BACKGROUND

Field

These inventions relate to concrete floats and float assemblies, and apparatus and methods for using concrete finishing tools in the manner of concrete floats for finishing concrete surfaces. They also relate to improved float profiles and methods of using concrete floats more easily and efficiently.

SUMMARY

In one example of a concrete float or other apparatus for finishing concrete, a longitudinally extending float body includes a finishing surface and means on an upper surface opposite the finishing surface for helping to control of the apparatus. The control helping means may take any number of configurations now or previously conventional with these types of devices, including but not limited to those described or cited in WO 2021/158690, all of which are incorporated herein by reference. As used herein, control helping means and means for engaging a control element for manipulating a concrete float includes mounting brackets, pivot assemblies, handles and manual control elements for controlling a concrete float, and components thereof, and such devices as described in WO 2021/158690. The float body includes a longitudinally extending substantially square or 90° edge at a first portion of the finishing surface. In one configuration, the first portion of the finishing surface is a distal end portion of the apparatus when the apparatus is manipulated or controlled by a user to finish a concrete surface, such as by pushing out and pulling back with a pole. In one example, the first portion extends longitudinally the entire length of the float body. In a further example, the finishing surface in transverse cross-section is substantially planar or flat or slightly convex (when looking at the finishing surface) up to the first portion, and in one example up to the substantially square or 90° edge. The float body also includes a longitudinally extending ramp surface and a substantially square or 90° edge on a side of the ramp surface opposite the finishing surface. The ramp surface and substantially square or 90° edge are on a second portion of the finishing surface opposite the first portion, and in the present example, the first and second portions of the finishing surface are on opposite sides of the control helping means or manipulating means.

In another example of a concrete float or other apparatus for finishing concrete, the apparatus is a manually controlled apparatus having a float body with a finishing surface, a first rail having a first longitudinally extending square edge at a first portion of the finishing surface and a second rail having a second portion on a side of the finishing surface opposite the first portion and having a ramp and second substantially square edge on the second portion. The first portion further includes a concave wall extending from the first square edge away from the finishing surface and forming a convex wall when viewed from a center of the float on a side opposite the finishing surface. The concave wall can be formed from first and second walls angled with respect to each other wherein the first wall joins the first square edge.

In a further example of a concrete float or other apparatus for finishing concrete, the apparatus is a manually controlled apparatus having a float body with a finishing surface extending longitudinally, and first and second border portions on opposite sides of the finishing surface extending longitudinally. The first border portion includes a longitudinally extending square edge, and the second border portion includes a ramp and second substantially square edge extending longitudinally. In one example, as viewed in a transverse cross-section of the apparatus, the ramp extends in an arc away from and out of a plane of the finishing surface, and may include a portion having a constant radius of curvature. The substantially square edge may additionally include a substantially flat portion when viewed in transverse cross-section on a side of the ramp opposite the finishing surface, and the substantially flat portion extends longitudinally with the ramp. The second substantially square edge extends from the ramp in a direction away from the finishing surface, coupled to and extending away from the ramp, for example from the arcuate portion of the ramp outward in the illustrated configuration, and upward from the ramp. The substantially square edge extends substantially perpendicular to the ramp. In one configuration of the curvature of the ramp, the ramp may include a radius of curvature of between approximately 30 mm and approximately 45 mm, and in another example a radius of curvature of approximately 38 mm. The ramp may terminate when the ramp reaches an approximately 30° angle relative to the horizontal, or relative to the finishing surface of the float. The second border portion may also include a concave wall structure, or convex when viewed from a center of the float on a side opposite the finishing surface, wherein the concave wall structure extends from the substantially square edge away from the finishing surface. The concave wall structure may be formed from first and second walls angled with respect to each other.

