WO2025194081A1

WO2025194081A1 - Dowel system

Info

Publication number: WO2025194081A1
Application number: PCT/US2025/020010
Authority: WO
Inventors: Bradley Danna; Marc Danna; Nicholas Danna; Charles Snooks, Sr.
Original assignee: Jd Russell Co
Current assignee: Jd Russell Co
Priority date: 2024-03-15
Filing date: 2025-03-14
Publication date: 2025-09-18
Anticipated expiration: 2026-09-15

Abstract

A dowel device may include a body that defines an internal cavity, and the cavity is configured to receive a load bearing member. A device may include a faceplate including a first lateral edge, a second lateral edge, a top edge, and a bottom edge defining a perimeter of the faceplate, as well as a first surface and a second surface opposite the first surface, a slot extending between the first and second surface, wherein the body is secured to the second surface of the faceplate such that the opening of the cavity of the body is aligned with the slot of the faceplate. A device may include a first spline connected to the first lateral edge, and a second spline connected to the second lateral edge.

Description

DOWEL SYSTEM

CROSS-REFERENCE TO RELATED APPLICATION 0001] This application claims priority to U.S. Provisional Application No. 63/565,688, filed March 15, 2024.

BACKGROUND

[0002] This disclosure generally relates to a system and a method for transferring loads between two sections of concrete. In construction, dowels, metal rods or plates are used to provide continuity and support between two sections of flooring or roadway.

[0003] Dowels are often used in expansion joints where slabs or sections of material are abutted, but need to move independently due to temperature variations in freeze/thaw cycles or due to other factors such as load transfer. The dowels allow for limited movement of the sections while still providing alignment and transference of loads between the sections. In road and highway construction, dowels are used in adjacent concrete slabs to align adjacent sections, distribute loads, and prevent substantial relative displacement between adjacent sections.

SUMMARY

[0004] This disclosure generally relates to a system and a method for transferring loads between two sections of concrete.

[0005] In some aspects, the techniques described herein relate to a dowel system for aligning two adjacent sections of concrete including: at least one device including: a body that defines an internal cavity, and the cavity is configured to receive a load bearing member; a faceplate including a first lateral edge, a second lateral edge, a top edge, and a bottom edge defining a perimeter of the faceplate, as well as a first surface and a second surface opposite the first surface, a slot extending between the first and second surface, wherein the body is secured to the second surface of the faceplate such that the opening of the cavity of the body is aligned with the slot of the faceplate; and a first spline connected to the first lateral edge, and a second spline connected to the second lateral edge. [0006] In some aspects, the techniques described herein relate to a dowel system, wherein the body has a triangular profile defined by a top surface, a bottom surface opposite to the top surface, and two lateral surfaces between the top and bottom faces.

[0007] In some aspects, the techniques described herein relate to a dowel system, the body including a plurality of gussets to provide additional support, wherein the plurality of gussets each have a first edge that is secured to the outer surface of the body and each of the plurality of gussets has a second edge that is secured to the second surface of the faceplate.

[0008] In some aspects, the techniques described herein relate to a dowel system, wherein a crossmember is secured to the body and the crossmember extends across the plurality of gussets.

[0009] In some aspects, the techniques described herein relate to a dowel system, wherein a gap separates the crossmember from each of the gussets.

[00010] In some aspects, the techniques described herein relate to a dowel system, wherein an outer surface of the body has a cylindrical profile.

[00011] In some aspects, the techniques described herein relate to a dowel system, wherein the dowel system is positioned between two adjacent sections of concrete such that the body is embedded within a first section of concrete and the faceplate protrudes from the first section of concrete so that the faceplate is flush with an edge of the first section and the faceplate abuts an edge of a second section.

[00012] In some aspects, the techniques described herein relate to a dowel system, wherein the body includes fins secured to the outer surface of the body and the fins protrude outward from the body and into the first section of the concrete to prevent the dowel system from pulling out of the first section of concrete.

[00013] In some aspects, the techniques described herein relate to a dowel system, wherein a bracing structure is secured to the body at a distal edge of the body and the bracing structure also contacts a ground surface at another end to provide support to the dowel system.

[00014] In some aspects, the techniques described herein relate to a dowel system for aligning two adjacent sections of concrete including; at least one device including a body that defines an internal cavity, and the cavity is configured to receive a load bearing member; a faceplate including a first lateral edge, a second lateral edge, a top edge, and a bottom edge defining a perimeter of the faceplate, as well as a first surface and a second surface opposite the first surface, a slot extending between the first and second surface, wherein the body is secured to the second surface of the faceplate such that the opening of the cavity of the body is aligned with the slot of the faceplate; a first spline connected to the first lateral edge at a first end of the spline, and a second spline connected to the second lateral edge at a first end of the second spline; and a bracing structure secured to the faceplate.

