WALL OPENING FORM

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates generally to forming openings and in particular to providing a frame, frame members and framing kits for forming openings in insulating concrete form construction.

2. Description of Related Art

In the construction industry, a method known as insulating concrete form construction is well known. Insulating concrete form construction utilizes walls having a central cast in place concrete layer bounded by a pair of insulating forms. In insulating form construction, the insulating forms are typically comprised of forming panels which are positioned as a pair of spaced apart walls so as to form a wall cavity therebetween. The wall cavity may then be filled with concrete to form the completed wall. In this type of construction the forming panels may be left in place to provide additional insulating qualities to the wall.

As is common with most forms of construction, it is frequently necessary to construct walls with openings for windows and doors for example. In insulating concrete construction, such openings are typically formed in the form blocks prior to filling the cavity with concrete. To form such an opening, the pair of opposed forms may have openings cut or formed into them corresponding to the desired opening. The cavity between the opposed forms may then be bridged about the perimeter of the opening by a framing member or buck.

Traditionally, bucks were constructed of dimensioned lumber cut to an appropriate size to substantially bridge the wall cavity between the two wall forms. The buck may then be screwed to the wall forms to secure it in place. A buck constructed from dimensioned lumber requires a significant amount of work to position within a wall cavity to form an opening therethrough. The

size of the lumber must firstly be cut to the appropriate dimensions and nailed or screwed together to form the buck. Secondly, the assembled buck must be screwed to the forms within the opening to secure it in place. Also, as a traditional dimensioned lumber buck has only flat smooth sides oriented towards the concrete, there is no positive engagement of the window or door buck with the concrete. This results in the opening not being as secure as is possible were the lumber to include a surface that positively engages the concrete. In addition, dimensioned lumber may be prone to rotting and water damage should water permeate the wall thereby damaging the structure to which the window or door is secured.

Natural fiber-plastic composite material is a well-known material comprising a composition of natural fibers set in a plastic matrix. The natural fibers may be provided as wood chips, sawdust or rice husks. The plastic matrix may comprise polyethylene, polyvinyl chloride, polypropylene, or any other suitable plastic material. Natural fiber-plastic composite material is often used as a decking material as it is able to be nailed or screwed in place and is also water and rot resistant. Natural fiber-plastic composite material is typically extruded into shapes resembling the cross-sections of traditional dimensioned lumber. The use of natural fiber-plastic composite material having such cross-sections, however, would not address some of the aforementioned difficulties with dimensioned lumber, namely, lack of positive engagement with the concrete.

In U.S. Patent No. 6,070,375 to Anderson et al., a frame for a wall opening is disclosed. The frame of Anderson et al. may be constructed of a plurality of extruded box sections, which may be cut to length and assembled into a buck by inserting a corner insert into adjacent boxes of the members. The frame members of Anderson et al. consist of extruded vinyl. Windows and doors are not as easily securable to the frame of Anderson et al. due to the material properties of the vinyl used in this construction. In addition, the relatively thin cross-section partitions of the frame of Anderson et al. provide a relatively small surface for a nail, screw or other fastener to engage with.

Also, the use of a plastic-only extrusion in the frame of Anderson et al. results in a weaker structure than is possible by using a composite material of wood and plastic, for example. The frame of Anderson et al. therefore requires extensive internal bracing when forming the wall so as to prevent deflection of the frame members of Anderson et al. However, it would be difficult to form the frame members of Anderson et al. from a wood and plastic composite material due to the complexity and thinness of the shape of the frame members. It is known to be difficult to extrude wood and plastic composite materials through small die openings.

What is needed is an insulating concrete form window or door buck that is constructed of frame members that are water and rot resistant while maintaining the strength and fastening characteristics of wood bucks. It would also be desirable to have a buck that offers improved engagement of the buck with the concrete.

SUMMARY OF THE INVENTION

The present invention provides a window buck that is resistant to water and rot and provides a surface that is easily securable to using nails, screws or other suitable fasteners. In addition, the present invention has a shape that retains the strength characteristics of wooden bucks thereby reducing required bracing and engages the surrounding concrete.

According to a first embodiment of the present invention there is provided a frame member for forming an opening through an insulating concrete form wall having opposed first and second forms. The frame member comprises an elongate member dimensioned to extend between the opposed forms. The elongate member is composed of a natural fiber plastic composite material having an opening forming surface and a wall forming surface and a pair of longitudinal retention fins extending from the wall forming surface. Each of the retention fins has a distal lip portion wherein the lip portions

cooperate to form a hollow between the lip portions and the wall forming surface.