In another example of a concrete float or other apparatus for finishing concrete, a concrete float or other apparatus for finishing concrete includes a finishing surface and means on a side of the float opposite the finishing surface for helping to control the use of the apparatus. The apparatus includes a first boundary or border portion having a sealing edge and a second boundary or border portion having an opening surface portion and a cutting edge. The first and second boundary or border portions are on opposite sides of the finishing surface, and extend longitudinally with the finishing surface. In one example, the sealing edge includes first and second mutually perpendicular surfaces extending longitudinally of the apparatus wherein the first perpendicular surface is substantially parallel to the finishing surface. The second perpendicular surface extends away from the finishing surface. The sealing edge may also be formed by first and second surfaces forming an acute angle less than 90° relative to each other, or wherein the second surface extends at an acute angle relative to the finishing surface, and extends longitudinally of the float. The sealing edge helps to seal the concrete surface when the sealing edge is the trailing edge during movement of the float. A further structure extends from the second perpendicular surface or the second surface away from the finishing surface and forms a convex structure, as viewed from a center of the apparatus on a side opposite the finishing surface. The opening surface portion includes a substantially continuously arcuate surface (convex when viewed from the finishing surface) or a curved ramp, curving away from the finishing surface. The opening surface may include a portion having a constant or varying radius of curvature (concave when viewed from a center of the apparatus on a side opposite the finishing surface). The cutting edge may include third and fourth acute or mutually perpendicular surfaces extending longitudinally of the apparatus, wherein the third surface may be flat and extending substantially parallel to an adjacent end portion of the arcuate portion or ramp where they meet, and the fourth surface extends away from the third surface and away from the finishing surface. In one configuration, the opening surface may terminate at a portion opposite the finishing surface when the opening surface approaches an approximately 30 degree angle from the finishing surface. An opening surface brings the cream to the surface, and may promote improved wicking when the opening surface is used as a leading edge, for example a leading edge on the float on a backward stroke. In one configuration, the third and fourth surfaces extend at an acute angle relative to each other, and in another configuration they are mutually perpendicular and extend longitudinally with the finishing surface. The third and fourth surfaces form a cutting edge when used on a leading edge on the float on a backward stroke.

In another example of a float, including any of the floats described herein, the float may include an upper surface having a channel or groove open to the elements. The channel or groove can be covered at least in part or completely by a cover for reducing the amount of material such as concrete or debris that enters the channel or groove. The cover may be retained in the channel or groove through an interference fit or other secure engagement to keep the cover in place during normal operation. The cover may be installed by sliding the cover longitudinally along the channel or groove, or by pushing the cover into engagement with upper rims or rails of the channel or groove, for example pushing the cover in a direction perpendicular to the float.

