Spacer nail for holding a rebar spaced away from a concrete mold

Abstract

The invention relates to a spacer nail (100) for spacing a reinforcement bar (210) away from a mold (200). The spacer nail (100) comprises a mold stop (110), a nail head (130), and a barrier (120). The barrier (120) is arranged to prevent water from passing to a reinforcement bar (210) located at the nail head (130). The barrier (120) is located along a shank (101) of the spacer nail (100) between the mold stop (110) and the nail head (130).

Description

[0001] SPACER NAIL FOR HOLDING A REBAR SPACED AWAY FROM A CONCRETE MOLD

[0002] TECHNICAL FIELD

[0003] The embodiments herein relate to a spacer nail for securely holding reinforcing bars in concrete constructions. More specifically, the embodiments herein provide an efficient and reliable solution to maintain precise spacing between a reinforcing bar and a concrete mold. The reinforcing bar ensures optimal structural integrity and load-bearing capacity of the construction at hand.

[0004] BACKGROUND

[0005] In the construction industry, reinforced concrete plays a pivotal role in enhancing the strength and durability of structures. The reinforcing bars, commonly known as rebars, are strategically placed within the concrete matrix to reinforce and support the structure against various forces. Achieving the desired spacing between these rebars during the concrete pouring process is crucial to ensure the structural integrity and longevity of the final construction.

[0006] Traditional methods of spacing rebars involve the use of manual tie wires or plastic spacers, which are often labor-intensive, time-consuming, and may not provide consistent and reliable results. There is a recognized need for an innovative spacer solution that simplifies the process of maintaining precise rebar spacing, thereby streamlining construction operations and improving overall construction quality.

[0007] Previous attempts to address the challenges associated with rebar spacing have led to various spacer designs and solutions. However, these existing solutions often suffer from drawbacks such as complexity, inefficiency, and limited adaptability to different construction scenarios. There is a need for an improved spacer nail that overcomes these limitations and provides a cost-effective, user- friendly, and reliable solution for maintaining optimal rebar spacing in concrete construction.

[0008] SUMMARY

[0009] An objective can be to provide a spacer nail specifically designed for efficiently holding and spacing a reinforcing bar at a distance from a mold of a concrete construction. The embodiments offer a versatile and reliable solution that simplifies the rebar installation process, reduces labor requirements, and enhances overall construction reliability. By addressing the shortcomings of existing spacer solutions, the proposed spacer nail contributes to the advancement of construction technology, promoting safer, faster, and more cost- effective construction practices.

[0010] In conclusion, the present invention represents a significant improvement over the current state of the art, offering a spacer nail that meets the demands of modern construction practices, ensuring precise and consistent rebar spacing from the mold for enhanced structural performance.

[0011] According to a first aspect, the invention provides a spacer nail for spacing a reinforcement bar away from a mold for a concrete construction. The spacer nail comprises a mold stop, e.g. arranged at a distance from an end of the nail, a nail head, e.g. arranged at the other end of the nail, and a barrier arranged to obstruct water from passing from the mold stop to a reinforcement bar located at the nail head. The barrier is located, e.g. at a position, along a shank of the spacer nail between the mold stop and the nail head, i.e. the position is between the mold stop and the nail head.

[0012] Thanks to that the barrier is located between the mold stop and the nail head, it is ensured that the barrier remains inside the concrete construction, e.g. even after a point of the spacer nail has been broken off. The breaking-off of the point can be a deliberate action or happen by accident. The breaking-off of the point can include that the mold stop is broken off as well, but it can also be that the mold stop remains at a surface of the concrete construction. Nevertheless, in both cases, any water will face a distance that includes a path that first runs along the shank, radially along one side of the barrier, and then back radially along the other side of the barrier. Next, again along the shank towards the head of the spacer nail. This means that it is very difficult for the water to reach the rebar at the nail head. As a result, the rebar is protected from corrosion, and the like. Consequently, integrity and construction requirements are preserved.

[0013] In some embodiments, the mold stop is located at a distance, e.g. a predetermined distance, or the like, from a point of the spacer nail, e.g. at one end of the nail, wherein the distance is adapted to a thickness of a mold at which the spacer nail is fastenable. Hence, the distance can be predetermined.

[0014] In some embodiments, the nail head has recessed areas for securing a wire arrangeable to hold a reinforcement bar.

[0015] In some embodiments, the nail head has a shape of an elongated element, extending in a transversal direction with respect to the shank of the spacer nail. In some embodiments, a length of the spacer nail from point to head is in the range of 30-100 mm, or the like.

[0016] In some embodiments, the spacer nail is made of a stainless material, preferably aluminum, stainless steel, or the like, and / or a combination thereof.