[00015] In some aspects, the techniques described herein relate to a dowel system, wherein the bracing structure includes an extendable arm and a flange, the flange connected at a first end to a top edge of the faceplate and including a slot at a second end, opposite to the first end, the slot configured to receive a first end of the extendable arm therethrough, the extendable aim including a hook portion at a second end, opposite the first end, the hook portion configured to engage a form.

[00016] In some aspects, the techniques described herein relate to a dowel system, wherein the extendable arm includes measurement markings and notches along its length, the notches configured to engage a portion of the flange near the slot, and the measurement markings correspond to a distance between the form and device.

[00017] In some aspects, the techniques described herein relate to a dowel system, wherein the bracing structure includes an arm member and an adjustable hook member, the arm member having a first end connected to a top edge of the faceplate and a second end opposite the first end, the adjustable hook member including a slot configured to receive the arm member at the second end, the hook member further configured to engage a form.

[00018] In some aspects, the techniques described herein relate to a dowel system, wherein the arm member includes notches along its length, the notches configured to engage a portion of the hook member adjacent to the slot, allowing the hook member to be adjustably positioned along the arm member.

[00019] In some aspects, the techniques described herein relate to a dowel system, wherein the bracing structure includes an elongated member having a first end connected to a bottom edge of the faceplate, a second end extending outward from the first end, and a plurality of segments between the first and second ends, the elongated member further including at least one joint along its length, the at least one joint configured to allow a segment to rotate between approximately 90 degrees and 180 degrees relative to an adjacent segment.

[00020] In some aspects, the techniques described herein relate to a dowel system, wherein segments of the plurality of segments between a selected joint and the second end of the elongated member define a base portion configured to contact a ground surface and support the device when two segments abutting the selected joint of arc oriented at a 90-dcgrcc angle relative to each other.

[00021] In some aspects, the techniques described herein relate to a dowel system, wherein the first spline has a second end opposite its first end, the second end forming a female mating end, and wherein the second spline has a second end opposite its first end, the second end forming a male mating end configured to engage the female mating end of a first spline of a second device of the at least one device.

[00022] In some aspects, the techniques described herein relate to a dowel system, wherein the first and second spline each include at least one breakpoint along a length of the spline between the first and second ends, respectively, and the breakpoints are configured to sever the spline into two sections.

[00023] In some aspects, the techniques described herein relate to a dowel system, the body including a plurality of gussets to provide additional support, wherein the plurality of gussets each have a first edge that is secured to the outer surface of the body and each of the plurality of gussets has a second edge that is secured to the second surface of the faceplate.

[00024] In some aspects, the techniques described herein relate to a dowel system, wherein a crossmember is secured to the body and the crossmember extends across the plurality of gussets.

BRIEF DESCRIPTION OF THE DRAWINGS

[00025] Figure 1 is a front view of a device.

[00026] Figure 2 is an elevated, front view of the device.

[00027] Figure 3 is an elevated, rear- view of the device.

[00028] Figure 4 is a top view of the device.

[00029] Figure 5 is another front view of the device.

[00030] Figure 6 is a rear view of the device.

[00031] Figure 7 is a top view of another implementation of the device including a crossmember spanning gussets.

[00032] Figure 8 is a top view of another implementation of the device with a tab.

[00033] Figure 9 is an elevated front view of the device of Figure 8.

[00034] Figure 10 is a rear view of the device of Figure 8. [00035] Figure 11 is a rear view of the device of Figure 8 including a bracing structure.

[00036] Figure 12 is a top view of the tab and bracing structure.

[00037] Figure 13 is a side view of the tab and bracing structure of Figure 12.

[00038] Figure 14 is a rear view of the device and bracing structure of Figure 11.

[00039] Figure 15 is an elevated, rear view of the device and bracing structure of Figure 11.

[00040] Figure 16 is an elevated, rear view of the device and bracing structure of Figure 11.

[00041] Figure 17 is an elevated, front view of another implementation of the device and bracing structure.

[00042] Figure 18 is an elevated, rear view of the implementation of the device and bracing structure of Figure 17.

[00043] Figure 19 is an elevated, front view of another implementation of the device and bracing structure.

[00044] Figure 20 is a front view of the implementation of the device and arm member of Figure 19.

[00045] Figure 21 is a front view of the implementation of the arm member of Figure 19.

[00046] Figure 22 is a side view of the implementation of the hook member of Figure 19.