In another example of a float, including any of the floats described herein, the float may include edge rails extending longitudinally of the float, at one or both of the leading and trailing edges of the float. One or both of the edge rails may include rail protectors extending about perimeter surfaces of the rails. Where a rail has a portion such as a free end that is partially circular or has a curving profile, a rail protector may extend over the partially circular or curved surface. The rail protector helps to reduce intrusion of material from the edge of the float, including but not limited to reducing debris from marring the surface of the float. In a further example of a float, including any of the floats described herein, the float may include an end cap or end caps. An end cap may be used for closing the ends of the float and limiting the possibility of material such as water, concrete or debris from intruding from the edge of the float or getting on the upper surface of the float. An end cap may be held in place on a lateral end of a float through interference fit with a corresponding end of the float. In one example of an end cap, the end cap may have a surface profile for a surface facing a concrete surface to be finished that is different from the surface profile of the immediately adjacent finishing surface of the float. For example for a float resting on a concrete surface to be finished, the finishing surface of the float faces at least in part the concrete surface, and will be the surface of the float that comes into contact with wet concrete for finishing the wet concrete during normal operation of the float. The finishing surface of the float will have a first profile, and the adjacent surface of the end cap will have a second profile different from the first profile. In one example, the finishing surface of the float will have a flat portion with a flat portion surface profile and the immediately adjacent profile of the end cap will be identical and flush with the flat portion surface profile. In such example, the flat portion surface profile and the immediately adjacent profile of the end cap will be substantially coplanar or flush with each other. In this same example, and in other examples, the finishing surface of the float will have end portions (as viewed from an end of the float, and which would correspond to a profile of a leading or trailing edge of the float) on opposite sides of the flat portion with respective adjacent surfaces of the end cap where the adjacent surfaces of the end cap have different surface profiles compared to the respective adjacent surfaces of the float finishing surface. For example, they are not coplanar and they are not flush. In one example, the adjacent surfaces of the end cap are spaced apart from the corresponding finishing surfaces of the float. In another example, the adjacent surfaces of the end cap are extending at respective angles relative to the corresponding adjacent surfaces of the float finishing surfaces. In another example, portions of the end cap are recessed upward from the respective adjacent surfaces of the float finishing surface. In such an example, the portions of the end cap are extending at respective angles relative to the adjacent surfaces of the finishing surface. In another example of a concrete finishing float, including any of the floats described herein, the float may include an end cap or end caps, for example for closing the ends of the float, having at least a portion of a profile in end elevation view on the float adjacent the float finishing surface different from a profile in end elevation view of the finishing surface of the float. In one example for evaluating possible differences in profiles over at least a portion of the end cap and the float finishing surface, an assembly of an end cap on the end of the float is viewed toward the end of the float assembly in a direction parallel to a concrete surface on which the float would be resting and in a direction normal to an outwardly-facing edge of the float forming the finishing surface. Points are selected with a point of the finishing surface on the edge of the float and a point on a bottom surface of the end cap that are both on, or on a projecton of, a vertical line perpendicular to the concrete surface and containing the point on the edge of the float. A float line is formed from the point on the finishing surface on the edge of the float that is tangent to the surface, and an end cap line is formed from the point on the bottom surface of the end cap that is on the vertical line that is tangent to the end cap point. If the float line and the end cap line are parallel, those portions of the profile of the finishing surface and the profile of the end cap are substantially the same. They are not spaced apart and they do not form an angle relative to each other. If the float line and the end cap line are not parallel, those portions of the profile of the finishing surface and the profile of the end cap are different. They can be spaced apart, they can form an angle relative to each other, or both. In one example, portions of the float finishing surface that are flat and contacting or substantially contacting a concrete surface when the float is resting on the concrete surface have a float profile at the end of the float that is the same as the profile of the adjacent surface of the end cap on the float. In this example, tangent lines to the points along the float surface are substantially parallel to tangent lines on points along the adjacent surface of the end cap on the float. In this example, or in other examples, portions of the float finishing surface that extend away from the flat float finishing surface have tangent lines that are either spaced apart from or at an angle to immediately adjacent tangent lines of the end cap on the end of the float, in which case the end profile of the concrete finishing surface of the float is different from the adjacent profile of the end cap on the end of the float. When an end cap is used on a float, the end cap profile that is different from the profile of the end of the concrete finishing surface on which the end cap is mounted reduces the possibility of the end cap causing marking or producing a line in the concrete as the float is used. For example, if an end cap is mounted on the end of the float and the profile of the concrete finishing surface is substantially the same as the adjacent profile of the end cap, surfaces of the end cap may mark the surface of the concrete, for example one or more portions of the end cap that that are on opposite sides of the flat finishing surface at the end of the float between the leading or trailing ends of the float. An end cap with an edge surface profile adjacent the concrete finishing end surface profile that is at least partly different reduces the possibility of the end cap marking the concrete surface.