[0017] In some embodiments, the barrier is disk-shaped and has a diameter in the range of 20-40 mm, or the like. In some examples, the barrier can be disk-shaped and have a diameter that is e.g. 2-5 times greater than the diameter of the shank. In some examples, the diameter of the barrier is three or four times, or between three to four times, greater than the diameter of the shank.

[0018] In some embodiments, the barrier is integrated with the spacer nail, e.g. the barrier is an integral portion of the spacer nail.

[0019] In some embodiments, the mold stop is integrated with the spacer nail, e.g. the mold stop is an integral portion of the spacer nail.

[0020] In some embodiments, the nail head is integrated with the spacer nail, e.g. the nail head is an integral portion of the spacer nail.

[0021] As used herein, the term "integrated with", "integral portion", or the like, can refer to that the portions, such as the barrier, the mold stop, the nail head, the shank, the spacer nail, or the like, being integrated are made in one piece, e.g. of the same material, e.g. non-separable from each other.

[0022] In some embodiments, the disk-shaped barrier has a main extension plane that is perpendicular to a longitudinal axis of the shank.

[0023] BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 illustrates a spacer nail, in accordance with some embodiments.

[0025] FIG. 2 illustrates a vertical cross section of a spacer nail being used to ensure proper distance between a wall and a rebar, in accordance with some embodiments. FIG. 2 has been drawn to scale.

[0026] FIG. 3 illustrates a schematical view of the spacer nail along its longitudinal axis, from head to point, in accordance with some embodiments.

[0027] FIG. 4 to FIG. 13 illustrate various cross-sections A-A, B-B and C-C, respectively. Like reference numerals include like elements.

[0028] DETAILED DESCRIPTION

[0029] As was noted above, the various embodiments described herein relate to a spacer nail designed for efficiently holding and spacing reinforcing bar in concrete construction molds. The various embodiments offer a versatile and reliable solution that simplifies the rebar installation process, reduces labor requirements, and enhances overall construction reliability and / or efficiency.

[0030] In one embodiment, as illustrated in FIG. 1, the spacer nail 100 comprises a shank 101 with a pointed tip 103 on one end and a head 130 at the opposite end, resembling the structure of a conventional nail. It should be noted that while the spacer nail 100 in the depicted embodiment is crafted from aluminum, alternative materials can be utilized to suit specific application requirements. Potential alternative materials include aluminum, stainless steel, a rustproof metal alloy, and / or other suitable materials with properties conducive to the intended use of the spacer nail 100, such as corrosion resistance, strength, resistance to rust (stainless, rust-proof), and / or weight considerations. The selection of material may vary based on factors like environmental conditions, structural demands, or cost considerations, thus offering flexibility in the design and manufacturing of the spacer nail 100 for diverse applications.

[0031] The length of the spacer nail 100 exhibits versatility, allowing for customization to suit specific application requirements. Typically, the length of the spacer nail falls within the range of 30-100 mm, provided in 5 mm increments to enable finer adjustments and precise installation. However, the design accommodates the production of longer or shorter spacer nails, as necessary, enabling the adaptation to diverse construction scenarios. Furthermore, the increment between the different lengths can be adjusted to be larger or smaller than 5 mm to suit various applications, providing flexibility in addressing specific spacing needs or structural considerations. These determinations pertaining to the length and increment adjustments can allow for seamless customization based on unique project requirements and construction specifications.

[0032] The spacer nail 100 is equipped with a ring-shaped mold stop 110 positioned at a predetermined distance from a tip 103 of the spacer nail 100, aka a point 103 of the spacer nail 100. The primary function of the mold stop 110, as illustrated in the embodiment, is to facilitate controlled installation by limiting the penetration depth of the spacer nail 100 into a mold 200. The mold stop 110 can be a mold stop element, or the like. In some examples, the mold stop 110 is positioned in the vicinity of the point 103 at one end of the spacer nail 100. The predetermined distance is preferably adapted to a thickness of the mold 200, i.e. the mold's 200 wall, thereby allowing the point 103 of the spacer nail 100 to enter the mold 200 to fasten the spacer nail 100. This feature holds significance when multiple spacer nails 100 are employed to maintain consistent spacing and alignment of the rebar 210 within the mold 200 throughout its length. While the mold stop 110 is depicted as a ring encircling the shank 101, it is worth noting that alternative shapes and configurations are feasible. Notably, the mold stop 110 can preferably be formed in a mold in which the entire spacer nail is formed. Hence, the mold stop 110 is an integral portion of the spacer nail 100. Variations may include different cross-sectional shapes, as demonstrated in FIGs. 4-6. The fundamental operational criterion of the mold stop 110 is that it possesses a distinctive diameter or protrusions, differing sufficiently from the shank's 101 diameter to prevent the spacer nail from being driven into the mold 200 beyond a predetermined distance. This ensures precise positioning and acts as a safeguard against unintended over-penetration, contributing to the consistent and reliable installation of the spacer nail within the mold.