According to a further embodiment of the present invention there is provided a frame for forming an opening through an insulating concrete form wall having opposed first and second forms. The frame comprises at least three frame members each comprising an elongate member dimensioned to extend between the opposed forms. The elongate member are composed of a natural fiber plastic composite material and have an opening forming surface and a wall forming surface and a pair of longitudinal retention fins extending from the wall forming surface. Each of the retention fins have a distal lip portion wherein the lip portions cooperate to form a hollow between the lip portions and the wall forming surface. The frame further comprises at least two corner connectors for connecting said frame members. The corner connectors comprise a bracket insertable into the hollows.

According to a further embodiment of the present invention there is provided a frame kit for forming an opening through an insulating concrete form wall having opposed first and second forms. The frame kit comprises at least three frame members, each comprising an elongate member dimensioned to extend between the opposed forms. The elongate member are composed of a natural fiber plastic composite material having an opening forming surface and a wall forming surface and a pair of longitudinal retention fins extending from said wall forming surface. Each of the retention fins have a distal lip portion wherein the lip portions cooperate to form a hollow between the lip portions and the wall forming surface. The frame kit further comprises at least two corner connectors for connecting the frame members. The corner connectors comprising a bracket insertable into the hollow.

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate embodiments of the invention,

Figure 1 is a perspective view of a wall section having an opening formed by a window buck according to the present invention.

Figure 2 is a perspective view of the window buck of Figure 1.

Figure 3 is a cross-sectional view of a window buck frame member of Figure 2 taken along line 3-3.

Figure 4 is a cross-sectional view of a window buck frame member mounted on a pair of wall forms.

Figure 5 is a cross-sectional view of a window buck frame member mounted on a pair of wall forms according to an alternative embodiment of the present invention.

Figure 6 is a cross-sectional view of a window buck frame member mounted on a pair of wall forms according to an alternative embodiment of the present invention which includes a raised nailing strip.

Figure 7 is a perspective exploded view of one corner of the window buck of Figure 1.

DETAILED DESCRIPTION

Referring to Figure 1 , an insulating concrete form wall is shown generally at 2. The insulating concrete wall comprises a pair of opposed first and second wall forms 4 and 6, respectively constructed of forming panels 7 and ties 9 forming a wall cavity 8 therebetween. The insulating concrete wall may include an opening 10 bounded by a wall-opening frame 12 according to a first embodiment of the invention. A window or a door may then be located within the opening 10 and secured to the wall-opening frame 12.

As shown in Figure 2, the wall-opening frame 12 comprises a plurality of frame members 20 connected at adjacent ends to form a completed frame.

The frame members 20 may be arranged in a rectangle as shown in Figure 2 or in an inverted U-shape to form an opening for a door (not shown).

Now referring to Figure 3, a cross sectional view of a frame member 20 of Figure 2 is shown taken along the line 3-3. Each frame member 20 comprises a substantially elongate member as shown in Figures 1 and 2. The frame member as shown in Figure 2 has an opening forming surface 22 and a wall forming surface 24, and first and second longitudinal edges 26 and 28 respectively. The frame member also includes retention fins 30 and 32, respectively, extending from wall forming surface 24 for engaging the concrete as well as assisting in locating adjacent frame members relative to each other as will be further explained below. As shown in Figure 2, retention fins 30 and 32 extend normal to the wall forming surface 24, however, it will be appreciated that other orientations will also be useful as well. The first and second retention fins 30 and 32 are parallel to and spaced apart from each other and include lip portions 34 and 36 at distal ends 38 and 40 respectively, thereof. The lip portions 34 and 36 extend from said distal ends 38 and 40 normal to the first and second retention fins 30 and 32 and are oriented towards each other. The wall forming surface 24, first and second retention fins 30 and 32 and first and second lip portions 34 and 36 form a hollow 42 therebetween. The frame member 20 that is located at the bottom of a frame may also include relief openings 14 as shown in Figures 1 and 2 to provide for venting of any entrapped air beneath the wall-opening frame 12 when concrete is poured into the wall cavity 8.

The frame member as shown in Figure 3 may also include first and second edge flanges 44 and 46, respectively extending from said first and second longitudinal edges 26 and 28 normal to said frame member 20. At each edge of the frame member, the edge flange 44 or 46 and retention fins 30 or 32 form panel receptacles 48 and 50 for receiving the forming panels 7 as shown in Figure 4. As show in Figure 3, the frame member may be thicker adjacent to the hollow 42 than it is adjacent to the panel receptacles 48 and 50. It will be appreciated that the distance between the respective edge flange 44 or 46 and the retention fin 30 or 32 will be selected so as to securely receive the form panel. The first and second edge flanges 44 and 46 also provide an integral drip ledge around the periphery of an opening so as to prevent water

from leaking through the opening and between the concrete and the forming panels.

