Bar support and method of making a bar support

Abstract

A rebar support chair having a chair body including a plurality of conjoined legs, the conjoined legs defining a receiving area and a foot affixed to at least one leg.

What is claimed is: 
     
         1 . A rebar support chair comprising:
 a chair body comprising a plurality of conjoined legs, the conjoined legs defining a receiving area; and   
       a foot affixed to at least one leg. 
     
     
         2 . The rebar support chair of  claim 1  wherein at least one leg terminates in a leg pin and wherein a foot is affixed to the at least one leg pin, wherein the foot includes a receptacle configured to receive the leg pin. 
     
     
         3 . The rebar support chair of  claim 2  wherein a foot is affixed to each leg. 
     
     
         4 . The rebar support chair of  claim 3 , wherein each foot is affixed to each of the legs by means of friction fit, snap-fit, bayonet connection, adhesive, threads, or welding. 
     
     
         5 . The rebar support chair of  claim 4 , wherein the foot is manufactured separately from the leg. 
     
     
         6 . The rebar support chair of  claim 1 , wherein the foot includes one or more friction-increasing features. 
     
     
         7 . The rebar support chair of  claim 6 , wherein the rebar support features comprise ridges, bosses or spikes. 
     
     
         8 . The rebar support chair of  claim 1 , wherein each leg includes a tapered section and a vertical section. 
     
     
         9 . A mold for a rebar support chair comprising:
 a mold cavity, the mold cavity including:
 a receiving area portion and a plurality of leg portions, wherein the leg portions are in fluid communication with the receiving area portion, each of the leg portions having a tapered section portion and a vertical section portion; and 
 one or more pin receiving areas positioned within each vertical section portion; and 
   a mold core.   
     
     
         10 . The mold of  claim 9  further comprising a plurality of pins, each pin located within the pin receiving area of each of the leg portions. 
     
     
         11 . A method of forming a rebar support chair comprising:
 providing a mold for a rebar support chair comprising:
 a mold cavity, the mold cavity including:
 a receiving area portion and a plurality of leg portions, wherein the leg portions are in fluid communication with the receiving area portion, each of the leg portions having a tapered section portion and a vertical section portion; and 
 one or more pin receiving areas positioned within each vertical section portion; and 
 
 a mold core; 
   positioning a pin within the pin receiving area of each vertical section portion;   clamping the mold cavity to the mold core; and   injecting melted raw plastic into the mold.   
     
     
         12 . The method of  claim 11  further comprising:
 allowing the melted raw plastic to cool to form the rebar support chair; 
 removing the rebar support chair from the mold, the rebar support chair having a plurality of legs; and 
 affixing feet to the legs of the rebar support chair. 
 
     
     
         13 . The method of  claim 12 , wherein the mold cavity comprises a plurality of pin receiving areas in each vertical section portion. 
     
     
         14 . The method of  claim 13  further comprising:
 repositioning the pin; and 
 injecting melted raw plastic into the mold. 
 
     
     
         15 . The method of  claim 12 , wherein the pin is positioned by inserting the pin through the vertical section portion until the pin receiving area is reached. 
     
     
         16 . The method of  claim 12 , wherein the pin is positioned by inserting the pin along the length of the pin receiving area.