Panel forming system and components

Abstract

A pre-cast panel forming system. The system includes one or more bulkheads to constrain the flow of uncured panel-forming material. The bulkhead is made up of an upstanding form and a base clip to secure the upstanding form to a panel-forming surface. The base clip is configured to promote ease of attachment to the panel-forming surface, even though the thickness dimension of the upstanding form is reduced relative to conventional forms. In accordance with 37 CFR 1.72(b), the purpose of this abstract is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract will not be used for interpreting the scope of the claims.

1 . A bulkhead for forming a pre-cast panel, said bulkhead comprising: 
 an upstanding form configured to at least partially constrain the flow of uncured casting material introduced adjacent said upstanding form; and    a base clip comprising: 
 a first attachment portion configured to secure said upstanding form to said base clip; and  
 a second attachment portion configured to secure said base clip to said panel-forming surface, said second attachment portion comprising an arm disposed laterally of a connection between said first attachment portion and said upstanding form such that said second attachment portion increases a base clip footprint formed on said panel-forming surface relative to that formed by said connection between said first attachment portion and said upstanding form.  
   
   
   
       2 . A bulkhead according to  claim 1 , wherein said upstanding form defines a monolithic structure.  
   
   
       3 . A bulkhead according to  claim 1 , wherein said second attachment portion is substantially planar.  
   
   
       4 . A bulkhead according to  claim 3 , wherein said second attachment portion is configured to engage said panel-forming surface.  
   
   
       5 . A bulkhead according to  claim 3 , wherein said second attachment portion defines an aperture in said laterally-disposed arm to accept a fastener therethrough.  
   
   
       6 . A bulkhead according to  claim 1 , wherein said first attachment portion comprises at least one projection configured to engage a complementary projection on said upstanding form.  
   
   
       7 . A bulkhead according to  claim 5 , wherein said first attachment portion is engaged with said upstanding form through a frictional fit therebetween.  
   
   
       8 . A bulkhead according to  claim 5 , wherein said projections engage one another through a plurality of interlocking prismatic members.  
   
   
       9 . A bulkhead according to  claim 5 , wherein an angle subtended between said second attachment portion and said at least one projection of said first attachment portion is substantially ninety degrees.  
   
   
       10 . A bulkhead according to  claim 1 , wherein said upstanding form comprises a pair of substantially planar walls disposed substantially parallel to one another to define a thickness dimension thereacross.  
   
   
       11 . A bulkhead according to  claim 10 , wherein said thickness dimension is less than that of the smaller dimension of a conventional two-by-four piece of lumber.  
   
   
       12 . A bulkhead according to  claim 11 , wherein said thickness dimension is less than about one and one-half inches.  
   
   
       13 . A bulkhead according to  claim 11 , wherein said thickness dimension is less than about one inch.  
   
   
       14 . A bulkhead according to  claim 11 , wherein said thickness dimension is about one-half inch.  
   
   
       15 . A bulkhead according to  claim 1 , wherein said upstanding form further comprises at least one chamfer.  
   
   
       16 . A bulkhead according to  claim 15 , wherein said chamfer comprises a sealing projection configured for substantially discrete engagement with said panel-forming surface.  
   
   
       17 . A bulkhead according to  claim 15 , wherein said at least one chamfer comprises a pair of chamfers.  
   
   
       18 . A bulkhead according to  claim 17 , wherein at least one of said pair of chamfers form a projection that, upon securing said base clip to said upstanding form, engages said first attachment portion.  
   
   
       19 . A bulkhead according to  claim 17 , wherein one chamfer is positioned on one side of said upstanding form while the other chamfer is positioned on another side of said upstanding form.  
   
   
       20 . A bulkhead according to  claim 1 , wherein said base clip comprises at least one chamfer.  
   
   
       21 . A bulkhead according to  claim 20 , wherein said chamfer is integrally formed with said base clip.  
   
   
       22 . A bulkhead according to  claim 1 , wherein said material making up said bulkhead is extrudable.  
   
