DEVICE FOR FLOATING WET CONCRETE EDGES TO GRADE AND RELATED METHODS

Description

FIELD OF THE INVENTION

The invention relates generally to the construction industry and more specifically to concrete applications. The invention is directed to a device that improves quality and accuracy of concrete leveling particularly by floating wet concrete edges to grade.

BACKGROUND OF THE INVENTION

Concrete is the most widely used building material in the world, and the second most used substance after water.

Concrete is a composite material composed of aggregate, cement, and water. Aggregate is a material such as sand, gravel, crushed stone. Cement is a chemical substance composed primarily of limestone powder. When mixed with water, the cement binds the aggregate together and creates a fluid slurry, or wet concrete, that is easily poured and spread into shape. Over time the wet concrete hardens and cures to form solid concrete.

A concrete form or formwork is a temporary or permanent mold used to hold poured concrete in place while it sets. The formwork is built into the shape that the user wants the concrete to take when it dries. The form is typically created using lumber or wood such as beams, planks, or boards defining the outside perimeter borders. Or the outside perimeter borders may be defined by an existing structure such as walls. Inside perimeter borders may be defined by structures or features that are located within the formwork, for example, pipes, columns, conduits, and drains.

All these perimeter borders create boundaries for the concrete to be poured within. Once poured, wet concrete is spread-out using shovels or rakes. Edges are formed where the wet concrete meets the perimeter borders of the form. These edges are leveled to grade. Grade refers to the ground level or the elevation at any given point, as defined by the project or application. This is performed manually and sometimes referred to as “troweling”, “mag the edges”, or “float the edges”. This requires use of a tool typically referred to as a “mag float” or “bull float” tool made from materials like aluminum, magnesium, wood, rubber that is moved over the top surface of wet concrete. These manual operations require the laborer to bend over or squat to reach the top surface of the wet concrete edges. This may induce back pain and discomfort and may further cause a laborer to be tired and fatigued.

While the prior art teaches various troweling and leveling methods, there is no such device for floating wet concrete edges to grade. The invention fulfills this need and provides further related advantages as described in the following summary.

SUMMARY OF THE INVENTION

The invention is directed to a device for floating wet concrete edges to grade.

Specifically, the invention is a power tool that floats wet concrete edges to grade using a vibrating blade. The vibrating blade, while moved along the top surface of the concrete, levels the concrete to grade while smoothing its surface. The device causes the aggregate within the wet concrete to drop below the remaining mixture - sometimes referred to as “cream” - that rises toward the top surface. This improves the durability and longevity of the concrete and reduces imperfections, such as cracks and air pockets, which can weaken the concrete surface over time.

The vibrating blade is rotatably movable to different positions. This makes the device adaptable to the edges to be worked. Specifically, the blade may rotate about a pivot point to achieve proper placement of the blade over the top surface of the concrete, and proper placement around edges of structures or features like conduit and columns.

While there are vibrating tools used with concrete applications, these are large and difficult to maneuver around wet concrete edges. There is no known tool that uses vibration to work concrete edges, and particularly a tool with a blade, or platform, sized and shaped to do so efficiently and effectively.

The device according to the invention improves the quality and accuracy of concrete leveling and smoothing, and particularly along wet concrete edges. However, while a primary purpose of the invention is to work wet concrete edges, it is contemplated that the device may be used at other areas other than the edges, for example to prepare “pads” used with leveling or screeding methods.

The concrete applications the invention may be used are limitless. For example, the device may be used with any concrete application such as foundations, footings, flooring, stairs, patios, to name a few.

A primary objective of the invention is to provide a device and related methods of use that provides advantages not taught by the prior art.

Another objective is to provide such an invention capable of floating wet concrete edges to grade.

Another objective is to provide such an invention capable of simultaneously leveling and smoothing wet concrete edges.

A further objective is to provide such an invention capable of being easily and ergonomically controlled by an operator.

A further objective is to provide such an invention capable of delivering forces to the concrete to level it to grade and smooth its surface.

A further objective is to provide such an invention that eliminates or replaces the need for mag float tools.

A further objective is to provide such an invention capable of providing concrete with uniform consistency and a shiny appearance.

A further objective is to provide such an invention operated while standing and steered by hand. The invention eliminates the requirement for a laborer to bend over or squat to trowel wet concrete or “mag the edges”. An advantage is that a laborer's back pain and discomfort may be reduced or even prevented, which may further help a laborer to avoid tiring and fatiguing.

A further objective is to provide such an invention capable of preparing various concrete compositions or mixes or mix designs, such as any type of stiff, low-slump and/or difficult to level cement, or fiber reinforced concrete mixes or compositions and/or the like.

Another objective is to provide such an invention capable of being cordless.

Other features and advantages of the invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the device according to the invention.

