CORNER BEAM FOR CONCRETE FORMWORK

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority benefit of U.S. 63/651,928 (filed May 24, 2024), which is hereby incorporated herein by reference in its entirety.

BACKGROUND

Support structures can be erected in various use cases, such as concrete formwork or scaffolding (e.g., temporary scaffolding) for supporting workers and supplies/materials during construction projections. In some instances, the support structures can form a corner, such as for extending or wrapping around a corner of the construction project or otherwise connecting one span or length to another span or length at a different angle. Sometimes the corner can be cantilevered above, and extend outward relative to, an underneath structure. In these cases, some conventional systems include an underneath support beam secured beneath one or more other beams that form the corner, and an example of such a conventional arrangement is shown in FIG. 1. In some instances, a railing or other barrier can extend along the corner.

DETAILED DESCRIPTION OF DRAWINGS

The present systems and methods for a support-structure corner beam are described in detail below with reference to these figures.

FIG. 1 depicts a conventional corner construction.

FIG. 2 depicts formwork including a corner beam based on an example of this disclosure.

FIG. 3 depicts an enlarged view of a portion of FIG. 2 showing a connection between the corner beam and another beam.

FIG. 4 depicts a partially exploded view of FIG. 3.

FIG. 5 depicts a different perspective view of an exploded assembly, similar to FIG. 4.

FIG. 6 depicts a corner beam based on an example of this disclosure.

FIG. 7 depicts an end clip of a corner beam of the present disclosure.

FIG. 8 depicts a filler beam based on an example of the present disclosure.

FIG. 9 depicts another example of a corner beam based on an example of this disclosure.

DETAILED DESCRIPTION

This detailed description is related to a support-structure corner beam, as well as various parts of the corner beam and assemblies that can be constructed using the corner beam. The corner beam can be used in various examples, such as concrete formwork, scaffolding, or other support structures. In examples, the corner beam simplifies corner constructions and contributes to easier and safer corner support-structure installation. For example, the corner beam can include end clips with a post (or other type of hook, tenon, projection, protuberance, etc.) that inserts into a pocket or recess of other beams. In addition, the corner beam can include a trough that extends along the side and that can connect to one or more other supports beams, such as the support beams (e.g., filler beams) described in U.S. Pat. No. 11,199,012 B2, which is incorporated herein by reference in its entirety.

Referring to FIG. 2, an example of a corner beam 110 is depicted based on an example. The corner beam 110 includes, on each end, components (e.g., end clips 124 in FIG. 4) that can connect to the other beams, including a first support beam 112 (e.g., first structural beam) and a second support beam 114 (e.g., second structural beam). For example, the first support beam 112 and the second support beam 114 can be oriented perpendicularly relative to one another, and in some instances, the corner beam 110 can span a distance between the first support beam 112 and the second support beam 114. In examples, the first support beam 112 and the second support beam 114 can include similar or the same features, and for brevity, only one of the support beams 112 or 114 might be described in this disclosure—but it is understood that the same or similar description can also apply to the other support beam 112 or 114.

The first support beam 112 and the second support beam 114 can each include a respective end cap 116 and 118. In at least some examples, the corner beam 110 can span a distance between the first end cap 116 and the second end cap 118. As such, the corner beam 110 can function to support various loads, such as platforms, workers, supplies/materials, equipment, etc. In examples, the corner beam 110 can be referred to as a corner structural beam, a third structural beam (e.g., the third structural beam extending between the first structural beam and the second structural beam), and/or other similar terminology. For brevity, the end cap 116 is described herein, and it is understood that a similar description can apply to the end cap 118.

Referring to FIGS. 3 and 4 and 5, the end cap 116 is shown in an enlarged view. In examples, the end cap 116 can include a pocket 120 (e.g., FIG. 4 that is partially exploded), that can connect to one or more other components of the formwork assembly. For example, the pocket 120 can receive a post 122 of a railing (or other barrier or safety structure), such as where the post 122 includes an anchoring bracket 123 that securably inserts into the pocket 120. In at least some examples, the pocket 120 can also receive a portion of the corner beam 110. For example, the pocket 120 can operate similar to a mortise, slot, or other recess for receiving a mating portion (e.g., element 126) of the corner beam 110. The pocket 120 in the end cap 116 is an example of a recess that can receive an end of the corner beam 110 (e.g., receive a portion of the end clip 124 of the corner beam 110). In at least some examples, the end of the corner beam 110 can connect to one or more other recesses along the support beams 112 and 114.