[00047] Figure 23 is another side view of the implementation of the hook member of Figure 19.

[00048] Figure 24 is an elevated, real' view of another implementation of the device and bracing structure.

[00049] Figure 25 is an elevated, rear view of the implementation of the device and bracing structure of Figure 24 with a bent joint of an elongated member forming a base portion.

[00050] Figure 26 is an elevated, front view of the implementation of the device and bracing structure of Figure 25.

[00051] Figure 27 is an elevated, rear view of another implementation of the device having a cylindrical profile.

[00052] Figure 28 is an elevated, front view of the implementation of the device of Figure 27.

[00053] Figure 29 is a front view of two devices mating at the ends of its respective splines.

[00054] Figure 30 is a side view of a female mating end of a spline.

[00055] Figure 31 is a side view of a male mating end of a spline. [00056] Figure 32 is an elevated, front view of multiple device manufactured as a single unit.

[00057] Figure 33 is an elevated, front view of the implementation of the devices of Figure 17 connected at respective mating ends.

[00058] Figure 34 is an elevated, front view of the implementation of the devices of Figure 27 connected at respective mating ends.

DESCRIPTION

[00059] The Figures included in this application illustrate a dowel system. The dowel system disclosed herein is primarily used for aligning adjacent sections of concrete. Generally, concrete is poured in sections using a form and those sections are positioned adjacent to one another and meet at a joint. A concrete form, also known as a formwork or mold, is a temporary structure used to contain and shape freshly poured concrete until it hardens. Assembling roadways and flooring in sections enables the concrete to move independently of the other sections of concrete. Independent movement of each section is necessary to combat changing temperatures that cause the sections to expand and contract. Further, a section must be able to move independently and compress/decompress when it is loaded/unloaded with a weight (e.g., when a vehicle drives over a section). The dowel system described in this disclosure constrains the amount of relative movement between adjacent concrete slaps or sections.

[00060] With reference to Figures 1-7, the dowel system 10 may include at least one device 12 that may include a faceplate 14, a body 16 secured to the faceplate 14, and two splines 18 which are also secured to the faceplate 14. Although this disclosure refers to the faceplate 14, body 16, and splines 18 as distinct features, these components of the device 12 may be manufactured as a single piece or as separate pieces joined using known attachment methods, such as injection molding. In one embodiment, the faceplate 14 has a perimeter defined by two lateral edges 20, a top edge 22, and a bottom edge 24. The faceplate 14 may have a first surface 26, and second surface 28 opposite to the first surface 26. The faceplate 14 may further include a slot 30 and one or more of aperture(s) 32. The slot 30 is adapted to receive a load plate (i.e., dowel) therethrough. The one or more aperture(s) 32 may extend through the faceplate 14 from the first surface 26 to the second surface 28. The apertures 32 may be adapted to receive nails that secure the dowel system 10 to forms before the concrete is poured. This implementation with the apertures 32 may be used with perforable forms, such as those made of wood. Arrow markings 33 may be provided on the first surface 26, directing toward the slot 30 to assist a user in locating the slot 30.

[00061] The devices 12 of the dowel system 10 disclosed herein may be manufactured, in whole or in part, by a molding technique such as injection molding, extrusion, or machining. The devices 12 may be made from a plastic, metal, wood, composite or any other suitable material and may be chosen based on design requirements, such as tolerances, load-bearing capacity, and flexibility.

[00062] The faceplate 14 has a length LI, a width Wl, and a thickness Tl. The length LI of the faceplate 14 corresponds to a distance between the lateral edges 20 of the faceplate 14. The width Wl of the faceplate 14 corresponds to a distance between the top edge 22 and bottom edge 24. The thickness Tl corresponds to a distance between the first surface and second surface 28 (see Figure 4). In one implementation, the length LI is approximately 9 inches, the width Wl is approximately 5 inches, and the thickness Tl is approximately *4 inch. For the purposes of this disclosure, the stated dimensions of the device 12 are exemplary, and other implementations with different dimensions fall within the scope of this disclosure. For the purposes of this disclosure, the term “approximately” means ±10 percent of the stated value or relationship unless otherwise indicated.

[00063] Each of the splines 18 are elongated beams that extend outwardly from the lateral edges 20 of the faceplate 14 to a distal end 34a, 34b. The splines 18 may include a first surface 36 and a second surface 38, opposite to the first surface 36. The first and second surfaces 36, 38 are bound by the distal end 34, 34b of the spline 18, edges 39 of the spline 18, and the lateral edges 20 of the faceplate 14. In one implementation the first and second surfaces 36, 38 of the splines 18 are planar to and flush with the first and second surfaces 26, 28, respectively, of the faceplate 14. In practice when the device 12 is secured to the forms and concrete is being poured into the forms, the device 12 is positioned such that the second surfaces 38 of the splines 18 and the second surface 28 of the faceplate 14 are flush to an edge of the concrete section and the body 16 extends into the concrete section.

