Insulated Concrete Form Connector

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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 edge

As shown in, the connection of the present invention is made with a connectorthat can be used for attaching a structural member to wall. The wallis made up of a cementitious memberand an insulated concrete form. The formcan be constructed by stacking hollow insulated form blocksupon each other. The blockstypically have two main panelsof expanded foam facing each other which are spaced apart the appropriate distance so that the cementitious memberwill have the desired thickness. The blocksmay have additional end panels or openings in the main panelsto form corners in the wall, or special corner blocks may be used. Typically, the panelsare connected to each other and spaced apart the appropriate distance by bridging members. In the preferred embodiment, the main panelsof the blocksare either three and one-quarter inches or four and one-half inches thick.

As shown in, the connectoris provided with an anchoring plateand first and second anchoring legsand. The anchoring plate is a substantially planar member, and the first and second anchoring legsandare 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 legsand, preferably, extending perpendicular from opposed edges of the anchoring plate. The connectoris 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 connectoris made fromgauge, galvanized steel.

The anchoring legsandpreferably have openingsinto which the concrete can flow to help anchor the connector. Reinforcing bars may also be installed through the openingsin the anchoring legsand.

The connectorcan also be attached to the bridging membersin the form with separate fasteners.

The connectorof the present invention is preferably attached to the concrete formbefore the cementitious member is poured. Slots are cut in the foam panelsof the form, and the one or more anchoring legsandare inserted through the slots in the panelsof the formand into the cavity that will receive the uncured cementitious member. Preferably, the anchor plateinterfaces with the outer surfaceof one or more panelsof the form though which the anchoring legsandof the connectorare inserted.

As shown in, preferably a plurality of embossmentsare formed in and extend substantially along the length of the anchoring legsand, except where the openingsare formed in the anchoring legsand. The embossmentsare preferably disposed parallel to each other and extend from the anchor platetoward the rear endsof the anchoring legsand. Preferably, the openingsin the anchoring legsandare formed near the rear endsof the anchoring legsand. Preferably, the anchoring legsorare each formed with four embossmentsextending parallel to each other along the anchoring legsand.

As shown in, the anchoring legsandare preferably formed with strengthening flangesat the upper and lower edgesandof the anchoring legsand. Preferably, each of the strengthening flangesattached to either the first or second anchoring legsorextends orthogonally and inwardly from either the first or second anchoring legandto which it is attached and toward the other of the opposed first and second anchoring legsand.

As shown in, the anchor platecan have an octagonal shape. Preferably, the anchor plateis asymmetrical. As shown in, the anchor plate can have an irregular, hexagonal shape, and again preferably, the anchor plate is asymmetrical.

As shown in, in one embodiment of the present invention, the first and second anchoring legsandcan be vertically disposed when installed in the concrete formfor a typical vertical wall. The first anchoring legextends from a first side edgeof the anchor plate, and the second anchoring legextends from an opposed, second side edgeof the anchor plate. The second side edgeis preferably disposed parallel to and slightly offset from the first side edge. Along the upper portion of the anchor plate, a first upper edgeextends upwardly and at an angle from an upper endof the first side edgetowards the opposed, second side edge. A middle upper edgeextends from an upper endof the first upper edgetoward the opposed, second side edgein a direction that is generally orthogonal to the first and second side edgesand. A second upper edgeconnects the middle upper edgeto the opposed, second side edge, extending downwardly from a terminating endof the middle upper edgethat is distal from the first side edgeof the anchor plate. The second upper edgeis preferably longer than the first upper edge. The second upper edgealso preferably extends from the middle upper edgeat a similar, but opposed angle as the first upper edgeextends from an initiating endof the middle upper edge, such that the second side edgeis disposed lower in the concrete formthan the first side edge, when the middle upper edgeis set generally horizontally with respect to the concrete form. This results in the second anchoring legbeing disposed lower in the concrete formthan the first anchoring leg, when the middle upper edgeis set generally horizontally with respect to the concrete form.