FIG. 2 is an assembled view of the device according to the invention.

FIG. 3 is an exploded view of the device according to the invention.

FIG. 4 illustrates a handle component according to the invention.

FIG. 5 illustrates a handgrip element according to the invention.

FIG. 6A illustrates a housing component according to the invention.

FIG. 6B illustrates another view of the housing component according to the invention.

FIG. 6C illustrates another view of the housing component according to the invention.

FIG. 7 illustrates a vibration motor according to the invention.

FIG. 8 illustrates a blade component according to the invention.

FIG. 9 illustrates a close-up assembled view of a portion of the device according to the invention.

FIG. 10 illustrates a laborer using the device according to the invention to float wet concrete edges to grade.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now specifically to the drawings and the illustrative embodiment depicted therein, a device 50 for floating wet concrete edges to grade includes a handle component 100, a housing component 200, a vibration component 300, and a blade component (FIGS. 1-3). The device 50 is moveable over and supported on wet concrete while the blade component 400 contacts the wet concrete and vibrates or shakes over the top surface. The vibrating blade 400, while moved along the top surface of the concrete, levels the concrete to grade while smoothing its surface. Device 50 causes the aggregate within the wet concrete to drop below the remaining mixture with the “cream”rising toward the top.

The handle component 100 comprises a cylindrical rod or elongated body 105 extending from a first end 110 to the second end 120 as shown in FIG. 4. The handle component 100 permits a laborer to operate the device while standing. The handle component 100 is connected, directly or indirectly, to the blade component 400 at one end 120 and a handgrip element 150 at the other end 110. An operator hand-steers the device 50 by holding onto the handgrip element 150 and moving the blade component 400 along the top surface of the concrete.

In certain embodiments of the invention, another handgrip element 155 may be used. For example, in addition to the handgrip element 150 at the first end 110 of the handle component 100, a handgrip element 155 may be located at any point along the body 105 such as halfway between the ends 110, 120. With two handgrip elements 150, 155 an operator may hold the device 50 at either or both locations which may improve control of the device 50 during operation.

The handle component 100 may be made from any known material such as lightweight material or combination of materials such as aluminum, steel, metal, an alloy, plastic, rubber, etc.

As shown in FIG. 5, the handgrip element 150 may be made from any material that is easy to grasp and hold onto by an operator such as lightweight materials or combination of materials like aluminum, steel, metal, an alloy, plastic, rubber, etc. The handgrip element 150 may be integrated with or attached to the first end 110 of the handle component 100 by any known means, e.g., hardware.

In the embodiment shown, the handgrip element 150 includes a power switch 160 that may easily be operated with one hand/finger to turn on/off the device 50. As shown in FIG. 5, the handgrip element 150 may further include a socket element 170. The socket element 170 is configured to receive power from a power supply 180 to activate the device 50 when the power switch 160 is turned to an “on”position.

In a preferred embodiment, the power supply 180 is an energy storage device. However, any source of power is contemplated such as that which may come from an electrical outlet, or other energy storage devices such as fuel cells, solar panels, etc. The power supply may also be gas powered. While a source of power may come from an electrical outlet, energy storage devices such as batteries, fuel cells, solar panels, or gas-powered devices are preferred so that the device is cordless so that it does not interfere with the concrete application.

As shown in FIGS. 6A, 6B, 6C, the housing component 200 is configured to connect, either directly or indirectly, each of the components of the device. The housing component 200 is connected to the second end 120 of the handle component 100, and may further be connected, directly or indirectly, to the vibration component 300, the blade component 400, the handle component 100, and/or the power supply 180.

The housing component 200 may be constructed of one or more elements and made from any durable, lightweight material or combination of materials such as aluminum, steel, metal, an alloy, plastic, rubber etc.

The housing component 200 comprises two elements: a top housing element 210 and bottom housing element 220. The top housing element 210 is connected to the second end 120 of handle component 100 and the bottom housing element 220 is connected to the blade component 400 using any known method like welding or securing with hardware. The bottom housing element 220 rotatably connects to the top housing element 210 using any fastener that permits rotation. Specifically, the bottom housing element 220 is capable of rotating with respect to the top housing element 210. This makes the device 50 adaptable to the edges to be worked. The blade component 400 is angularly directable, or rotatably movable to different positions. This facilitates proper placement of the blade component 400 over the top surface of the concrete and around edges of structures or features like conduit and columns. The blade component 400 can be rotated, for example, 45 degrees as defined from fastener 230 (i.e., pivot point), to work hard to reach or nonuniform/uneven edges, however any angle is contemplated, even a completely (360 degrees) rotatable blade.