[00064] The splines 18 may have a length L2, a width W2, and a thickness T2. The length L2 of each spline 18 corresponds to the distance between a respective lateral edge 20 of the faceplate 14 and distal end 34a, 34b of the spline 18. The width W2 corresponds to the distance between respective edges 39 of the spline 18. In one implementation, the width W2 is % inch. The thickness T2 of each spline 18 corresponds to the distance between the first and second surfaces 36, 38. In one implementation, the thickness T2 of the splines 18 is the same as the thickness T1 of the faceplate 14. While the figures depict each spline 18 with the same length L2, it should be understood that, in practice, each of the splines 18 of a single device 12 may have different lengths. Further, in one implementation, the splines 18 may be adjustable in length L2 to accommodate variable spacing requirements between the devices 12.

[00065] Generally, sections of concrete require more than one device 12 in order to properly regulate the relative movement between concrete sections. The number of devices 12 and the spacing between the devices 12 on an edge of the concrete section will change depending on the requirements of the construction project and technical factors such as expected load and temperature fluctuations. The splines 18 provide the user with an accurate distance between adjacent devices. In this example, the splines 18 connect adjacent devices 12 to define the length of a system 10 of multiple devices 12. The splines 18 may also be connected to achieve a desired length and number of devices 12.

[00066] The splines 18 may include apertures 40 extending through the spline 18 from the first surface 36 to the second surface 38. These apertures 40 are may be positioned near’ the distal ends 34a, 34b and are adapted to receive nails for securing the device 12 to the forms. Additionally, one of the splines 18 may include a recessed portion 42 at one of the distal ends 34a that may include a port 44 extending through the spline 18 from the first surface 36 to the second surface 38. In practice, when the devices 12 are secured to the forms and properly spaced from each other, the distal end 34b of an adjacent device 12 overlaps the recessed portion 42 such that the aperture 40 of the distal end 34b aligns with the port 44 of the recessed portion 42. The aligned aperture 40 and port 44 are adapted to receive the same nail therethrough, aiding in securing the devices 12 to the forms.

[00067] With reference to Figure 2, the body 16 of the device 12 defines an internal cavity 46 that is adapted to receive a portion of a dowel therein.

[00068] With reference to Figure 3, the body 16 is secured to the second surface 28 of the faceplate 14 and extends outwardly therefrom. The slot 30 of the faceplate 14 aligns with an opening of the cavity 46. The body 16 may be secured to the faceplate 14 using known methods such as snap-fit or press-fit connections, adhesives, welding, and overmolding. In other implementations, the body 16 and faceplate 14 may be integrally molded as a single piece. [00069] In some implementations, the body 16 has a triangular profile, but other profiles arc within the scope of this disclosure. In implementations in which the body 16 has a triangular profile, the body 16 is defined by two lateral surfaces 48, a top surface 50, and a bottom surface 52 opposite to the top surface 50. For the purpose of this disclosure, unless otherwise stated, "top" and "bottom" refer to the relative orientation of the device 12 with respect to the ground surface in practice (i.e., the bottom surface 52 is positioned closer to the ground surface than the top surface 50 when the device 12 is installed). The top surface 50 is oriented generally parallel to the bottom surface 52, and both surfaces 50, 52 are triangular- in shape, giving the body 16 its triangular profile. The two lateral surfaces 48 meet at a distal edge 53.

[00070] With reference to Figures 3-4, in some implementations, one or more fin(s) 54 may be attached to the body 16. The fins 54 help secure the device 12 within the concrete section. Specifically, the fins 54 are designed as a barb to trap concrete between the fins 54 and faceplate 14 to prevent the device 12 from slipping out of the concrete section. Fins 54 may be secured at one end to each lateral surface 48 of the body 16, with the opposite end extending outwardly from the respective lateral surface 48.

[00071] With reference to Figures 2-6, in some implementations, the body 16 may also include one or more gusset(s) 56. The gussets 56 enhance the rigidity of the device 12 by serving as additional support between the second surface 28 of the faceplate 14 and either the top surface 50 or bottom surface 52 of the body 16. In some implementations, the gussets 56 are triangular members that attach at one edge to the top or bottom surface 50, 52 of the body 16 and attach at a second edge to the second surface 28 of the faceplate 14 (see Figure 6). In implementations with multiple gussets 56, the dimensions of each gusset 56 may be uniform or vary. For example, in some implementations, three gussets 56 connect the second surface 28 to each of the top and bottom surfaces 50, 52 of the body 16, with the middle gusset 56 having a greater length than adjacent gussets 56.

