US 6,668,502 B2Granted

Ledger mould for building a ledger

AssigneePolyform A.G.P. Inc.

InventorJean-Louis Béliveau

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Abstract

A ledger mould assembly is suitable for use with a wall form assembly of the type comprising a pair of spaced-apart parallel foam panels defining therebetween a cavity for the setting of a flowable material for building an insulated wall. The ledger mould is used to receive a hardening flowable material and integrally forming a ledger to the wall. The ledger mould assembly comprises an elongated mould made of foam having a planar front face spanning from top to bottom, a tapered bottom edge and at least one flared recess in the front face, opening outwardly and upwardly from bottom to top. Mounting means are provided for horizontally mounting the mould against either one of the foam panels with the bottom down and the planar front face of the ledger mould in contact with the planar outside face of the foam panel. This set-up allows flowable hardening material to be poured from the top of the mould into the flared recesses to form a ledger once it has hardened.

Claims18

Dependent claims

A ledger mould assembly for use with a wall form assembly, the wall form assembly comprising a pair of spaced-apart parallel foam panels defining therebetween a cavity for the setting of a flowable material for building an insulated wall, the ledger mould being for receiving a hardening flowable material and integrally forming a ledger to the wall, the mould assembly comprising:

an elongated mould made of foam and having:
a front, a back, a top and a bottom;
a planar front face spanning from top to bottom;
a tapered bottom edge;
a plurality of flared recesses in the front face, opening outwardly and upwardly from bottom to the top;
and
a transversal partition wall separating each two adjacent flared recesses, each partition wall having a top edge including an upwardly protruding portion;
mounting means for horizontally mounting said mould against a planar outside face of one of said foam panels with the bottom down and the planar front face of the ledger mould contacting said planar outside face of the foam panel and thereby allowing flowable material to be poured from the top of the mould into said flared recesses to form a ledger, the mounting means comprising:
a V-shaped bracket shaped to receive and support the tapered bottom edge of the mould;
a set of capping brackets each comprising:
a cap-shaped portion adapted to fit on the upwardly protruding portion of each partition wall;
and
a flange extending at right angle on a side of the cap-shaped portion;
and
a set of fasteners to secure the V-shaped and capping brackets to the planar outside face of the panel.

12 more elements

A ledger mould assembly for use with a wall form assembly, said wall form assembly comprising a pair of spaced-apart parallel foam panels defining therebetween a cavity for the setting of a flowable material for building an insulated wall, the ledger mould being for receiving a hardening flowable material and integrally forming a ledger to the wall, the mould assembly comprising:

an elongated mould made of foam and having:
a front, a back, a top and a bottom;
a planar front face spanning from top to bottom;
a tapered bottom edge;
and
at least one flared recess in the front face, opening outwardly and upwardly from bottom to the top;
and
mounting means for horizontally mounting said mould against a planar outside face of one of said foam panels with the bottom down and the planar front face of the ledger mould contacting said planar outside face of the foam panel and thereby allowing flowable material to be poured from the top of the mould into said at least one flared recess to form a ledger, wherein the mounting means comprise:
a V-shaped bracket shaped to receive and support the tapered bottom edge of the mould;
and
a fastener to secure the V-shaped bracket to the planar outside face of the panel.

8 more elements

A kit for building an insulated wall with a ledger, the kit comprising:

a pair of foam panels tied together by means of connectors, each panel having a top, a bottom, an inside face and a planar outside face;
the foam panels being settable in a spaced-apart relationship for forming a cavity between the inside face of each panel for receiving a flowable material;
an elongated ledger mould made of foam for forming a ledger to the wall, the ledger mould having:
a front, a back, a top and a bottom;
a planar front face spanning from top to bottom;
a tapered bottom edge;
and
at least one flared recess in the front face, opening outwardly and upwardly from bottom to the top;
and
mounting means for horizontally mounting said mould against said planar outside face of either one of said foam panels with the bottom down and the planar front face contacting said planar outside face of the panel and thereby allowing flowable material to be poured from the top of the ledger mould into said at least one flared recess to form a ledger, wherein each of said connectors comprises:
two opposite and elongated flange plates extending longitudinally and deep inside a respective one of said foam panels;
and
a link element interconnecting the flange plates.

10 more elements

Dependencies are inferred from the claim text.