As shown in, along the lower portion of the anchor plate, a first lower edgeextends downwardly and at an angle from a lower endof the first side edgetowards the opposed, second side edge. A middle lower edgeextends from a lower endof the first lower edgetoward the opposed, second side edgein a direction that is generally orthogonal to the first and second side edgesand. A second lower edgeconnects the middle lower edgeto the opposed, second side edge, extending upwardly from a terminating endof the middle lower edgethat is distal from the first side edgeof the anchor plate. The second lower edgeis preferably shorter than the first lower edge. The second lower edgealso preferably extends from the middle lower edgeat a similar, but opposed angle as the first angled lower edgeextends from an initiating endof the middle lower edge, such that the second side edgeis disposed lower in the concrete formthan the first side edge, when the middle lower edgeis set generally horizontally with respect to the concrete form. This results in the second anchoring legbeing disposed lower in the concrete formthan the first anchoring leg, when the middle lower edgeis set generally horizontally with respect to the concrete form.

As shown in, in another embodiment of the present invention, preferably the first and second anchoring legsandare generally disposed offset from a vertical line when installed in a typical concrete formfor a vertical wall. The first anchoring legextends from a first side edgeof the anchor plateand the second anchoring legextends from an opposed, second side edgeof the anchor plate. The second side edgeis preferably disposed parallel to and slightly offset from the first side edge. When installed in typical concrete formfor a vertical wall, preferably the first and second anchoring legsandare disposed slightly offset from the vertical. When installed as described, along the upper portion of the anchor plate, a first upper edgeextends horizontally from an upper endof the first side edgetowards the opposed, second side edge. A second upper edgeextends from a terminating endof the first upper edgeto the opposed, second side edgein a direction that is downwardly from the first upper edgewhen the connectoris installed in a concrete formas described. The second upper edgeextends downwardly from the terminating endof the first upper edgethat is distal from the first side edgeof the anchor plate, such that the second side edgeis disposed lower in the concrete formthan the first side edge, when the connectoris installed as described. The second upper edgeis preferably longer than the first upper edge. The second upper edgeconnects with the second side edgeat the upper endof the second side edge.

As shown in, when installed as described, along the lower portion of the anchor plate, a first lower edgeextends downwardly from a lower endof the first side edgetowards the opposed, second side edge, such that the second side edgeis disposed lower in the concrete formthan the first side edge, when the connectoris installed as described. A second lower edgeextends from a terminating endof the first lower edgeto the opposed, second side edgein a direction that is horizontal from the first lower edgewhen the connectoris installed in a concrete formas described. The second lower edgeextends horizontally from the terminating endof the first lower edgethat is distal from the first side edgeof the anchor plate. The second lower edgeis preferably shorter than the first lower edge. The second lower edgeconnects with the second side edgeat the lower endof the second side edge.

In the embodiment shown in, the first upper edgeis preferably 1 and ⅜ inches long. The second upper edgeis 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 panelsof the blocks. The angle between the first and second upper edgesandis preferably 123 degrees. The angle between the first and second lower edgesandis the same. The first and second side edgesandare preferably 3 and ½ inches long. As is also shown in, the first lower edgeis preferably 5 and ⅝ inches long, and the second lower edgeis 1 and 3/8 inches long. The longest embossments are preferably 7 and ⅜ inches long, when the anchoring legsandare 8 inches long. The distance between the first and second anchoring legsandis preferably 6 and 25/32 inches. The distance between the first upper edgeand the second lower edgeis preferably 6 and 9/16 inches. Preferably a central axis for the part shown incan be drawn from the intersection between the first and second upper edgesandand the first and second lower edgesand, and preferably a plurality of openings are provided on the center line of the partfor assisting with alignment and the installation of the part on the panelof the block. The connectorcan be attached to the panelof the blockwith fasteners provided through the anchor plateto hold the connectorin place while the concrete is poured, if needed.

Once the cementitious memberhas been poured and set, such that the connectoris anchored to the wall, the structural member is held against the wallin the proper position and fasteners are driven through the structural member and into the anchor plateof the connector. The preferred fasteners are self-drilling and self-tapping screws.

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. Fasteners are driven through the upwardly extending flange of the additional bracketing, through the ledger board and into the anchor plateof the connector.