Pin cap

Abstract

A stamped pin cap and method of manufacturing the same. There is a frame coupling together a mount, a stop flange and a cradle. The mount couples to a reinforced bar (rebar) as used in construction and the cradle receives a construction pipe, thereby coupling the construction pipe to the rebar. The cradle, in cooperation with the stop flange may mount to lumber. The stamped pin cap requires no welding or expensive molded materials and thereby may be produced cheaply and quickly.

Claims

1. A stamped pin cap for use with reinforcing bars; comprising: a. a cap frame; b. a stamped mount disposed within a bottom region of the cap frame and including three bands alternately protruding laterally from the cap frame thereby forming a channel there between through which a reinforcing bar may be disposed; c. a stop flange disposed at a top portion of the channel and protruding laterally from the cap frame such that a reinforcing bar disposed through the channel is prevented from further travel therethrough, and d. a pair of arms extending from a top region of the cap frame opposite the stamped mount and extending away from the stamped mount and the stop flange, the pair of arms together forming cradle extending upwardly from a top region of the cap frame and wherein far ends of the pair of arms are spaced apart from each other and oriented away from each other.

2. The cap of claim 1, further comprising a pair of holes through the cradle at opposite arms thereof such that coupling shafts may be disposed therethrough.

3. The cap of claim 1, further comprising a first reinforcing groove extending along the frame and continuing along a first arm of the pair of arms, and a second reinforcing groove extending along the frame spaced from the first reinforcing groove and continuing along a second arm of the pair of arms.

4. The cap of claim 1, wherein the three bands are adjacent to each other and are at a bottom-most portion of the cap.

5. The cap of claim 1, wherein the pair of arms are coplanar with the cap frame.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In order for the advantages of the invention to be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawing(s). It is noted that the drawings of the invention are not to scale. The drawings are mere schematics representations, not intended to portray specific parameters of the invention. Understanding that these drawing(s) depict only typical embodiments of the invention and are not, therefore, to be considered to be limiting its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawing(s), in which:

(2) FIG. 1 is a front perspective view of a stamped pin cap according to one embodiment of the invention;

(3) FIG. 2 is a front elevational view of a stamped pin cap according to one embodiment of the invention;

(4) FIG. 3 is a rear elevational view of a stamped pin cap according to one embodiment of the invention;

(5) FIG. 4 is a side elevational view of a stamped pin cap according to one embodiment of the invention;

(6) FIG. 5 is a top plan view of a stamped pin cap according to one embodiment of the invention;

(7) FIG. 6 is a bottom plan view of a stamped pin cap according to one embodiment of the invention;

(8) FIG. 7 is a front perspective view of a stamped pin cap mounted on a rebar and coupled to a 24 piece of lumber according to one embodiment of the invention;

(9) FIG. 8 is a side elevational view of a stamped pin cap mounted on a rebar and coupled to a 24 piece of lumber according to one embodiment of the invention;

(10) FIG. 9 is a flowchart illustrating a method of manufacturing a stamped pin cap according to one embodiment of the invention;

(11) FIG. 10 is a front view of a strip of stampable material from which a series of stamped pin caps may be manufactured, according to one embodiment of the invention;

(12) FIG. 11 is a perspective view of a pin cap according to one embodiment of the invention;

(13) FIG. 12 is a perspective view of a pin cap according to one embodiment of the invention;

(14) FIG. 13 is a perspective view of a pin cap according to one embodiment of the invention;

(15) FIG. 14 is a perspective view of a pin cap according to one embodiment of the invention; and

(16) FIG. 15 is a perspective view of a partially manufactured pin cap according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

(17) For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the exemplary embodiments illustrated in the drawing(s), and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

(18) Reference throughout this specification to an embodiment, an example or similar language means that a particular feature, structure, characteristic, or combinations thereof described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases an embodiment, an example, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, to different embodiments, or to one or more of the figures. Additionally, reference to the wording embodiment, example or the like, for two or more features, elements, etc. does not mean that the features are necessarily related, dissimilar, the same, etc.

(19) Each statement of an embodiment, or example, is to be considered independent of any other statement of an embodiment despite any use of similar or identical language characterizing each embodiment. Therefore, where one embodiment is identified as another embodiment, the identified embodiment is independent of any other embodiments characterized by the language another embodiment. The features, functions, and the like described herein are considered to be able to be combined in whole or in part one with another as the claims and/or art may direct, either directly or indirectly, implicitly or explicitly.