[0033] The barrier 120, situated between the mold stop 110 and the head 130 of the spacer nail 100, serves to mitigate the potential for rebar corrosion within a concrete construction application. Its primary function is to impede the movement of water from the point 103 of the nail 100 along the length of the shank 101, thereby preventing water accumulation at the head 130 and around the rebar 210. This proactive measure prevents rebar corrosion, a well-recognized and significant concern in construction engineering and infrastructure durability. Rebar corrosion poses a multitude of detrimental effects, including compromised structural integrity, reduced operational lifespan, safety hazards, increased maintenance costs, aesthetic degradation, and environmental impact. By hindering the ingress of water, the barrier 120 contributes to the safeguarding of corrosion of the rebar(s). Through this deliberate design feature, the barrier 120 addresses an aspect of construction integrity, demonstrating a proactive approach to mitigating the potentially deleterious effects of rebar corrosion, thereby contributing to the longevity and reliability of construction projects.

[0034] The configuration of the barrier 120 presents a versatile aspect of the spacer nail design, offering flexibility to accommodate various construction requirements. While the barrier 120 is typically disk-shaped, alternative shapes can be envisaged to fulfill the essential function of impeding the movement of water along the shank 101 towards the head 130. The design encompasses adaptability, allowing for the exploration of diverse cross-sectional shapes, as exemplified in FIGs. 7-9, to effectively fulfill this water-impeding role. The disk shape represents a conventional and widely applicable form for the barrier 120. However, recognizing that different construction scenarios may necessitate tailored solutions, the provision of alternative shapes aligns with the aim of addressing specific project demands and construction constraints. It signifies adaptability and innovation in considering geometry that optimally obstructs water movement, thereby safeguarding against potential corrosion and ensuring the longevity and structural robustness of construction projects. The illustration of varied cross-sectional shapes in FIGs. 7-9 demonstrates the scope of potential configurations, highlighting the versatility inherent in the barrier 120 design. This adaptability contributes to the comprehensive applicability of the spacer nail across diverse construction contexts, offering an adaptable and effective solution to address the challenge of water protection and corrosion prevention. Generally, it can be preferred that at least a central portion of the barrier 120 is formed as a disk, having a diameter in a range of 20-40 mm, 25-35 mm, or the like.

[0035] The positioning of the barrier 120 along the shank 101 can vary. As mentioned, the barrier is located, e.g. at a position, along a shank of the spacer nail between the mold stop and the nail head, i.e. the position is between the mold stop and the nail head. E.g. while the position still allows for convenient wire winding close to the head 130. Further, e.g. while the position still allows for the barrier to be shielded from a surface of the concrete construction by a layer of concrete, e.g. when the mold 200 has been removed and e.g. when the spacer nail 100 is used for securing the rebar 210 in the concrete construction.

[0036] In some examples, the barrier 120 is situated as far away from the mold stop 110 as possible, while still allowing for convenient wire winding close to the head 130. This positioning supports the effective tying up of the rebar 210 against the head 130 of the spacer nail 100, promoting secure and stable construction configurations. Furthermore, this positioning also contributes to the prevention of water reaching all the way to the head and the intrinsic corrosion protection aspects of the spacer nail's functionality. Thanks to that the barrier 120 is located at a distance from the mold stop 110, any water that attempts to reach the rebar must first travel along the shank 101 to the barrier 120 and then out to the barrier's 120 periphery. Further, again back to the shank 101 and also again along the shank 101. This means for example that the water would have to travel approximately twice the radius of the barrier 120, e.g. in addition to the distances along the shank 101. In more detail, the water would for example have to travel twice the radius minus twice the radius of the shank 101 plus the thickness of the barrier 120, e.g. in addition to the distances along the shank 101.

[0037] In some examples, the position of the barrier 120 can be, e.g. positioned, located, or the like, in a range along the shank 101. The range thus extending from the mold stop 110 to the nail head 130, e.g. exclusively the mold stop 110 and / or the nail head 130, e.g. in that the barrier 120 does not abut, or become integrated with, the mold stop 110 and / or the nail head 130.