[00072] With reference to Figures 5-6, in some implementations, each spline 18 may include one or more centerline window(s) 58 stamped through the spline 18 from the first surface 36 to the second surface 38. The centerline window 58 aids a user with orienting the device 12 relative to the form during installation. The centerline windows 58 may be designed as a doublesided arrow and may be arranged proximate to respective lateral edges 20 of the faceplate 14. [00073] With reference to Figure 7, in another implementation, the device 112 (shown for illustrative purposes without splines 118) includes a first and second fin 154 secured to each lateral surface 148 of the body 116 at one edge of the fin 154 and to the second surface 138 of the faceplate 14 at a second edge of the respective fin 154. In this configuration, the fin 154 also includes a tubular member 171 along a third edge, with the tubular member 171 defining a channel 172 that is adapted to receive a nail, which extends through both the faceplate 114 and the channel 172 of the tubular member 171. This arrangement of the fin 154 relative to the lateral surface 148 and faceplate 114 enhances the rigidity of the device 12.

[00074] The device 112 may include four gussets 156 forming a gusset architecture on each of the top and bottom surfaces 150, 152 of the body 116. A crossmember 147 may span each of the gussets 156 of the gusset architecture and a gap 145 separates the crossmember 147 from the gussets 156. The gap 145 is approximately Yi to 1 and Yz inches. This arrangement of the crossmember 147 with respect to the gussets 156 reduces the bowing of the device 112 when the concrete sections are being poured into the forms.

[00075] With reference to Figures 8-16, in another implementation, the device 212 may include a tab 260 secured to the distal edge 253. The tab 260 may include an aperture 262 extending through the tab 260 (see Figures 8-11, and 17) that is adapted to facilitate the connection of the device 212 to a bracing structure 263. The bracing structure 263 is designed to support the device 212 during the concrete pouring process and to prevent it from tilting or shifting out of its proper position or alignment with adjacent devices 212. Specifically, the bracing structure 263 allows a user to position the device 212 relative to the form without directly securing it to the form. The bracing structure 263 is particularly useful when the form is made from metal or another non- perforable material.

[00076] The bracing structure 263 includes a rod 264, and a base 266 adapted to contact a ground surface. The rod 264 may be connected to the base 266 at one end and may extend outward from the base 266 to a second end, opposite the first end. The aperture 262 of the tab 260 may be adapted to receive the rod 264 therethrough. The rod 264 may include a mating surface 268 (such as threads or grooves) along a length of the rod 264, while the aperture 262 includes a complementary surface 270, (such as circumferential grooves, tabs, or notches), to engage the mating surface 268. This configuration allows the device 212 to articulate vertically relative to the rod 264, enabling height adjustment of the device 212 relative to the base 266 and ground surface. [00077] With reference to Figures 11-14, in one implementation, the complementary surface 270 may be a tab and the mating surface 268 is a groove that receives the tab.

[00078] With reference to Figures 15-16, in another implementation, the mating surface 268 may comprise threads and the complementary surface 270 may include circumferential notches that engage the threads.

[00079] With reference to Figures 17-18, in another implementation, a bracing structure 374 may be connected to the device 312 and may be adapted to engage a top member of the form, allowing the device 312 to hang at a variable distance from the top member. The bracing structure 374 includes an extendable arm 376 and a flange 378. The flange 378 is secured to the top edge 322 of the faceplate 314 at a first end 380 and extends outwardly from the top edge 322 at a second end 382, opposite to the first end 380. The flange 378 includes a slot 384 proximate the second end 382 of the flange 378, and the slot 384 is adapted to receive the extendable arm 376 therethrough. The extendable arm 376 includes notches 381 and measurement markings 387 along its length. The notches 381 are adapted to engage a portion of the flange 378 near the slot 384, allowing the extendable arm 376 to be securely positioned at different points along its length relative to the faceplate 314. The extendable arm 376 also includes a hook portion 386. The hook portion 386 of the extendable arm 376 is generally L-shaped and is designed to engage the top member of the form, allowing the device 12 to hang securely from it.