(20) As used herein, comprising, including, containing, is, are, characterized by, and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional unrecited elements or method steps. Comprising is to be interpreted as including the more restrictive terms consisting of and consisting essentially of.

(21) FIGS. 1-6 are various views of a stamped pin cap (also known as screed chairs) according to one embodiment of the invention. There is shown a stamped pin cap 100 for use with reinforcing bars. The stamped pin cap includes a cap frame 110 having a pair of reinforcing grooves 114 extending along the frame within which is disposed a stamped mount 120. The stamped mount 120 is disposed within a bottom region 112 of the cap frame 110 and includes three adjacent channel guides that are bands 122, 124, 126 alternately protruding laterally from the frame thereby forming a channel 128 therebetween through which a reinforcing bar may be disposed. At a top portion 129 of the channel 128 there is a stop flange 130 that protrudes laterally from the frame 110 such that a reinforcing bar disposed through the channel is prevented from further travel therethrough. Extending from a top region 119 of the frame 110 is a cradle 140 that is shaped to receive and confine a member therein under gravity.

(22) There are a pair of holes 142 through the cradle at opposite arms 144 thereof such that coupling shafts may be disposed therethrough. The illustrated cradle 140 is shaped with a semi-circular interior surface 146 to receive a circular pipe such that a pipe having a circular cross section may nestle therein.

(23) The illustrated cap frame 110 provides support structure for the mount 120, stop flange 130, and cradle 140. The illustrated cap frame is shaped as a pair of parallel supports extending along the length of the channel 128 and thereby coupling each of the bands 122, 124, 126 together and coupling the mount to each of the stop flange 130 and cradle 140. The illustrated cap frame is symmetrical, but it is understood that there are plethoric shapes, configurations and orientations of such frames that would still provide the benefits thereof and that such frames may also display various decorative shapes and decorative structures thereon as desired. Indeed, as a non-limiting example, there may be a frame that only frames one side of the bands and that includes a stamped logo of a particular company extending outwardly therefrom. Such a frame would be asymmetrical, as compared to the illustrated frame, and would include a decorative structure.

(24) The illustrated mount 120 operates to couple to a rebar or other similar structure and to stay mounted thereon. The illustrated bands 122, 124, 126 cooperate together with the stop flange 130 to firmly secure the device to an end of a rebar, or other similar structure, under the presence of gravity, such that typical jostling of the device during operation does not knock the device off the rebar. The illustrated bands 122, 124, and 16 are not all the same height, as the middle band 124 is taller than the other two, which improves the stability thereof. As the illustrated mount is stamped without creating lateral overlap between the bands (See FIGS. 2 and 3), the alternating bands, together as a triad, trap the rebar within the channel 128 such that the mount will not fall off the rebar if tipped one way or the other. While the illustrated mount includes a series of alternating bands that together form a channel, a mount may include additional or alternative structures, such as but not limited to fold-over tangs that cooperate to form a channel, accordion-style structures that are punched/folded/stamped into a channel shape, a stamped/folded zig-zag structure of material with a hole in the middle, and various other wrapped/folded structures, such as but not limited to a wrapped/folded triangle of material at a base of a device.

(25) The illustrated stop flange 130, shown in FIG. 1 as dotted lines as it would otherwise be obscured by the cradle, provides a stable rest against which a tip of a rebar, or other similar structure, rests when the device is installed thereon. The stop flange may also, advantageously, provide a support for coupling the device to another structure (See FIGS. 7 and 8 as non-limiting examples). While the illustrated stop flange (tang) is a simple tab of material that has been punched and folded outwardly to extend at about a 90 degree angle from the frame, various other structures for such a stop flange are contemplated herein, including but not limited to a double-tang sticking out both sides, no tang/tab at all (e.g. just an edge of material from which the top-most band was stamped), and/or tabs having shapes and orientations different from the illustrated rectangular tab extending at a right angle, such as but not limited to a triangular tab extending upwardly at an angle greater than 90 degrees from the frame, a multi-tabbed stop flange that may include tabs of different shapes extending at different angles, and/or wherein the tab/flange is created not by punching out the tab from the material, but from folding the material over on itself to form the frame, the cradle, and/or the mount.