The blade component 400 may freely rotate or be locked into position using a locking mechanism, shown here as a locking pin element 250. In the embodiment shown, the top housing element 210 comprises a topmost surface 212 and a bottommost surface 214 through which a pin element 250 passes through. The pin element 250 includes a grasping portion 251 located above the topmost surface 212 and an end portion 252 located below the bottommost surface 214.

The bottom housing element 220 includes two connected wall portions: a horizontal wall portion 260 connected to a vertical wall portion 270 along a side 275. The horizontal wall portion 260 includes an upper surface 262 and a lower surface 264 through which a plurality of spaced-apart apertures 280 or holes are located. The vertical wall portion 270 secures both the blade component 400 and the vibration component 300 using any known fastening methods.

To rotate the blade component 400, an operator pulls upwardly on the grasping portion 251 to raise the pin 250 vertically. The end 252 of the pin 250 clears the apertures 280 allowing the bottom housing element 220, that is connected to the blade component 400, to rotate. Once the desired angle is determined, the operator releases the grasping portion 251 to lower the pin 250 vertically with the end 252 engaging within an aperture 280 to secure the blade 400 into position. Is it contemplated that the pin element may be spring loaded.

The vibration component 300 is shown in FIG. 7 and is configured to vibrate the blade component 400. The vibration component 300 may include any device, that in operation, causes the blade component to move repetitively back/forward, right/left, up/down as defined by frequency, displacement, velocity, and acceleration. Vibration components may include any mechanical device in operation, for example, a motor or engine, and may further help propel the device along the concrete surface. As shown in FIG. 7, the vibration component 300 is a vibrator motor 310.

According to one embodiment of the invention, the vibration component 300 operates at a constant speed, but it is contemplated that variable speed motors may be used. This may be particularly useful since concrete is known to differ in consistency and is usually offered in various grades, mixes and strengths. As an example, stiff, low-slump and/or difficult to level cement or cement with large dense aggregate may require a highly repetitive motion or a greater vibration than a soft cement.

The blade component 400 is configured to be positioned on and moved along the top surface of the concrete. The blade component 400 is constructed of aluminum, magnesium, alloy, rubber, or any material that is lightweight, resistant to deterioration and corrosion, and that does not pull at the wet surface.

The blade component 400 comprises two connected panel portions: a horizontal panel portion 420 connected to a vertical panel portion 430 along a side 450. The horizontal panel portion 420 includes a top surface 422 and a bottom surface 424 separated by a boundary surface 426. Specifically, the bottom surface 424 is configured to be directed on the top surface of the wet concrete. And the boundary surface 426 defines the length and width of the blade component 400. The length and width of the blade component 400, along with the material composition, determine the weight of the blade component 400. It should be noted that the weight and output of the vibration component 300 are correlated, that is, the greater the weight the greater the vibration output as compared to a lighter weight blade component 400.

The boundary surface 426 includes rounded or curved corner areas 428 which may be considered useful when working edges around various structures, e.g., circular-shaped features such as conduit or drains.

As shown in FIG. 9, the vertical panel portion 430 of the blade component 400 is secured to the vibration component 300 and the housing component 200 using any known fastening methods. Specifically, the vibration component 300 is secured to the blade component 400 such that a distance remains between the top surface 422 of the horizontal panel portion 420 and the vibration motor 310. It is not desirable to have the vibration component 300 resting on, touching, or abutting the blade component 400. However, it is noted that certain concrete applications may require this.

The blade component 400 may be constructed preferably of magnesium, which is the same material float tools are usually made from, but any material is contemplated such as aluminum, alloy, rubber, or something that is lightweight, resistant to deterioration and corrosion.

More importantly, it is contemplated that the length of the blade component 400 does not exceed approximately 20 inches so that the blade is maneuverable around wet concrete edges. Thus, a preferred embodiment comprises a blade component 400 of approximately 20 inches or less. Examples include 10-20 inches, or preferably 12-20 inches, or more preferably 15-20 inches. By using a blade component 400 with a length equal to or less than 20 inches makes it easy for a laborer to work edges efficiently and effectively.

FIG. 10 illustrates a laborer using the device 50 according to the invention to float wet concrete edges to grade. The power supply 180 activates the vibration component 300 so that the blade component 400 vibrates. As shown here, the power supply 180 is connected indirectly to the housing component 200 through the handle component 100. More specifically, the power supply 180 is connected to the handle component 100 through a handgrip element 150 so that an operator can quickly and easily turn the power supply on/off. The device 50 floats wet concrete edges to grade using a blade component 400 with a length approximately 20 inches or less configured to vibrate as it is moved along the top surface of wet concrete edges such as those created by forms, structures, or features such as walls, pipes, columns, conduits, and drains. The invention represents an improvement over prior art machines and methods used in the concrete construction industry.

Changes and modifications to the specifically described embodiments can be carried out without departing from the principles of the invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law.