Turning now to Figure 5, a frame member 20 may be provided in which the spacing between one or both of the respective edge flanges 44 or 46 and the retention fin 30 or 32 is increased. This enables the placement of a plurality of form panels in the corresponding panel receptacle 48 or 50. As shown in Figure 5, panel receptacle 48 may be enlarged by increasing the distance between edge flange 44 and first retention fin 30 enabling the placement of a thicker form panel 11 therebetween. As shown in Figure 5, panel receptacle

50 is sized so as to receive a first thinner panel 7. It will be appreciated, however, that it is also possible to increase the distance between edge flange 46 and second retention fin 32 so as to enable the placement of a thicker form panel 11 therebetween as well. It will also be appreciated that panel receptacles 48 and 50 may be sized so as to allow for the placement of more than one panel or a different sized panel therein. By allowing the use of multiple width forming panels or multiple panels on each side of the wall, walls of different insulating or "R" values may be achieved. This is particularly useful in colder climates where better insulating walls increase the energy efficiency of the structure.

Now referring to Figure 6, the frame member 20 may also include a securing strip 54 extending from the opening forming surface 22. The securing strip comprises an elongate raised portion from the opening forming surface, which may include interior and exterior securing surfaces 56 and 58 and a top surface 59. The interior surface 56 faces towards the interior of the wall while the exterior surface 58 faces towards the exterior of the wall. A door or window frame (not shown) may be inserted into the wall-opening frame 12 into abutment with the securing strip 54 and secured thereto by means of nails, screws or other fasteners. It will be appreciated that a window or doorframe may be secured to either side of the securing strip, although the exterior surface will be most commonly used. As shown in Figure 6, the frame member 20 may also includes a tapered portion 68 between the

exterior surface 58 and the second edge 28 which advantageously assists with water drainage away from the wall opening or to the exterior of the building.

The securing strip 54 may be located such that the distance between the exterior surface 58 and the first edge 28 of the frame member 20 corresponds to the thickness of the window or door frame intended to be secured at that location. In addition, the height of the securing strip 54 will typically be chosen to adequately secure the window or doorframe while not hindering access thereto.

The frame members 20 are composed of a natural fiber-plastic composite material. In such a material, natural fibers are set into a matrix of a plastic material. The natrual fibers may be provided by wood chips, saw dust or other small wood elements. It will also be understood that although wood fibers are used in the above description, other natural fibers such as for example, rice husks, bamboo, straw, and peanut shells may also be used. The plastic matrix natural fiber-plastic composite material may be any suitable plastic material such as, for example, polyethylene, polypropylene or polyvinyl chloride.

Now referring to Figure 7, an exploded perspective view of two frame members 20 and a corner bracket 60 are shown according to a further embodiment of the present invention. The corner bracket 60 comprises first and second orthogonal members 62 and 64, respectively adapted to be received within the hollow 42 of two adjacent frame members 20. As shown in Figure 7, the first and second members may have a rectangular cross- section, however it will be appreciated that other cross-sections will be useful as well so as to correspond to the cross-section of the hollow 42 of the frame member 20. The corner bracket may also include external stiffening ribs 66, which are locatable between the lip portions 34 and 36 of the frame members. The corner bracket shown in Figure 7 includes two stiffening ribs 66, however it will be appreciated that other multiples of stiffening ribs will also be useful as

well. The corner bracket may also include pre-drilled securing holes 70 which may receive a nail, screw or other fastener therein for securing the corner bracket 60 to the frame members 20.

To form a frame for insertion into a wall opening, first and second members

62 and 64 of the corner bracket may be inserted into the hollows 42 of two adjacent frame members 20 and secured therein with a fastener. Once connected in this fashion, the two frame members 20 will form a corner. An additional frame member 20 and corner bracket 60 may be located at a distal end of one of the frame members so as to form a U-shaped frame. Such a U- shaped frame may be useful for forming an opening for a door. A further frame member and two additional corner brackets may be used to close the open end of the U-shaped frame so as to form a rectangular frame that is useful for forming an opening for a window. It will be appreciated that the lengths of the frame members used may be adjusted to the desired length so as to provide any desired opening size and shape. In addition to securing with corner bracket 60, the frame members may be secured to each other by nails, screws or other suitable fasteners.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.