[0038] In some examples, a head end of the range is spaced away from the nail head 130, e.g. to allow a wire to be winded around the shank 101, whereby the rebar 210 can be secured in its position by use of the wire. For example, the head end of the range can be spaced away from the nail head by 1 mm, 2 mm, 3 mm, 4 mm, 5 mm, 10 mm, 15 mm, 20 mm, more than 20 mm, or the like.

[0039] In some examples, a mold end of the range is spaced away from the mold stop 110, e.g. to allow the layer of concrete to shield the barrier from the surface of the concreate construction. For example, the mold end of the range can be spaced away from the mold stop 110 by 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, more than 30 mm, or the like. In some examples, the head end of the range can be located closer to the head 130 than the mold end of the range. In the depicted embodiment, the head 130 is shown to feature two recessed areas 140, which play a role in preventing the wire from sliding around the rim of the head 130 when the rebar 210 is secured, ensuring the stability of the construction arrangement. While the illustration in FIG. 1 portrays a head 130 with a circular cross-section and two relatively narrow and deep recessed areas 140, it is noteworthy that alternative embodiments may feature varying numbers, depths, and widths of recessed areas, offering further customization to suit specific project requirements. Additionally, the cross-sectional shape of the head 130 need not be limited to circular configurations, as depicted in FIGs. 10-13, which showcase alternative embodiments with diverse head shapes, underscoring the adaptability of the spacer nail design to varying project needs and structural demands. As evident in FIG. 12, in certain embodiments, the head 130 may be designed without any recessed areas if the head's specific shaping nullifies significant wire sliding when taut. This underscores the potential for innovative and function-driven head designs to ensure secure wire tie-up without compromising the core functionalities of the spacer nail or the integrity of the construction configuration. Overall, this comprehensive consideration of barrier positioning, head design variations, and wire tie-up mechanisms collectively highlights the adaptability and versatility of the spacer nail, emphasizing its potential for effective implementation in diverse construction scenarios.

[0040] In a further example, shown in FIG. 13, the head 130 can be realized in the form an elongated element, such as an elongated bar, a cylinder, a half cylinder with a half circular base area, a rectangular block, or the like. The nail head 130 can thus have a shape of an elongated bar, extending in a transversal direction with respect to the shank 101 of the spacer nail 100. A short side 352 of the cross-section of the elongated element shown in FIG. 13 can correspond to a diameter of the shank at, or close to, the head 130. In this manner, the wire for holding of the rebar 210 can be conveniently secured at the heat 130. A long side 351 of the cross-section, shown in FIG. 13, can be in a range from 5-40 mm, e.g. 30 mm, or the like.

[0041] In FIG. 2, a vertical cross section of the spacer nail 100 in practical application is depicted, providing insight into its utilization within a construction context. The illustration portrays a mold 200, commonly fabricated from materials such as plywood, which serves as a common component in the creation of molds for concrete pouring. The spacer nail 100 is shown being driven into the mold 200 until the mold stop 110 comes into contact with and rests against the mold 200. This positioning aligns with the functionality of the mold stop 110 in ensuring controlled penetration depth and consistent spacing within the mold, contributing to precise and standardized construction configurations.

[0042] The barrier 120 is situated in the space between the mold 200 and the rebar 210, effectively preventing water ingress and offering corrosion protection, as previously detailed. The rebar 210 is positioned to rest against the head 130 of the spacer nail 100, underscoring the spacer nail's role in facilitating secure and reliable reinforcement alignment within the construction framework. As noted earlier, a wire is ordinarily utilized to tie the rebar 210 to the head 130 of the spacer nail 100, although not explicitly shown in FIG. 2 for clarity of illustration.

[0043] This comprehensive depiction of the spacer nail's practical application within a construction framework offers a tangible understanding of its role in reinforcing structural integrity, moisture protection, and corrosion prevention. It emphasizes the spacer nail's capability to effectively contribute to the stability, reliability, and longevity of construction projects, aligning with industry standards and best practices for ensuring durable and resilient infrastructure.

[0044] Notably, once the concrete in the mold 200 has solidified, such as dried, or the like, the mold 200 is typically removed. Then, the point 103 of the spacer nail 100 will protrude out from the concrete construction build. Sometimes, the point of the spacer nail 100 can be broken off, not to harm any nearby workers that could potentially hurt themselves at the point. When the point is broken off the shank 101, the shank 101 can break near the mold stop 110. This means that sometimes the mold stop 110 can be broken off as well and sometimes the mold stop 110 remains at the shank 101 and thus stays in the concrete construction.