[00080] With reference to Figures 19-23, in another implementation, the bracing structure 474 may include an arm member 488 and an adjustable hook member 490. The hook member 490 engages a top member of the form and allows the device 412 to hang at a variable distance below the top member. The arm member 488 may be affixed to the top edge 422 of the faceplate 414 at one end 492 and may extend outwardly therefrom to a second end 494, opposite the first end 492. The arm member 488 may include notches 481 and measurement markings 487 along a portion of its length. The hook member 490 may include a slot 498 that is configured to receive the arm member 488 therethrough. The notches 481 are adapted to engage a portion of the hook member 490 near- the slot 498. Accordingly, the hook member 490 may be variably positioned along the length of the arm member 488. In this manner, a distance separating the top member of the form and device 412 can be adjusted. [00081 ] In one implementation, as shown in Figures 19-20, the device 420 may also include a vertical slot 495. In this implementation, the device 412 is adapted to receive a cross-shaped dowel within the cavity 446.

[00082] With reference to Figures 22 and 23, the hook member 490 includes a first end 489 and a second end 491 opposite to the first end 489. The hook member 490 includes a first surface 493 and a second surface 496. The slot 498 is positioned proximate to the first end 489 and extends through the hook member 490 from the first surface 493 to the second surface 496. A first flange 497 is positioned at the second end 491 and may extend outward from the first surface 493. A second flange 499 is positioned between the second end 491 and first end 489 and may extend outward from the second surface 496, in a direction opposite to the first flange 497. The first and second flanges 497, 499 may enable the hook member 490 to engage the top member of the form. A distance between the first end 489 and the first flange 497 is greater than the distance between the first end 489 and the second flange 499 and allows the hook member 490 to engage with forms of varying thicknesses.

[00083] With reference to Figures 24-26, a bracing structure 574 is an elongated member 576 that may include one or more joint(s) 579 spaced along its length, thereby segmenting the elongated member 576 into two or more segments. A first end 592 of the elongated member 576 is attached to the faceplate 514 at the bottom edge 524 of the faceplate 514, and extends outwardly from the faceplate 514 to a second end 594, opposite to the first end 592. Each joint 579 may be configured to bend from a 180-degree angle (between adjacent segments) to a 90-degree angle, enabling a portion 583 (e.g., base portion) of one or more segments of the elongated member 576, located between the selected joint 579 and the second end 594, to form a base that contacts the ground surface, thereby supporting the device 512 (see Figures 25-26). An extension portion 585 of the elongated member 576 corresponds to the one or more vertical segment(s) extending between the selected joint 579 and the first end 592. Consequently, the user can adjust the distance between the device 512 and the ground surface by selectively choosing which joint 579 along the length of the elongated member 576 to bend to a 90-degree angle, thus forming the base portion 583. A gusset 577 is associated with each joint 579 and is secured to the elongated member 576 at a first edge 559. A second edge 561 of the gusset 577 extends outwardly from the elongated member 576. When a joint 579 is bent to 90-degrees, thereby forming the base portion 583 and extension portion 585, the second edge 561 is adapted to contact the extension portion 585 of the elongated member 576, thereby limiting further bending and preventing the elongated member 576 from bending beyond approximately 90-dcgrccs.

[00084] With reference to Figures 27 and 28, in one implementation, the device 612 may include a body 616 having a cylindrical profile. The cylindrical body 616 has a rounded outer surface 635 and a cap 637 opposite to the second surface 628 of the faceplate 614. The body 616 defines a cylindrical cavity 646 which is adapted to receive a cylindrical dowel rod therein. One or more rib(s) 641 extend longitudinally along a length of the body 616 and terminate short of the second surface 628 and cap 637. One or more fin(s) 654 may be secured to the body 616. In the implementation shown in Figures 26 and 27, first and second fins 654 are secured to the outer surface 635 at one end and extend outwardly from the body 616 to a second end.

[00085] With reference to Figure 29, in one implementation, the devices 712 include one or more breakpoint(s) 713 along the length of each of the splines 718. The breakpoints 713 are frangible connections designed to sever the spline 718 into two sections when a user-applied force is exerted. These breakpoints 713 allow the user to adjust the length of the device 712 to conform to dimension requirements of the forms and concrete sections.

[00086] With reference to Figures 30 and 31, in another implementation, the devices 712 may include a female mating end 734a and a male mating end 734b. The female mating end 734a may include a recessed portion 733a extending inward from the first surface 736 of the spline 718, while the male mating end 734b may include a recessed portion 733b extending inward from the second surface 738 of the spline 718. These recessed portions 733a, 733b are configured to overlap, aligning the first and second surfaces 736, 738 of the female mating end 734a and male mating end 734b so that they are flush with each other, respectively. When in this overlapped configuration, a single nail may be inserted through the aligned apertures 740.