A method of using a float or other apparatus for finishing concrete, for example manually with a pole or other control apparatus, includes positioning a longitudinally extending float or finishing apparatus so that the apparatus can be moved transversely of a longitudinal axis of the apparatus in a forward direction and a backward direction. The apparatus has a longitudinally extending finishing surface extending both longitudinally and transversely of the axis. The apparatus also includes a sealing surface on a forward portion of the apparatus (leading the apparatus on an outbound stroke), for example forward of the finishing surface, and a ramp portion on a rearward portion of the apparatus, for example rearward of the finishing surface. The apparatus is moved forward and backward with the finishing surface extending longitudinally, and when the apparatus is moved backward the finishing surface contacts a surface of the concrete during a portion of the backward movement. During a portion of a backward movement of the apparatus, the apparatus is positioned such that at least one of the ramp portion and the cutting edge contacts the surface of the concrete. In one example, the apparatus is pulled backward while the ramp portion contacts the concrete surface, and in another example the apparatus is pulled backward with the cutting edge contacting the surface of the concrete, for example at a portion of the concrete surface having a raised concrete area to be leveled. In one example, the apparatus is pulled backward so that the cutting edge moves a portion of concrete from a raised concrete area to another portion of the concrete surface. In a further example, the apparatus is pulled backward pulling a portion of concrete and depositing a portion of concrete in a concrete depression or low area. In another example of using the apparatus, the apparatus is pushed forward with the ramp portion contacting the concrete surface. In a further example of using the apparatus, the apparatus is pulled backward so that the cutting edge scrapes concrete from the concrete surface. In another example of using the apparatus, the apparatus is pulled backward so that a substantially flat surface between a ramp portion and a cutting edge moves along the concrete surface with the cutting edge in contact with the concrete surface. In another example of using the apparatus, the float is pushed forward with the ramp portion contacting the concrete surface, for example with the float at an angle, followed by a return stroke or backward stroke so that the cutting edge scrapes concrete in the concrete surface, followed by pushing the float forward with the ramp portion contacting the concrete surface, followed by placing the float flat or slightly angled on a return stroke or backward stroke for sealing the concrete surface.

In any of the foregoing examples, a profile of the apparatus in transverse cross-section may have the apparatus asymmetric relative to a longitudinally extending plane perpendicularly intersecting a middle portion of the apparatus, for example on a center line where the manipulating means engages the apparatus. Additionally or alternatively in any of the foregoing examples, a profile of the apparatus in transverse cross-section may have the apparatus asymmetric relative to a longitudinally extending plane perpendicularly intersecting a middle portion of the apparatus on a lower half of the apparatus, for example a half of the apparatus containing the finishing surface, and symmetric on an upper half of the apparatus, for example a half of the apparatus opposite the finishing surface.

These and other examples are set forth more fully below in conjunction with drawings, a brief description of which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a rear upper left dimetric view of a concrete float and means for manipulating the concrete float. FIG. 2 is a left side elevation view of the concrete float of FIG. 1 .

FIG. 3 is a schematic representation of a position of a float relative to a concrete surface when being pushed forward on the concrete surface.

FIG. 4 is a schematic representation of a position of a float relative to the concrete surface when being pulled backward on the concrete surface.

FIG. 5 is a schematic representation of a position of a float relative to the concrete surface when being pulled backward on the concrete surface and having a ramp and cutting edge in contact with the concrete surface.

FIG. 6 is an isometric and broken view of a float for use with any of the inventions described herein having radiused ends, a channel cover, end caps, rail protectors, and beveled surfaces on the ends of the finishing surface of the float, any one or more of which can be included or excluded from a float.

FIG. 7 is a top plan view and detail of an end of the float of FIG. 6 with an end cap removed showing the radiused end of the float.

FIG. 8 is an end view of the float of FIG. 6 showing the extrusion and end profile of the float, namely with the end caps removed, the rail protectors removed and the channel cover removed.

FIG. 9 is a transverse cross-section of the float of FIG. 6, representative of any transverse cross-section along the longitudinal length of the float except for the end portions in the area of the radiused ends and bevels in the ends of the finishing surface, and without any of the channel cover removed that would otherwise be removed for accommodating means for helping to manipulate or control the float.

FIG. 10 is an end elevation view of the float of FIG. 6 illustrating differing portions of the end profiles as between the float end and the end cap.

FIG. 11 is a detailed rear elevation view taken from the left side of FIG. 10 illustrating one example of a differing end profile.

FIG. 12 is a detail of a bottom plan view of the end of the float of FIG. 6 showing a bevel end surface of the finishing surface.

FIG. 13 is a detail of a longitudinal cross section along the center line of the float showing an end cap having a lower rim structure covering the adjacent structure of the end of the float finishing surface.

