertical panel of the one or more vertical panels;ii. a plurality of anchoring legs attached to the anchor plate and extending from the anchor plate and through the first vertical panel of the one or more vertical panels and into the cementitious member with the cementitious member supporting the embedded anchoring legs and the anchoring legs supporting the anchor plate;d. the structural member interfacing with or in close association with the anchor plate of the connector and attached to the anchor plate of the connector with the anchor plate of the connector supporting the structural member, and the first vertical panel of the one or more vertical panels disposed between the cementitious member and the anchor plate, and the anchor plate disposed between the first vertical panel of the one or more vertical panels and the structural member.

2. The connection of claim 1, wherein:a. each of the plurality of anchoring legs of the connector has a top edge and a bottom edge and an end edge, with the top and bottom edges being opposed to each other and the end edge being opposed to where the anchoring leg attaches to the anchor plate of the connector; andb. first and second strengthening flanges extend along portions of the top and bottom edges of each anchoring leg respectively, and the first and second strengthening flanges connected to each anchoring leg also extend away from the anchoring leg to which they are attached.

3. The connection of claim 2, wherein:the first and second strengthening flanges connected to each anchoring leg of the plurality of anchoring legs extend in the same direction from each anchoring leg to which they are attached.

4. The connection of claim 3, wherein:a. the anchor plate of the connector has a center region; andb. the first and second strengthening flanges connected to each anchoring leg of the plurality of anchoring legs extend toward the center region of the connector.

5. The connection of claim 4, wherein:the first and second strengthening flanges connected to each anchoring leg of the plurality of anchoring legs extend orthogonally to the anchoring leg to which they are connected.

6. The connection of claim 1, wherein:a. the anchor plate is formed with a top portion and a bottom portion, with a vertical axis of the connector running from the top portion to the bottom portion, andb. the anchor plate is formed with a first side edge and a second side edge, with the first side edge being parallel with and generally opposed to the first side edge and offset from the first side edge along the vertical axis of the anchor plate; andb. first and second anchoring legs of the plurality of anchoring legs attached to the face place are disposed parallel to each other, with the first anchoring leg being attached to the first side edge and the second anchoring leg being attached to the second side edge, and with the first anchoring leg being offset from the second anchoring leg such that one of the first and second anchoring legs is disposed closer to the top edge and the other of the first and second anchoring legs is disposed closer to the bottom edge.

7. The connection of claim 1, wherein:each of the plurality of anchoring legs are formed with one or more embossments.

8. The connection of claim 7, wherein:each of the plurality of anchoring legs is formed with four embossments.

9. The connection of claim 7, wherein:at least one of the one or more embossments in each of the plurality of anchoring legs extends substantially the entire length of the anchoring leg of the plurality of anchoring legs in which it is formed.

10. The connection of claim 1, wherein:each of the plurality of anchoring legs are formed with one or more openings.

11. The connection of claim 9, wherein:at least one of the one or more openings in each of the plurality of anchoring legs is formed near the rear end of the anchoring leg of the plurality of anchoring legs in which it is formed.

12. The connection of claim 1, wherein:a. the first anchoring leg extends from a first side edge of the anchor plate and the second anchoring leg extends from an opposed, second side edge of the anchor plate, with the second side edge being disposed parallel to and slightly offset from the first side edge; andb. a first upper edge extends from an upper end of the first side edge towards the opposed, second side edge, and a second upper edge extends from a terminating end of the first upper edge to the opposed, second side edge in a direction that is downwardly from the first upper edge, and the second upper edge is preferably longer than the first upper edge, and the second upper edge connects with the second side edge at an upper end of the second side edge.

13. The connection of claim 12, wherein:a first lower edge extends downwardly from a lower end of the first side edge towards the opposed, second side edge, and a second lower edge extends from a terminating end of the first lower edge to the opposed, second side edge, and the second lower edge is preferably shorter than the first lower edge, and the second lower edge connects with the second side edge at a lower end of the second side edge.

14. The connection of claim 13, wherein:the first upper edge and the second lower edge are disposed generally horitzontally.

15. The connection of claim 1, wherein:a. the first anchoring leg extends from a first side edge of the anchor plate, and the second anchoring leg extends from an opposed, second side edge of the anchor plate, with the second side edge being disposed parallel to and slightly offset from the first side edge; andb. a first upper edge extends at an angle from an upper end of the first side edge towards the opposed, second side edge, and a middle upper edge extends from a terminal end of the first upper edge toward the opposed, second side edge in a direction that is generally orthogonal to the first and second side edges and, and a second upper edge connects the middle upper edge to the opposed, second side edge, extending downwardly from a terminating end of the middle upper edge that is distal from the first side edge of the anchor plate, and the second upper edge is preferably longer than the first upper edge.

16. The connection of claim 15, wherein:a. a first lower edge extends downwardly and at an angle from a lower end of the first side edge towards the opposed, second side edge, a middle lower edge extends from a lower end of the first lower edge toward the opposed, second side edge, and a second lower edge connects the middle lower edge to the opposed, second side edge, extending upwardly from a terminating end of the middle lower edge that is distal from the first side edge of the anchor plate, and the second lower edge is preferably shorter than the first lower edge.

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