[00087] With reference to Figure 32, in one implementation, the system 810 includes multiple devices 812 manufactured as a single unit 811, connected at the ends of the spline 818. Specifically, these devices 812 are overmolded together and include breakpoints 813 along the splines 818 (denoted by the vertical lines). In this implementation, the unit 811 includes one female mating end 834a and one male mating end 834b so that the unit 811 may connect with other devices 812 and/or units 811 of devices 812.

[00088] With reference to Figure 33, the system 310 of Figures 17-20 is shown with devices 312 connected to each other at the ends 334a, 334b of the splines 318. [00089] With reference to Figure 34, the system 610 of Figures 27-28 is shown with devices 612 connected to each other at the ends 634a, 634b of the splines 618.

[00090] A method of assembling the dowel system 10 between two, adjacent sections of concrete or other compositions follows. A form is assembled to define the edges of a concrete slab. The faceplate 14 of one device is attached to the form such that the body 16 portion extends inward to an area designated to receive concrete. In some embodiments, as shown in Figures 1-7 and 27- 28, the device is attached to the form with nails that are received by the apertures in the faceplate. However, the attachment method utilizing nails only works if the forms are made from wood or another penetrable material. If the forms are made from a metal, hard plastic, or other non- penetrable material, the implementations described below may be used to orient the device with respect to the forms.

[00091] In the implementation shown in Figures 8-16, the user adjusts the height of the device 212 above the ground surface by articulating the rod 264 through the aperture 262 of the tab 260. The user positions the bracing structure 263 such that the base 266 firmly contacts the ground surface and the faceplate 214 presses flush against the form.

[00092] In the implementation shown in Figures 17-18, the user inserts the extendable arm 376 through the slot 384 and adjusts its length by engaging one of the notches 381 with the flange 378 to achieve the desired hanging distance. Finally, the user secures the device 312 in place by hooking the hook portion 386 of the extendable arm 376 onto the top member of the form, allowing the device 312 to hang at a variable distance as needed.

[00093] In the implementation shown in Figures 19-23, the user inserts the ami member 488 through the slot 498 of the hook member 490 and adjusts its position by engaging one of the notches 481 with the hook member 490 to set the desired hanging distance. Finally, the user secures the device 420 by positioning the hook member 490 over the top member of the form, allowing the device 412 to hang at a variable distance below it.

[00094] In the implementation shown in Figures 24-26, the user selects a joint 579 along the elongated member 576 and bends it to a 90-degree angle, forming a base portion 583 that contacts the ground surface for support. Finally, the gusset 577 at the selected joint 579 engages the extension portion 585, preventing further bending beyond 90 degrees and ensuring the device 512 is stably positioned at the desired height above the ground. [00095] After the device is attached to the form, a layer of concrete is poured within the form and over the device. The device is positioned at the edge of the first section of concrete such that the body is encased in the first slab of concrete. Once the first concrete slab has cured, the forms are removed and device remains within the now cured concrete slab. The slot accessible through the faceplate is exposed at a side of the cured concrete slab and is ready to accept a load plate.

[00096] Before the second section of concrete is poured, a first end of the load plate is inserted into the slot of the device and received by the cavity of the body. A second end of the load plate, opposite to the first end, protrudes from the slot of the device. The second concrete slab is then poured and cured adjacent to the first concrete slab with the load plate protruding from the slot of the device. Upon pouring of the second concrete slab, the second side of the load plate is encapsulated. Once the second concrete slab has cured, the load plate extends across the joint between the adjacent first and second concrete slabs. The load plate constrains movement between the first and second concrete slabs to maintain a desired alignment between top surfaces.

[00097] Accordingly, the disclosed dowel system aligns two adjacent sections of concrete, offering additional support and assisting with load transfer between the sections, while also enabling the sections to move independently.

[00098] A method for manufacturing a unit composed of multiple devices is as follows. Multiple devices are formed as a single unit using an overmolding process. Each device includes a female mating end and a male mating end at the respective ends of its spline. Initially, each device is independently molded in an injection molding machine. Once molded, the device is transferred to a conveyor adjacent to the injection molding machine while one of its mating ends — either male or female — remains in the mold. As the next device is molded, its mating end is overmolded onto the corresponding mating end of the previously molded device, forming a continuous, single unit. This process is repeated until the desired number of devices is incorporated into the unit.

[00099] Although the different non-limiting implementations are illustrated as having specific components or steps, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. The preceding description is illustrative rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this invention.

Claims

CLAIMS We claim:

1. A dowel system for aligning two adjacent sections of concrete comprising: at least one device comprising: a body that defines an internal cavity, and the cavity is configured to receive a load bearing member; a faceplate including a first lateral edge, a second lateral edge, a top edge, and a bottom edge defining a perimeter of the faceplate, as well as a first surface and a second surface opposite the first surface, a slot extending between the first and second surface, wherein the body is secured to the second surface of the faceplate such that the opening of the cavity of the body is aligned with the slot of the faceplate; and a first spline connected to the first lateral edge, and a second spline connected to the second lateral edge.

