Panel-forming component and system for use in tilt-up construction

Abstract

The present invention relates to a novel configuration for a panel-forming component for use in tilt-up construction. The present invention further relates to a panel-forming device comprising the panel-forming component of the present invention. A panel-forming component of the present invention is configured as a comer guard that protects a comer of cured casting material from damage during the tilt-up construction process. The panel-forming component of the present invention generally is configured such that it is free of void-enabling obstructions that may hinder a flow of casting material within a panel form. The absence of void-enabling obstructions ensures that the casting material flows about the panel-forming component and cures substantially free of voids.

1 . A device comprising a panel-forming component comprising a slab engaging face, a form engaging face, and an anchoring portion, wherein: 
 said panel-forming component defines a cross sectional profile defining said slab engaging face, said form engaging face, and said anchoring portion;    said panel-forming component is configured such that, where said slab engaging face is oriented horizontally and said form engaging face is oriented vertically in a panel form, said cross sectional profile comprises a casting material engaging surface; and    said casting material engaging surface is configured such that a flow of a casting material within said panel form is directed along substantially all of said casting material engaging surface as a level of said casting material rises within said panel form.    
   
   
       2 . The device of  claim 1 , wherein: 
 said casting material engaging surface comprises an inboard portion and an outboard portion; and    said inboard portion of said casting material engaging surface defines a substantially continuous, upwardly directed face.    
   
   
       3 . The device of  claim 1 , wherein: 
 said anchoring portion is configured to define a transition from an inboard side of said panel-forming component to an outboard side of said panel-forming component; and    said anchoring portion comprises at least one casting material flow-through opening extending through said inboard side of said anchoring portion to said outboard side of said anchoring portion.    
   
   
       4 . The device of  claim 1 , wherein at least a portion of said casting material engaging surface defines a curved cross-sectional profile.  
   
   
       5 . The device of  claim 4 , wherein said curved cross-sectional profile of said casting material engaging surface is configured to encourage the flow of said casting material within said panel form while substantially precluding void creation.  
   
   
       6 . The device of  claim 1 , wherein said anchoring portion comprises an anchoring extension and an anchoring protrusion.  
   
   
       7 . The device of  claim 6 , wherein at least a portion of said anchoring protrusion defines a curved cross-sectional profile.  
   
   
       8 . The device of  claim 6 , wherein said anchoring protrusion is configured to encourage the flow of said casting material about said anchoring portion while substantially precluding void creation.  
   
   
       9 . The device of  claim 6 , wherein said anchoring protrusion is configured such that a cross-sectional width of said anchoring protrusion is substantially larger than a cross-sectional width of said anchoring extension.  
   
   
       10 . The device of  claim 9 , wherein said cross-sectional width of said anchoring protrusion is about fifty percent larger than said cross-sectional width of said anchoring extension.  
   
   
       11 . The device of  claim 9 , wherein said cross-sectional width of said anchoring protrusion is about two times as large as said cross-sectional width of said anchoring extension.  
   
   
       12 . The device of  claim 1 , wherein: 
 said panel-forming component further comprises at least one sealing edge; and    said sealing edge defines a cross section that is tapered relative to a remainder of said cross-sectional profile of said panel-forming component.    
   
   
       13 . The device of  claim 12 , wherein said tapered sealing edge defines a slope of less than 45 degrees relative to said slab engaging face.  
   
   
       14 . The device of  claim 12 , wherein said tapered sealing edge defines a slope of less than 45 degrees relative to said form engaging face.  
   
   
       15 . The device of  claim 12 , wherein: 
 said sealing edge is configured of PVC; and    said PVC is comprised of a material softer than that comprising said panel-forming component.    
   
   
       16 . The device of  claim 1 , wherein said panel-forming component is configured such that it is substantially free of void-enabling obstructions to the flow of said casting material within said panel form.  
   
   
       17 . The device of  claim 1 , wherein: 
 said device further comprises a plurality of panel-forming bulkheads in addition to said panel-forming component; and    said panel-forming bulkheads and said panel-forming component are configured in said panel form to define dimensions of a panel-shaped cavity such that a sufficient amount of said casting material is contained within said panel-shaped cavity to define a panel having peripheral dimensions matching the dimensions of said panel-shaped cavity.    
   
   
       18 . The device of  claim 1 , wherein: 
 said device further comprises a panel of cured casting material in addition to said panel-forming component; and    said anchoring portion of said panel-forming component is configured such that said anchoring portion is embedded within said panel of cured casting material.    
   
   
       19 . A panel-forming component comprising a slab engaging face, a form engaging face, and an anchoring portion, wherein: 
 said panel-forming component defines an extrudable cross-sectional profile defining said slab engaging face, said form engaging face, and said anchoring portion; and    said panel-forming component is configured such that it is substantially free of void-enabling obstructions to a flow of casting material within a panel form where said slab engaging face is oriented horizontally and said form engaging face is oriented vertically in said panel form.    
   
   
       20 . A device comprising a panel-forming component comprising a slab engaging face, a form engaging face, and an anchoring portion, wherein: 
 said panel-forming component defines a cross-sectional profile defining said slab engaging face, said form engaging face, and said anchoring portion;    said panel-forming component is configured such that, where said slab engaging face is oriented horizontally and said form engaging face is oriented vertically in a panel form, said cross sectional profile comprises a casting material engaging surface defined at least in part by said anchoring portion; and    said anchoring portion that defines said casting material engaging surface is configured such that said anchoring portion is substantially free of void-enabling obstructions to a flow of casting material within said panel form.