(26) The illustrated cradle 140 provides coupling, under the influence of gravity, for the device to another structure, such as but not limited to a construction pipe, such as but not limited to those used in the installation of concrete. The illustrated cradle is shaped to receive such a circular member and trap the same, under the influence of gravity, therein. Accordingly, wherein a plurality of such devices are installed within a grid of rebars, a grid of pipe may be laid there-across, such as but not limited to for the purposes of providing a predetermined leveling structure for proper leveling/grading of wet concrete. While the illustrated cradle is a pair of arms cooperating to form a semi-circular receiving member, other variations of the cradle are contemplated, including but not limited to plethoric different shapes, orientations, and sizes that may match up to other additional structures that may be different from inch-and-a-quarter construction pipe. AS a non-limiting example. There may be a cradle having arms extending horizontally in a flat configuration to match with a flat bar or 24 piece of lumber. Such a flat cradle may or may not have upwardly extending arms at the ends to form boundaries within which to trap the additional structure. Further, the illustrated holes may positioned at different places on the cradle than those illustrated, there may be more or less than such holes, and one may put other things besides screws in them. Further, the holes need not even be complete holes, as they may instead be spikes, clips, snaps, nails, staples, or the like or other structures that couple to another structure.

(27) In one non-limiting embodiment, there is a pin cap that is stamped out so that it sits over a rebar. It has a cradle to hold a pipe and a tang (stop flange) sticking out the side so it can support a 24 piece of lumber or other similar structure. The pin cap may include a cradle having one or more screw-holes through arms thereof, a tang disposed under the cradle and extending outwardly to form a stop that prevents further vertical travel upward through a channel in the device, a mount shaped to couple to an end of a rebar, and a frame coupling each to the other.

(28) FIGS. 7 and 8 are various views of a stamped pin cap mounted on a rebar and coupled to a 24 piece of lumber according to one embodiment of the invention. There is shown a device mounted on an end of a reinforcing bar (rebar) 720 and also mounted to a piece of lumber 700 that is resting on the stop flange of the device. Screws 710 extend through washers 712 and through holes in the device to thereby couple the lumber to a top portion (cradle portion) of the device.

(29) In the illustrated embodiment, the device is able to be coupled to a construction pipe as well as a piece of lumber or other similar structure. This allows for the device to serve multiple purposes with a single form of manufacture, thereby decreasing the need for on-hand inventory of multiple variations of such devices for use in construction.

(30) FIG. 9 is a flowchart illustrating a method of manufacturing a stamped pin cap for use in construction according to one embodiment of the invention. There is shown a step of configuring a press 900 followed by making any pre-cuts 910 in material to be stamped that may be needed before stamping such material. The material is then stamped 920 in a sequence that stamps out the proper structures as desired, including those that were precut. The device(s) are then decoupled 930 from each other and then finished 940.

(31) The illustrated configuring step 900 may include forming, casting, molding, shaping or otherwise creating and placing various stamp dies and configuring stamping tools within a stamping assembly to create the desired stamps, folds, cuts, and shapes desired within the stampable material. Such a configuring step may include determining an order of sequential stamping that is to occur to generate the desired stamped product. One of ordinary skill in the art would recognize how the various stamping/cutting/folding/etc. operations made during manufacturing would impact each other and the final product in making such a sequential determination, as well as selecting the appropriate stamps/dies/cuts/etc. to utilize in the process. Such a stamping assembly may be configured to perform the stamping method or manufacture in series along the strip of stampable material such that a plurality of pin caps may be stamped therefrom. Such may also include selecting the material which is to be stamped, generally a strip of ductile material of predetermined thickness, such as but not limited to strips/rolls of sheet metal.

(32) As non-limiting example, there may be one or more punch dies used to punch out holes as shown in element 142 of FIGS. 1-6, there may be one or more beveled punches used to cut and bend under force the stop flange illustrated as element 130 of FIGS. 1-6, there may be one or more dies shaped to stamp grooves such as those illustrated as element 114 in FIGS. 1-6, there may be one or more curved dies shaped to press and cut the bands 122, 124, and 126 illustrated in FIGS. 1-6, and there may be one or more dies that stamp-cut the arms 144 and frame 110 of the device as illustrated in FIG. 1-6 herein.

(33) The illustrated precutting step 910 may include making one or more cuts before performing a stamping step, the cuts positioned and oriented to facilitate stamping. As a non-limiting example, such cuts may be made at any of the dotted or solid lines in FIG. 10 within the strip of material 1000. Such cuts may be performed using blades, saws, water cutting, or the like or combinations thereof, depending upon the properties of the materials and/or the properties of the stamping/cutting tools used therewith. The cuts may be made all the way through the material or may merely score the material. The cuts may extend in a line or may form an array of perforation.