FIG. 14 is a detail of a longitudinal cross section near the square edge of the float showing an end cap having a lower rim structure not covering the adjacent structure of the end of the float finishing surface and beginning to separate or space apart from the adjacent surface of the float .

DETAILED DESCRIPTION

This specification taken in conjunction with the drawings sets forth examples of apparatus and methods incorporating one or more aspects of the present inventions in such a manner that any person skilled in the art can make and use the inventions. The examples provide the best modes contemplated for carrying out the inventions, although it should be understood that various modifications can be accomplished within the parameters of the present inventions.

Examples of floats and of methods of using the floats are described. Depending on what feature or features are incorporated in a given structure or a given method, benefits can be achieved in the structure or the method. For example, floats having a sealing edge on a forward or distal portion of the float and an opening surface and a cutting surface on a trailing, proximal or back portion of the float can be used more efficiently and often more easily than existing floats using existing methods.

These and other benefits will become more apparent with consideration of the description of the examples herein. However, it should be understood that not all of the benefits or features discussed with respect to a particular example must be incorporated into a float, component or method in order to achieve one or more benefits contemplated by these examples. Additionally, it should be understood that features of the examples can be incorporated into a float, component or method to achieve some measure of a given benefit even though the benefit may not be optimal compared to other possible configurations. For example, one or more benefits might not be optimized for a given configuration in order to achieve cost reductions, efficiencies or for other reasons known to the person settling on a particular product configuration or method.

Examples of float configurations and of methods of making and using the floats are described herein, and some elements of the configurations have particular benefits in being used together. However, even though these apparatus and methods are considered together at this point, there is no requirement that they be combined, used together, or that one component or method be used with any other component or method, or combination. Additionally, it will be understood that a given component or method could be combined with other structures or methods not expressly discussed herein while still achieving desirable results.

As used herein, “substantially” and “approximately” shall mean the designated parameter or configuration, plus or minus 10%. However, it should be understood that terminology used for orientation or relative position, such as front, rear, side, left and right, upper and lower, and the like, may be used in the Detailed Description for ease of understanding and reference, and may not be used as exclusive terms for the structures being described and illustrated.

In an example of apparatus for finishing concrete (FIG. 1 ), a float assembly 100 includes a float 200 and a pivot assembly 300. The pivot assembly is an example of means for helping to manipulate or control the float. In the present example, the pivot assembly 200 is similar to those described in WO 2021/158,690, and includes gears (not shown in FIG. 1 ) for adjustably positioning the float at a desired angle relative to a concrete surface. The pivot assembly includes a handle adapter 302 for receiving and supporting a handle (not shown), and a selector 304 for adjusting the ease with which the handle can be used to position the float at the desired angle. In several examples of the apparatus and methods described herein, the handle adapter 302 extends approximately toward the user and over a proximal portion of the float 200, for example over a second portion of the float having a ramp and acute or square edge or cutting-edge, described more fully below. During use, the handle would extend to the user and over the proximal portion of the float 200 having the ramp and acute or square edge or cutting-edge. The pivot assembly engages an interface component 306, substantially the same as or similar to the adapters 500, 500A and other adapters described and illustrated in WO 2021/158,690. As used herein, “means for manipulating” and “means for helping to control” a float such as that described herein includes one or more of the interface component 306, adapters 500, 500A described in WO 2021/158,690 and other apparatus for mounting a pivot assembly on a concrete float, including fasteners such as nuts and bolts, wing bolts, and the like, clamps, releasable engagements, and other components for reliably mounting a pivot assembly on concrete floats, and also includes pivot assemblies for concrete floats, handles and handle mounts for concrete floats.

The float 200 (FIGS. 1-5) extends longitudinally, as illustrated in FIG. 1 , and has a side profile such as that illustrated in FIGS. 2-5. The profile of the float as illustrated is substantially the same along the entire length of the float, but in other configurations lateral end portions can be different such as changing thickness, forming a bevel surface, or other edge effects, for example in the last 1-10% of the float. In the illustrated example, the float profile will be described with respect to the appearance of a transverse crosssection with the understanding that the float profile will be the same for substantially all or all of the entire length of the float.

