Foam-concrete rebar tie

Abstract

A fastener is disclosed having a an extension portion configured to be inserted into a first construction material such as foam, and having a stirrup portion configured to retain portion of a second construction material, such as rebar at a distance from the first construction material. A third construction material such as concrete can then be inserted (poured) in contact with the first construction material and surrounding the second construction material such that the second construction material is not directly in contact with the first construction material.

1 . A rebar-holding member configured to be positioned in a foam material having an outer surface, the rebar-holding member comprising:
 a) an extension portion having a longitudinal axis, the extension portion having at least one spiral protrusion extended radially outward from the longitudinal axis;   b) a support portion fixed to the extension portion, the support portion having a base surface located in a forward longitudinal direction;   c) a stirrup portion having a rebar-holding region, the rebar-holding region comprising first and second arms comprising an interior surface configured to hold a rebar member therein at a prescribed distance from the base surface;   d) wherein the first and second arms comprise a gap therebetween smaller than the diameter of the rebar to be held therein so as to form a snap-in connection with the rebar;   e) whereas the support portion comprises a base surface configured to be placed adjacent to the foam material.   
     
     
         2 . The rebar-holding member as recited in  claim 1  where the spiral protrusion is tapers along its entire length from a longitudinally rearward portion of the spiral protrusion which extends radially further outward than a longitudinally forward portion of the spiral protrusion to the longitudinally forward portion. 
     
     
         3 . The rebar-holding member as recited in  claim 1  where the interior surface of the rebar-holding region has a plurality of radially inward extensions having a width sufficiently narrow so the extensions undergo plastic deformation when the rebar is placed between the first and second arms of the rebar-holding region. 
     
     
         4 . The rebar-holding member as recited in  claim 3  where the width of the radially inward extensions are less than one half the width of the first and second arms. 
     
     
         5 . The rebar-holding member as recited in  claim 1  where the first and second arms each provide an inward slanting surface defining a central open region configured to have a portion of rebar pass therethrough. 
     
     
         6 . The rebar-holding member as recited in  claim 5  where the rebar is operatively configured to be held within the interior surface of the rebar-holding region when the rebar-holding region is positioned beneath the extension portion. 
     
     
         7 . The rebar-holding member as recited in  claim 1  further comprising at least one void in the support portion configured to receive a flexible fastener which is configured to further retain the rebar within the rebar-holding region. 
     
     
         8 . The rebar-holding member as recited in  claim 1  where the extension portion, base portion, and stirrup portion are formed as a unitary structure. 
     
     
         9 . The rebar-holding member as recited in  claim 8  where the unitary structure is substantially formed as a polymer. 
     
     
         10 . The rebar-holding member as recited in  claim 1  further comprising a non-circular sub-base portion operably configured to fit a rotatably driven insertion tool. 
     
     
         11 . The rebar-holding member as recited in  claim 10  wherein the insertion tool comprises a standard or metric drive socket. 
     
     
         12 . A device comprising:
 a) an extension portion operatively configured to be inserted into a portion of resilient material wherein the extension portion further comprises;   b) at least one spiral protrusion;   c) a base portion having a first side and a second side, the first side fixedly coupled to the extension portion;   d) a stirrup portion coupled to the second side of the base portion, the stirrup portion operatively configured to hold a portion of construction material;   e) the stirrup portion comprised of a plurality of resilient arms;   f) wherein the plurality of arms comprise a gap therebetween smaller than the diameter of the rebar to be held therein so as to form a snap-in connection with the rebar.   
     
     
         13 . The device of  claim 12  wherein the extension portion, base portion, and stirrup portion are formed as a unitary structure. 
     
     
         14 . The device of  claim 13  wherein the unitary structure is formed of a polymer. 
     
     
         15 . The device of  claim 12  wherein the resilient material is substantially a foam material. 
     
     
         16 . The device of  claim 12  wherein the portion of construction material is a length of rebar. 
     
     
         17 . The device of  claim 12  wherein the portion of construction material is a portion of wire mesh. 
     
     
         18 . The device of  claim 12  wherein the portion of construction material is a length of tubing. 
     
     
         19 . A rebar holding member configured to be rotatably inserted in a foam material having an outer surface, the rebar holding member comprising:
 a) an extension portion having a longitudinal axis;   b) at least one barb member extending from extension portion in a spiral configuration;   c) wherein the barb member forms a spiral in a longitudinal, and a radially outward direction;   d) a base portion extending radially outward beyond the extension portion and the radially outermost portion of the barb member portion;   e) the base portion having a base surface located in a forward longitudinal direction;   f) a stirrup portion having a base region and a rebar holding region, the rebar holding region comprising first and second arms comprising an interior surface configured to hold a rebar member therein;   g) wherein the longitudinal axis of the extension portion passes through the interior surface of the rebar holding region;   h) whereas the base region maintains a minimum prescribed distance from the base surface which is configured to be placed adjacent to the foam material;   i) the rebar holding member configured to be placed at any desired position, and rotational orientation relative to the surface of the foam material.   
     
     
         20 . The rebar-holding member as recited in  claim 19  further comprising a non-circular sub-base portion operably configured to be engaged by a rotatably driven insertion tool.