2. The dowel system of claim 1, wherein the body has a triangular profile defined by a top surface, a bottom surface opposite to the top surface, and two lateral surfaces between the top and bottom faces.

3. The dowel system of claim 2, the body including a plurality of gussets to provide additional support, wherein the plurality of gussets each have a first edge that is secured to the outer surface of the body and each of the plurality of gussets has a second edge that is secured to the second surface of the faceplate.

4. The dowel system of claim 3, wherein a crossmember is secured to the body and the crossmember extends across the plurality of gussets.

5. The dowel system of claim 4, wherein a gap separates the crossmember from each of the gussets.

6. The dowel system of claim 1 , wherein an outer surface of the body has a cylindrical profile.

7. The dowel system of claim 1 , wherein the dowel system is positioned between two adjacent sections of concrete such that the body is embedded within a first section of concrete and the faceplate protrudes from the first section of concrete so that the faceplate is flush with an edge of the first section and the faceplate abuts an edge of a second section.

8. The dowel system of claim 1, wherein the body includes fins secured to the outer surface of the body and the fins protrude outward from the body and into the first section of the concrete to prevent the dowel system from pulling out of the first section of concrete.

9. The dowel system of claim 1, wherein a bracing structure is secured to the body at a distal edge of the body and the bracing structure also contacts a ground surface at another end to provide support to the dowel system.

10. A dowel system for aligning two adjacent sections of concrete comprising: at least one device comprising a body that defines an internal cavity, and the cavity is configured to receive a load bearing member; a faceplate including a first lateral edge, a second lateral edge, a top edge, and a bottom edge defining a perimeter of the faceplate, as well as a first surface and a second surface opposite the first surface, a slot extending between the first and second surface, wherein the body is secured to the second surface of the faceplate such that the opening of the cavity of the body is aligned with the slot of the faceplate; a first spline connected to the first lateral edge at a first end of the spline, and a second spline connected to the second lateral edge at a first end of the second spline; and a bracing structure secured to the faceplate.

11. The dowel system of claim 10, wherein the bracing structure includes an extendable arm and a flange, the flange connected at a first end to a top edge of the faceplate and including a slot at a second end, opposite to the first end, the slot configured to receive a first end of the extendable arm therethrough, the extendable arm including a hook portion at a second end, opposite the first end, the hook portion configured to engage a form.

12. The dowel system of claim 11, wherein the extendable arm includes measurement markings and notches along its length, the notches configured to engage a portion of the flange near the slot, and the measurement markings correspond to a distance between the form and device.

13. The dowel system of claim 10, wherein the bracing structure comprises an arm member and an adjustable hook member, the arm member having a first end connected to a top edge of the faceplate and a second end opposite the first end, the adjustable hook member including a slot configured to receive the arm member at the second end, the hook member further configured to engage a form.

14. The dowel system of claim 13, wherein the arm member includes notches along its length, the notches configured to engage a portion of the hook member adjacent to the slot, allowing the hook member to be adjustably positioned along the arm member.

15. The dowel system of claim 10, wherein the bracing structure includes an elongated member having a first end connected to a bottom edge of the faceplate, a second end extending outward from the first end, and a plurality of segments between the first and second ends, the elongated member further comprising at least one joint along its length, the at least one joint configured to allow a segment to rotate between approximately 90 degrees and 180 degrees relative to an adjacent segment.

16. The dowel system of claim 15, wherein segments of the plurality of segments between a selected joint and the second end of the elongated member define a base portion configured to contact a ground surface and support the device when two segments abutting the selected joint of are oriented at a 90-degree angle relative to each other.

17. The dowel system of claim 10, wherein the first spline has a second end opposite its first end, the second end forming a female mating end, and wherein the second spline has a second end opposite its first end, the second end forming a male mating end configured to engage the female mating end of a first spline of a second device of the at least one device.

18. The dowel system of claim 17, wherein the first and second spline each include at least one breakpoint along a length of the spline between the first and second ends, respectively, and the breakpoints are configured to sever the spline into two sections.

19. The dowel system of claim 18, the body including a plurality of gussets to provide additional support, wherein the plurality of gussets each have a first edge that is secured to the outer surface of the body and each of the plurality of gussets has a second edge that is secured to the second surface of the faceplate.

20. The dowel system of claim 19, wherein a crossmember is secured to the body and the crossmember extends across the plurality of gussets.