The float includes a finishing surface 202, in the present example extending from a first border or boundary portion 204 to a second border or boundary portion 206. The finishing surface may be substantially flat, for example as flat as extrusion processes allow, and in the present example is slightly convex as viewed when looking at the finishing surface, for example with a substantially constant radius of curvature. Alternatively, as described in the publication WO 2021/158,690, the finishing surface can be slightly concave as viewed from the side of the finishing surface.

The first and second border portions provide boundaries for the finishing surface. The first and second border portions provide finishing effects for helping to finish a concrete surface, for example cutting, opening and sealing all or portions of the concrete surface. The first border portion occupies little if any of the float surface parallel to the finishing surface 202, and in the present example a finishing side 208 occupies only enough of the float surface parallel to the finishing surface necessary to form a square edge 210. For example, the square edge 210 may include one or more millimeters of surface parallel to the finishing surface extending from the finishing surface to a corner 212 forming the square edge 210. The square edge is also formed by a normal or perpendicular surface 214 extending at a 90° angle upward and away from the finishing surface 202 to form a right angle for the square edge 210. In the present example, the perpendicular surface 214 extends upwardly approximately 0.2 inch (4.8 mm), or for example between 4 and 5 mm. Alternatively, the surface 214 can be other than precisely perpendicular. For example, the surface 214 can extend at an acute angle less than 90° relative to that portion of the finishing surface 202 adjacent the corner 212, or relative to the horizontal when the float is placed on the concrete surface.

The square edge 210 in the present float configuration forms a sealing edge for the float. As the float is being pulled back, toward the user or in a proximal direction, the finishing surface 202 can be placed flat against the concrete surface or at a slight positive angle, or lower at the sealing edge than for the rest of the finishing surface, as the float is being pulled back. The square edge 210 trailing the float forms a sealing edge for sealing the surface of the concrete as the float is being pulled back.

In the illustrated configuration, the first border portion also includes a convex wall 216 extending upward from the square edge 210 and forming a rail, described more fully below. The convex wall is convex from a middle portion of an upper surface 218 of the float, opposite the finishing surface 202. In the present example, the convex wall is formed from first and second straight walls 220 and 222 joined at an intermediate angular junction 224. Conversely, the wall 216 would appear concave from outside the float. The first wall 220 extends upwardly and inwardly toward an interior of the float, above the upper surface 218, and in the illustrated configuration is substantially straight. The second wall 222 extends upwardly and outwardly relative to the upper surface 218. The first and second walls help to contain concrete if the float is reversed and the first and second walls and the first border portion become the proximal portion of the float and leading edge relative to the user and if the user pulls back to move the float over the concrete surface.

The second border portion 206 of the float includes a substantially continuously arcuate surface (convex when viewed from the finishing surface) or a ramp 226 and a square edge 228. As illustrated, both the ramp and the square edge extend upwardly and away from the finishing surface 202. The ramp is an arcuate surface extending upwardly and away from the finishing surface 202 or out of the plane of the finishing surface, and can be considered to begin at the point 230 where the finishing surface ends, or is no longer flat and ends at the end of the curvature, or where a straight portion 232 begins. In another configuration, the curvature can extend to the square edge 228.

The square edge 228 may form little if any of the ramp surface, but in the present example the square edge includes the straight portion 232 extending to a corner 234 to form the square edge 228. The square edge 228 is also formed by a normal or perpendicular surface 236 extending at a 90° angle upward and away from the ramp surface and away from the finishing surface 202.

The square edge 228 forms a cutting surface on the float for cutting raised surface portions on the concrete surface. The cutting surface in the illustrated configuration is formed by the 90° angle to the ramp surface, and is used to cut the concrete when the ramp surface contacts the concrete surface sufficiently to allow the square edge 228 to cut into a raised portion of concrete on the concrete surface. Alternatively, a cutting edge may be formed from other than an exactly 90° or perpendicular surface so long as the desired cutting can be achieved, for example with an acute angle less than 90°, where the surfaces 232 and 236 form an acute angle less than 90°, or otherwise.