[0045] An advantage with the spacer nail according to the embodiments herein is that it can be used with any type of concrete. That is to say, this is in contrast to some known spacer nails, which includes a concrete holder that must be made of the same type of concrete as the construction at hand. In some examples, a diameter 301, 302, 303 of the shank 101 can be in a range of 3-15 mm, 5-

[0046] 10 mm, or the like. The diameter 301, 302, 303 can be the same along the shank 101 or it can be different along the shank 101. As an example, the diameter can be 7 mm.

[0047] In some examples, a diameter 305 of the mold stop 110 can be in a range of 5-15 mm, or the like. The diameter 305 can be 10 mm, or the like.

[0048] In some examples, a diameter 310 of the barrier 120 can be in a range of 20-40 mm, 25-35 mm, or the like. In some examples, the diameter 310 can be 30 mm, or the like.

[0049] In some examples, a length 315, 351 of the nail head, or a diameter if the nail head is circular, can be in a range of 10-40 mm, 20-30 mm, or the like.

[0050] In some examples, a thickness 321 of the mold stop 110 can be in a range of 1-5 mm, such as 2 mm, or the like.

[0051] In some examples, a thickness 323 of the barrier 120 can be in a range of 1-5 mm, such as 3 mm, or the like.

[0052] In some examples, a thickness 325 of the nail head 310 can be in a range of 1-5 mm, such as 3 mm, or the like.

[0053] In some examples, a distance 331 from the point of the spacer nail 100 to the mold stop 110 can be in a range of 3-30 mm, 5-25 mm, or the like. The distance 331 can be 17 mm, 20 mm, or the like.

[0054] In some examples, a distance 333 between the mold stop 110 and the barrier 120 can be in a range of 10-50 mm, 15-30 mm, or the like. The distance 333 can be 20 mm, 25 mm, 30 mm, or the like.

[0055] In some examples, a distance 335 between the barrier 120 and the nail head 130 can be in a range of 2-50 mm, 5-50 mm, 10-50 mm, 15-30 mm, or the like. The distance 333 can be 20 mm, 25 mm, 30 mm, or the like.

[0056] In FIG. 3, a longitudinal axis view of the spacer nail 100 is presented, from the head 130 to the pointed tip. Notably, this specific embodiment reveals distinctive features of the head 130, underscoring its geometry and functional considerations. The visualization shows how the head 130 exhibits a smaller diameter relative to the barrier 120. This differentiation in diameter between the head 130 and the barrier 120 aligns with the spacer nail's fundamental functionalities, including controlled penetration depth and water ingress prevention. Moreover, the head 130 is detailed to feature two diametrically opposite recessed areas 140, which facilitates secure wire tie-up and rebar immobilization, as previously outlined. These recessed areas demonstrate a purposeful design feature aimed at ensuring stability and reliability when fastening the rebar to the head of the spacer nail, contributing to the overall robustness and structural integrity of the construction framework.

[0057] The spacer nail 100 and its installation have been described herein with respect to particular embodiments. However, it should be noted that there are many variations that can be envisioned by those having ordinary skill in the art and which fall within the scope of the appended claims.

Claims

CLAIMS1. A spacer nail (100) for spacing a reinforcement bar (210) away from a mold (200) for a concrete construction, comprising: a mold stop (110), a nail head (130), and a barrier (120) arranged to prevent water from passing from the mold stop (110) to a reinforcement bar (210) locatable at the nail head (130), wherein the barrier (120) is located along a shank (101) of the spacer nail (100) between the mold stop (110) and the nail head (130), wherein the mold stop (110) is positioned at a distance (331) from a point (103) of the spacer nail (100).

2. The spacer nail (100) according to claim 1, wherein the mold stop (110) is an integral portion of the spacer nail (100).

3. The spacer nail (100) according to claim 1 or 2, wherein a distance (335) between the barrier (120) and the nail head (130) is in a range of 10-50 mm.

4. The spacer nail (100) according to any one of the preceding claims, wherein the mold stop (110) is located at a distance (331) from a point (103) of the spacer nail (100), wherein the distance is adapted to a thickness of a mold (200) at which the spacer nail (100) is fastenable.

5. The spacer nail (100) according to any one of the preceding claims, wherein the nail head (130) has recessed areas for securing a wire arrangeable to hold a reinforcement bar (210).

6. The spacer nail (100) according to any one of the preceding claims, wherein the nail head (130) has a shape of an elongated element, extending in a transversal direction with respect to the shank (101).

7. The spacer nail (100) according to any one of the preceding claims, wherein a length of the spacer nail (100) from point to head is in the range of 30-100 mm.

8. The spacer nail (100) according to any one of the preceding claims, wherein the spacer nail (100) is made of a stainless material.

9. The spacer nail (100) according to any one of the preceding claims, wherein the barrier (120) is diskshaped and has a diameter in the range of 20-40 mm.

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