The corner beam 110 can include a top portion 150, a bottom portion 152, a first side 154, a second side 156 (opposite the first side 154), a first beam end 158, and a second beam end 160 that is opposite the first beam end 158 (e.g., viewable in FIG. 2). In at least some instances, the first side 154 and the second side 156 can include similar features (e.g., mirrored features), and the first beam end 158 and the second beam end 160 can include similar features (e.g., mirrored features). For reference purposes, the corner beam 110 can include a longitudinal midline (e.g., longitudinal midline reference plane) that extends from the first beam end 158 to the second beam end 160 and that bisects the corner beam 110 into the first side 154 and the second side 156. In some examples, the first side 154 on one side of the longitudinal midline mirrors the second side 156 on the other side of the longitudinal midline, such that at least some features the corner beam 110 are symmetrical on opposing sides of the midline.

In examples, the corner beam 110 can include a first extension 162 (e.g., FIGS. 3 and 4) that extends from the first beam end 158. For instance, the first extension 162 can include a neck-like body that extends from the first beam end 158 near the top portion 150. In addition, the corner beam 110 can include a first tenon 126 (e.g., post, pin, or other similar projection) that extends downward from the first extension 162. In at least some examples, the first tenon 126 can insert into the pocket 120 of the end cap 116 to couple the corner beam 110 to the first beam 112. In this sense, the pocket 120 can operate similar to a mortise that mates with the first tenon 126. In some examples, the first tenon 126 can insert into other recesses along the a beam that can function similar to the pocket 120.

The second beam end 160 (e.g., FIG. 2) can include elements similar to the first end 158 for mating with the second end cap 118, such as a second extension with a neck-like body extending from the second beam end 160 near the top portion and a second tenon that extends downward from the second extension. For brevity, the features of the second beam end 160 may not be illustrated, but it is understood that those elements can mirror the elements described with respect to the first beam end 158. In examples, the longitudinal midline of the corner beam 110 passes through the first tenon 126 and the second tenon that is associated with the second beam end 160.

The corner beam 110 can, in some instances, include a main central beam 164 (e.g., FIG. 2) having a first end portion 166 and a second end portion 168. In some instances, the main central beam 164 can include lumber. In some examples, the main central beam 164 can include a metal beam. For example, the metal beam might include a metal tube (e.g., welded metal tube, extruded metal tube, etc.) or other style of metal beam (e.g., I beam, C-channel, etc.).

The corner beam 110 can include, at each end, a component that attaches to the first end portion 166 and the second end portion 168 of the main central beam 164 and that is configured to attach to one of the other beams (e.g., to the end cap 116 or 118 of the other beam 112 or 114). In at least some examples, the corner beam 110 includes, at each end, an end clip 124. For example, the end clips 124 can attach to the first end portion 166 and the second end portion 168 of the main central beam 164. In addition, the end clips 124 can include the extension 162 and the first tenon 126. As such, the end clips 124 can function to connect to the first support beam 112 or the second support beam 114. In at least some cases, the end clips 124 allow for easy installation into the end cap(s) 116, since the tenon 126 can simply be inserted into the pocket(s) 120 of the end cap(s) 116. In addition, the post 122 can still be installed (e.g., as shown in FIG. 3) into the pocket 120. That is, both the anchoring bracket 123 of the post 122 and the tenon 126 of the end clip 124 can be co-retained within the pocket 120 of the end cap 116.

The end clip 124 can include various elements. For example, the end clip 124 can include a main body 170 (e.g., FIG. 7), which can include a top portion 172, a bottom portion 174, a proximal side 176, and a distal side 178 that is opposite the proximal side 176. The main body 170 can also include a first side 177 and a second side 179. In at least some examples, the end clip 124 can include one or more elements on the proximal side 176 for attachment to the main central beam 164 and one or more elements on the distal side 178 for securement to another beam (e.g., 112 or 114).

The end clip 124 can include various mounting elements on the proximal side 176 for attachment to the main central beam 164. For example, the end clip 124 can include a mounting insert 180 that extends from the proximal side 176 and that can be slid into an interior void 182 (e.g., FIG. 6) of the main central beam 164 (e.g., an interior void at the end of the main central beam). The mounting insert 180 can include a size (e.g., height and width) that are smaller than the interior void 182 and that are shaped to fit into the interior void. For example, if the interior void 182 is rectangular shaped, then the mounting insert 180 can include a cross-sectional profile that fits into the rectangular-shaped interior void 182.

In at least some examples, the mounting insert 180 can include one or more openings or recesses 132 (e.g., slots), which can receive a fastener 130 (e.g. bolt) for attachment to the end portion 166 of the main central beam 164. For example, the end portion 166 of the main central beam 164 can also include apertures 133 that can also receive the fastener 130. In at least some examples, the recesses 132 can include elongated slots, which permit the end clip 124 to be slid outward or inward in order to adjust an overall length of the corner beam 110. Adjusting the overall length can be useful in various use cases, such as when beams are misaligned or when needing to adjust to varied lengths of other beams. In some cases, the bolted end clips 124 allow for easier repair, since the end clip 124 can be easily, simply, and quickly removed and replaced (e.g., by simply decoupling the fasteners 130, sliding the end clip out, and reinserting a new end clip or a repaired end clip).