   
       23 . A bulkhead according to  claim 22 , wherein said extrudable material comprises a plastic.  
   
   
       24 . A bulkhead according to  claim 1 , wherein said upstanding form is fabricated from the group consisting of plastic, metal, fibrous composites, or combinations thereof.  
   
   
       25 . A bulkhead according to  claim 1 , wherein said base clip is fabricated from the group consisting of plastic, metal, fibrous composites, or combinations thereof.  
   
   
       26 . A bulkhead according to  claim 1 , wherein said bulkhead comprises an extruded member.  
   
   
       27 . A bulkhead according to  claim 26 , wherein said bulkhead comprises an extruded plastic member.  
   
   
       28 . A bulkhead comprising: 
 an upstanding form configured to be secured to a panel-forming surface to at least partially constrain the flow of uncured casting material introduced adjacent said upstanding form; and    a base clip comprising: 
 a first attachment portion configured to engage said upstanding portion; and  
 a second attachment portion configured to engage said panel-forming surface and comprising a proximal end and a distal end, wherein said first attachment portion is located at said proximal end of said second attachment portion and extends away from an attachment plane defined by said second attachment portion, and said distal end of said second attachment portion is substantially free of structure extending away from said attachment plane.  
   
   
   
       29 . A bulkhead according to  claim 28 , wherein said second attachment portion defines a substantially planar profile from said proximal end to said distal end.  
   
   
       30 . A bulkhead according to  claim 28 , wherein said second attachment portion defines a substantially planar base clip anchoring zone between said proximal end and said distal end of said second attachment portion.  
   
   
       31 . A bulkhead according to  claim 28 , wherein said base clip is configured such that substantially all structure extending away from said attachment plane is defined by said first attachment portion.  
   
   
       32 . A bulkhead according to  claim 31 , wherein substantially all of said first attachment portion extends from said proximal end of said second attachment portion.  
   
   
       33 . A panel forming system comprising: 
 a plurality of bulkheads, each of said bulkheads comprising: 
 an upstanding form configured to at least partially constrain the flow of uncured casting material introduced adjacent said upstanding form; and  
 a base clip comprising: 
 a first attachment portion configured to secure said upstanding form to said base clip; and  
 a second attachment portion configured to secure said base clip to said panel-forming surface, said second attachment portion comprising an arm disposed laterally of a connection between said first attachment portion and said upstanding form such that said second attachment portion increases a base clip footprint formed on said panel-forming surface relative to that formed by said connection between said first attachment portion and said upstanding form; and  
 
   a plurality of connectors, each of which are configured to be disposed between adjacent end portions of respective bulkhead members.    
   
   
       34 . A panel forming system according to  claim 33 , wherein said plurality of connectors comprises at least one of a corner connector, in-line joint connector and a T-joint connector.  
   
   
       35 . A panel forming system according to  claim 33 , wherein said connectors and said bulkheads are arranged to define a substantially rectangular panel form.  
   
   
       36 . A panel forming system according to  claim 35 , wherein said substantially rectangular panel form comprises at least four bulkheads and at least four corner connectors.  
   
   
       37 . A panel forming system according to  claim 35 , wherein said pair of substantially rectangular panel forms further comprises a plurality of in-line joint connectors.  
   
   
       38 . A bulkhead comprising: 
 an upstanding form configured to at least partially constrain the flow of uncured casting material introduced adjacent said upstanding form; and    a base clip configured to couple said upstanding form to said panel-forming surface, said base clip comprising: 
 an upper anchoring member;  
 a lower anchoring member substantially aligned with said upper anchoring member at least partially along a fastening axis such that both said members accept a fastener therethrough along said fastening axis; and  
 a pedestal configured to displace said upper anchoring member from said lower anchoring member along said fastening axis, at least one of said pedestal and said form comprising a plurality of projections extending from a surface thereof, further the other of said pedestal and said form comprising a plurality of recesses formed therein that are substantially complementary with said plurality of projections such that upon engagement of said form and said pedestal, a locking arrangement is formed by said plurality of projections and said plurality of recesses.