(34) The illustrated stamping step 920 may include stamping one or more of the following into a strip of stampable material, thereby forming a pin cap section: a plurality of alternating channel guides at a bottom end of a predefined pin cap; a stop flange at a top end of a predefined channel formed by predefined alternating channel guides; a cradle at a top end of a predefined pin cap; and a frame. The stamping step may also include stamping a hole through an arm of the cradle through which a coupling shaft may be disposed; and/or stamping a reinforcing groove through the frame.

(35) As stamped, the cradle may be shaped to nestle a circular pipe therein (See FIGS. 1-6). As stamped, a center channel guide may be taller than each channel guide adjacent thereto (see band 124 as compared to bands 122 and 126 FIGS. 1-6).

(36) Stamping steps may include operation of various stamping tools, such as but not limited to stamping of stamp dies, cutters, folding devices/machines and the like and combinations thereof. Accordingly, there may be a step of stamping channel guides which includes a step of folding a pin cap to bring channel guides adjacent to each other.

(37) The illustrated decoupling step 930 may include decoupling a pin cap section from the strip of stampable material, thereby forming the pin cap. Such may be performed through a final stamp and/or cut that cuts the pin cap out of the strip of material.

(38) The illustrated finishing step 940 may include one or more steps of cleaning, deburring, sanding, coating, imprinting, annealing, anodizing, or otherwise treating the stamped pin cap as desired to alter its characteristics to those of a finished product.

(39) In one non-limiting embodiment there is a method of manufacturing a pin cap for use in construction comprising the steps of: stamping each of the following into a strip of stampable material, thereby forming a pin cap section: a channel; a stop flange at a top end of the channel; a cradle near the stop flange and opposite the channel; and a frame disposed about the channel; and decoupling the pin cap section from the strip of stampable material, thereby forming the pin cap.

(40) Such a method may further comprise the step of stamping a hole through an arm of the cradle through which a coupling shaft may be disposed; the step of stamping a reinforcing groove through the frame; and/or the step of making one or more cuts before performing a stamping step, the cuts positioned and oriented to facilitate stamping.

(41) Advantageously, the illustrated method requires no welding, use of molds, or other expensive manufacturing tools/techniques and thus may be manufactured quickly and inexpensively relative to other pin caps.

(42) FIG. 10 is a front view of a strip of stampable material from which a series of stamped pin caps may be manufactured from a strip of stampable material, according to one embodiment of the invention. The material may be selected from materials that are able to be stamped, such as but not limited to metals and plastics, generally strips/rolls of sheet metal. The illustrated strip of material 1040 includes a full view of intended stamping lines 1010 and 1050 within the strip of stampable material 1000 including those for adjacent pin caps 1020 and 1030 to be stamped therefrom. Stamping, cutting may occur along any of the dotted and/or continuous lines within the strip to thereby form the final product. The illustrated continuous lines within the strip of stampable material may be the final stamp to cut the product out of the strip so that it is ready for finishing.

(43) FIG. 11 is a perspective view of a pin cap according to one embodiment of the invention. There is shown a cap frame/mount having a rectangular cross section. The pin cap may be a stamped pin cap.

(44) FIG. 12 is a perspective view of a pin cap according to one embodiment of the invention. There is shown a cap frame/mount having a triangular cross section. The pin cap may be a stamped pin cap.

(45) FIG. 13 is a perspective view of a pin cap according to one embodiment of the invention. There is shown a cap frame/mount having a zig-zag shape. The pin cap may be a stamped pin cap.

(46) FIG. 14 is a perspective view of a pin cap according to one embodiment of the invention. There is shown a cap frame/mount having a circular cross section. The pin cap may be a stamped pin cap.

(47) FIG. 15 is a perspective view of a partially manufactured pin cap according to one embodiment of the invention. The pin cap has yet to be folded over to form the final pin cap shape wherein there is a mount having a circular cross-section bounded by a simple, straight frame. The material folds over onto itself at fold lines that are between the paired apertures, thereby also forming the cradle. The pin cap may be a stamped pin cap.

(48) It is understood that the above-described embodiments are only illustrative of the application of the principles of the present invention. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiment is to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

(49) Thus, while the present invention has been fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made, without departing from the principles and concepts of the invention as set forth in the claims. Further, it is contemplated that an embodiment may be limited to consist of or to consist essentially of one or more of the features, functions, structures, methods described herein.