In at least some examples, the end clip 124 can include one or more other kinds of brackets or structures for attachment to the end of the main beam. For example, the end clip 124 can include a bracket or brace that fits at least partially around the outside of the end of the main beam.

In examples, the end clip 124 can include the extension 162 that extends out from the distal side 178 and near the top portion 172 of the main body 170 of the end clip 124. In addition, the tenon 126 or other pin, post, projection, protuberance, etc. can extend downward from the extension 162, such that there is a gap or void between the tenon 126 and the distal side 178, which can permit the tenon 126 to nest into the pocket 120. In some examples, the tenon 126 is relatively broad and flat (e.g., as opposed to more cylindrical), which can reduce the tendency of the corner beam 110 to pivot relative to the end cap.

In at least some examples, the end clip 124 can include elements for handling the end clip 124 and/or the corner beam 110. For example, at least one of the first side 177 or the second side 179 can include an opening or a recessed side wall that, together with the top portion 172, forms a handle 181 that can be used for manually grasping the end clip 124 and/or securing other carrying implements onto the end clip 124.

In examples, the corner beam 110 can be secured in position to the other beams 112 and/or 114 via one or more other connection points. For example, and referring also to FIG. 5, the bottom portion 174 can include one or more lower grooves 125a and/or 125b, which are configured to nest into a lower trough (e.g., 113 in FIG. 5) on the beams 112 and/or 114. In examples, the one or more lower grooves can include a first groove 125a and a second groove 125b that are oriented perpendicularly to one another, which can permit the corner beam 110 to be installed either direction. That is, because the first end 158 and the second end 160 can each include a respective end clip 124 with mirrored grooves, the corner beam 110 can be installed either direction (e.g., with the first end 158 or the second end 160 coupled to the end cap 116). In at least some cases, this engagement between the groove 125a or 125b and the trough 113 can impede rotation or other shifting of the corner beam 110.

The corner beam 110 can include one or more other elements. For example, in some instances, the corner beam can include a nailer 134. In at least some examples, the corner beam 110 can include a trough 136 on each side for connecting to other beams 138 (e.g., FIG. 2), such as the beams described in U.S. Pat. No. 11,199,012 B2. For example, a trough 136 can extend along each side (e.g., 154 and 156) of the corner beam 110, such as from one end 166 of the main central beam 164 to the opposing end 168 (e.g., see the troughs 936a and 936b in FIG. 9).

An example of a beam 138 (e.g., filler beam) is shown in FIG. 8, including a first end 810 having a first lower edge 812 that fits into the trough 113 of the other beam 112 and a second end 814 having a second lower edge 816 that fits into a trough that is similar to the trough 136 and that is on the second side 156 of the corner beam 110. In addition, the first end 810 and the second end 814 include respective hinged connections 818 and 820 (e.g., piano-hinge style) that pivot or rotate, such that an orientation of the lower edges 812 and 816 can be adjusted to match the orientations of the troughs on the first beam 112 and the corner beam 110. This also permits the orientation of the filler beam 138 to be tailored base on the use case.

End clips of the present disclosure can include one or more other features. For example, referring to FIG. 9, another example end clip 924 is depicted, which unless otherwise described can include features similar to the end clip 124. In examples, the end clip 924 can include an L-shaped bracket 926, which includes a first arm 928 and a second arm 930 that is perpendicular to the first arm 928. In examples, the first arm 928 can be removably coupled (e.g., via one or more fasteners 932) to the extension 962. In addition, the second arm 930 can include the tenon for securing the corner beam to another beam. In examples, the L-shaped bracket 926 with the removable attachment allows for easy, quick, and less costly replacement or repair in the event that the L-bracket (e.g., second arm 930) is damaged.

Based on the above, a corner beam of the present disclosure can include any one or more of the following features or characteristics diagonal beam connecting perpendicular main beams to create corner condition; eliminates cantilevered low beam as shown in FIG. 1; provides a trough 136 for a filler beam 138, which can span between the corner beam 110 and another beam (e.g., 112 or 114); integrated nailer 134 for deck attachment; adjustable length end clips 124 to accommodate misalignment; locks into beam end cap 116 while still allowing installation of guardrail post 122; interlocks into lower trough 113 to prevent rotation; bolted end clips 124 for ease of repair; ambidextrous design reduces the likelihood of improper installation; and/or safer install from top of deck while tied off.

As used herein, a recitation of “and/or” with respect to two or more elements should be interpreted to mean only one element, or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

This detailed description is provided in order to meet statutory requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways, to include different steps, different combinations of steps, different elements, and/or different combinations of elements, similar or equivalent to those described in this disclosure, and in conjunction with other present or future technologies. The examples herein are intended in all respects to be illustrative rather than restrictive. In this sense, alternative examples or implementations can become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof.