WO2015171175A1 - Keyway mold and method of constructing interlocking concrete slabs - Google Patents

Abstract

A key way mold (1) and method of use for constructing interlocking concrete slabs (2) in roadways, driveways, sidewalks and so forth. The key way mold is a planar panel (3) having a concave indentation (10) proximate to a central section (11). The key way mold simultaneously forms a mortise b on a first section of concrete slab and a tenon (13) on a second section of concrete as the sections are constructed using a continuous pour of concrete.

Description

TITLE OF THE INVENTION:

KEYWAY MOLD AND METHOD OF CONSTRUCTING INTERLOCKING CONCRETE

SLABS

Patent Application of

Christopher J. Collins and Dean Giardini

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part of International Application No, PCT/US 2014/037036, filed on May 6, 2014, which is a continuation of U.S. Application No.

13/787,487, filed on March 6, 2013, which is currently pending.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable,

MICROFICHE APPENDIX

No t Applicable member DESCRIPTION

Title of the Invention: Keyway Mold and Method of Constructing Interlocking Concrete Slabs

1. Technical Field.

This invention relates to the construction of retaining, gravity, barriers walls and junction slabs from concrete such as on bridges and sidewalks, and more particularly, a keyway mold and method of use in pouring roadway junction slabs in a continuous manner while simultaneously forming keyways between the sections of the slab, thereby preventing the need to form such slabs individually in alternating fashion.

2. Background Art.

A keyway is found in a wall made of concrete, such as a retaining wall or gravity wall and in junction slabs where there is at least two separately poured concrete sections on which the ends abut each other. The keyway acts like a mortise and tenon, thereby interlocking the ends of the concrete sections together and creating a stronger connection than simply abu tting the two pours end to end using a but joint with nothing to connection sections.

However, forming concrete junction slabs and creating keyways in the widely used conventional manner in sections of a concrete wall or junction slabs can be time consuming and costly as each poured section of concrete must be poured and dried in separate alternating sections and cannot be created using a continuous pour. First, a concave keyway is formed in the center of an end of the first section poured. This is accompl ished using a wooden form, such as a 2x4 placed in the form at one end of the section, that must be chipped out and removed from the concrete after the concrete has dried. After the first section has dried a second section may then be poured abutting the first section with the concave portion of the keyway in the first section acting as a form to create the tenon portion of the keyway on the second section that inserts into the first section. A bond breaker, such as felt paper is placed over the end of the first section prior to pouring the second section to ensure the concrete of the second section does not cure to the first section, thereby allowing the sections may be removed from each other. This is a very time consuming process due to the fact that the sections must be poured and cured separately in alternating sections. For example, a first section is poured, then the second section must be measured and skipped, then the third section is poured and so on. After the first section is cured, the 2x4 piece of wood is removed from the first section and then the second section is poured to connect the first and third sections.

Therefore, a need exists for a keyway mold and method of using the keyway mold that allows individuals to pour multiple sections of concrete at one time while still creating keyway molds between each section of the concrete to interconnection the sections of concrete for strength and support.

The relevant prior art includes the following references: Patent No. Inventor Issue/Publication Date

(U.S. Patent References)

873,739 Edmondson 12-17-1907

5,551,204 Mayrand 09-03-1996

4,059,362 Smith 11-22-1977

D431,082 Jaros 09-19-2000

5,975,793 Simmons, Jr. et al 11-02-1999

4,954,009 Kellison 09-04-1990

6,526,721 Nash 03-04-2001 SUMMARY OF INVENTION

The primary object of the present invention is to provide a keyway mold and method of using the keyway mold that allows individuals to pour multiple sections of concrete at one time while still creating keyway molds between each section of concrete.

An additional objection of the present invention is to provide a keyway mold and method of using the keyway mold to construct multiple junction slabs using one continuous pour of concrete.

The present invention fulfills the above and other objects by providing a keyway mold that allows a concrete slab having multiple sections to be poured continuously without having to wait for individual sections to dry prior to pouring additional intermediary sections. The present invention is a planar panel with a mortise located thereon that forms a mortise on an end of the first section of concrete slab and a tenon on an opposing second section of concrete slab. The planar panel has edges that are substantially shaped in the desired shape of the concrete slab to be poured and the keyway mold is placed between the outer walls that form a mold to form the outer surfaces and shape of that concrete slab sections being constructed. Using the keyway mold and method of use, two interlocking sections may then be poured at one time with the concave section of the first slab section being formed simultaneously with the tenon portion located on the second slab. The keyway mold may then be left between the slabs after the concrete is cured and the outer walls of the form may be removed to reveal the c ured outer surfaces of the concrete slabs.

This method results in significant time and labor savings as a road or other concrete surface may be poured continuously as opposed to moving back and forth to pour the concrete the separate sections. The concrete slabs illustrated herein have shapes of typical interlocking slabs or junction slabs, however the keyway moid of the present invention may be used to create a concrete surface having multiple interlocking sections of any shape.

The above and other objects, features and advantages of the present invention should become even more readily apparent to those skilled in the art upon a reading of the follo wing detailed description in conjunction with the drawings wherein there is shown and described illustrative embodiments of the invention. BRIEF DESCRIPTION OF DRAWINGS

In the following detailed description, reference will be made to the attached drawings in which:

FIG. 1 is a cross section view of a keyway mold of the present invention in use for connecting concrete slabs in a road:

FIG. 2 is an exploded view of keyway mold of the present invention being used to form interlocking concrete slabs;

FIG. 3 is a front perspective view of a keyway mold of the present invention used for connecting junction slabs; and

FIG. 4 is a front perspective view of a keyway mold of the present invention having sleeves located thereon used for interlocking concrete slabs in a roadway.

For purposes of describing the preferred embodiment, the terminology used in reference to the numbered accessories in the drawings is as follows:

DESCRIPTION OF EMBODIMENTS

With reference to FIG. 1, a front perspective view of a keyway mold 1 of the present invention used for connection slabs is illustrated. The keyway mold 1 is substantially rectangular shaped and comprises a planar panel 3 having a front surface 4, rear surface 5, lower edge 6, upper edge 7, right side edge 8 and left side edge 9. A concave indentation 10 is located proximate to a central section 1 1 of the planar panel 3. As illustrated here, the concave indentation 10 is substantially rectangular shaped, however, the concave indentation may be any other shape that protrudes outward into two abutting junction slabs. When concrete is poured on both sides of the keyway mold 1 , a mortise and tenon are created on opposing sides of the keyway moid to create interlocking sections of the junction slabs.

With reference to FIG. 2, an exploded view of keyway moid 1 of the present invention being used to form interlocking concrete slabs 2 is illustrated. The keyway mold 1 is placed between and perpendicular to outer form Avails 16 that form a mold to form outer surfaces 16 of the interlocking sections of concrete slabs 2. The keyway mold 1 is held in place by chamfers 22 or other means. After the outer form Avails 16 are removed from the cured concrete slabs 2 the keyway mold 1 is left between the cured concrete slabs 2. The keyway moid 1 of the present invention may be used to form interlocking concrete slabs in a roadway, driveway, sidewalk, buildings or any other concrete surfaces. With reference to FIG, 3 a front perspective view of a keyway mold I of the present invention having sleeves 19 located thereon used for connecting junction slabs is illustrated. The one or more sleeves 19 extend preferably from the front surface 4 or rear surface 5 and act to provide a holding means for a dowel 20 or reinforcing bar to provide additional structural support to the concrete slabs. The sleeves 19 are also preferably closed on a distal end 21 to prevent concrete from entering the sleeves 19 on both sides, thereby making it easier to separate two sections of slab if needed in the future. The sleeves 19 may be in combination with the concave indentation 10 or independent of the conca ve indentation 10.

With reference to FIG. 4, a side perspective plan view of a keyway mold 1 of the present invention in use for interlocking concrete slabs 2 in a roadway 17 is illustrated. The keyway mold 1 forms a mortise 12 and tenon 13 between two slabs 2 of poured concrete. Because the keyvvay mold 1 is left between the slabs 2, the slabs may be poured at the same time with the mortise 12 and tenon 13 being between the two slabs 2 simultaneously. One or more sleeves 19 extend preferably from the front surface 4 or the rear surface 5 and act to provide a holding means for a dowel 20 or reinforcing bar to provide additional structural support to the roadway 17. A concrete wall 15 is located on the outer edge of the roadway. Asphalt 14 may be poured on top of the concrete slabs 2 after the concrete slabs 2 are dried. The keyway mold 1 provides an expansion joint and interlocks the concrete slabs 2 to prevent lateral and vertical movement that could cause cracks in the driving surface or concrete wall 15.

It is to be understood that while a preferred embodiment of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without depaxtmg from the scope of the in vention and the invention is not to be considered limited to what is shown and described in the specification and drawings.

Claims

CLAIMS Having described my invention, I claim:

Claim 1. A keyway mold for forming interlocking sections of concrete slabs

comprising:

a planar panel having a front surface, a rear surface, a lower edge, an upper edge, a right side edge and left side edge;

at least one concave indentation located proximal to central section of the planar panel; and

the at last one concave indentation is substantially rectangular shaped and is parallel to the lower edge of the planar panel.

Claim 2. The keyway mold of claim 1 further comprising:

at least two outer form w alls that form outer surfaces of the interlocking sections of concrete slabs to hold the keyway mold in place between at least two interlocking sections of concrete slabs.

Claim 3. The keyway mold of claim 2 further comprising:

the keyway mold is connected to the outer form walls via chamfers located on the outer form walls.

Claim 4. The keyway mold of claim 1 further comprising:

at least one sleeve extending from the keyway mold.

Claim 5. A keyway mold for forming interlocking sections of concrete slabs comprising:

a planar panel having a front surface, a rear surface, a lower edge, an upper edge, a right side edge and left side edge;

at least one conca ve indentation located proximal to a central section of the planar panel;

at least two outer form walls that form outer surfaces of the interlocking sections of concrete slabs to hold the keyway mold in place between at least two interlocking sections of concrete slabs; the at last one concave indentation is substantially rectangular shaped and is parallel to the lower edge of the planar panel; and

at least one sleeve extending from the keyway mold

Claim 6. The keyway mold of claim 5 further comprising:

the keyway mold is connected to the outer form walls via chamfers.

Claim 7. A method of pouring interlocking concrete slabs using at least one keyway mold having a planar panel having a front surface, a rear surface, a lower edge, an upper edge, a right side edge, a left side edge, at least one concave indentation located proximal to a central section of the planar panel, the at last one concave indentation is substantially rectangular shaped and is parallel to the lower edge of the planar panel, said method comprising the steps of:

a. securing the keyway mold between the area where at least two slabs are to be connected between at least two form walls;

b. pouring concrete between the at least two form walls;

c. allowing the concrete to cure;

d. removing the at least two form walls from the at least two slabs;

e. leaving the keyway mold between the at least two slabs.

Claim 8. The method of claim 7 wherein:

at least one sleeve extending from the keyway mold.

Claim 9. The method of claim 7 further comprising a step before b. of:

placing a dowel in the at least one sleeve extending from the keyway mold.