In the illustrated configuration, the finishing surface 202 forms substantially a planar surface extending axially and proximally and distally, or forward and backward from the centerline 250. The cutting edge 228 is positioned upwards or away from the plane of the finishing surface 202, or is raised from the surface of the concrete when the finishing surface is substantially flat on the concrete surface. This provides a cutting surface spaced apart from the concrete surface when the float is flat against the concrete surface and moved on the concrete surface with the cutting edge 228 leading. The user can finish the concrete surface without the cutting edge 228 in contact with the concrete surface, while still allowing the user to angle the float as desired to position the cutting edge to cut a portion of the concrete surface.

In the illustrated configuration, the ramp 226 extends from the end 230 where the finishing surface ends to the straight portion 232. The ramp includes an arcuate portion 238 extending outwardly and upwardly from the finishing surface to form a convex surface as viewed from the side of the finishing surface. In one example, the arcuate portion extends over an arc having a radius of curvature of between approximately 30 and approximately 45 mm, and in the illustrated example approximately 38 mm. Also as illustrated, the radius of curvature is substantially constant over the arc, but may be varied as desired, such as to form a suitable surface for opening the concrete surface as the float is moved over the concrete surface. In the present example, the arc of the ramp terminates at a substantially straight surface 232, extending upwardly and outwardly from the arcuate portion 238 to the straight portion 232.

The ramp 226 forms an opening surface portion for opening the surface of the concrete as the float is moved over the concrete surface. Additionally, the ramp forms a bearing surface for the float on the surface of the concrete as the float is being pulled backward to use the square edge 228 for cutting.

In the illustrated configuration, the second border portion also includes a convex wall 240 extending upward from the square edge 228. The convex wall is convex from a middle portion of an upper surface 218 of the float, opposite the finishing surface 202. In the present example, the convex wall is formed from first and second straight walls 242 and 244 joined at an intermediate angular junction 246. The wall 240 would appear concave from a side of the float outside of the upper surface 218. The first wall 242 extends upwardly and inwardly toward an interior of the float, above the upper surface 218, and in the illustrated configuration is substantially straight. The second wall 244 extends upwardly and outwardly relative to the upper surface 218. The first and second walls help to contain concrete cut from the concrete surface when the square edge 228 is pulled backward along the concrete surface.

Also in the illustrated configuration, the float is asymmetric about a longitudinally-extending vertical plane represented by the vertical line 250 (FIG. 2) through the float. In the present example, the vertical line 250 bisects an engagement structure 252 formed, attached or otherwise made part of the upper surface 218 of the float, wherein the engagement structure receives one or more elements of the means for manipulating the float. As illustrated, the finishing surface 202 of the float extends substantially symmetrically on each side of the plane 250, while the first border portion 204 includes the sealing structure and the second border portion 206 on the opposite side of the finishing surface includes the ramp 226 for opening the concrete surface and the cutting edge 228 for cutting raised portions of the concrete. Therefore, the float is asymmetric about the vertical plane 250. Also, the first and second border portions are asymmetric. The cutting edge 228 is raised significantly above the finishing surface 202 and is positioned adjacent the arcuate surface 238, which has a significantly smaller surface area than the finishing surface 202. Additionally, in the illustrated configuration, the float can be divided between upper and lower halves or upper and lower horizontal portions, and the lower half or lower horizontal portion is asymmetric about the vertical plane 250. Also in the illustrated configuration, the upper halves or upper horizontal portion are symmetrical relative to each other. Even though the lower portion is asymmetric, symmetric upper portions help to maintain the float as a balanced structure for the user, having a weight on one side of the vertical plane the same as or similar to the weight on the other side.

In other examples of apparatus for finishing concrete, the float assembly 100 can use other float configurations and other pivot assembly configurations. In an alternative float, a float assembly 500 (FIGS. 6-12) can have a float 502 (FIG. 8) that is identical to the float 200 except as described below. Specifically, the float 502 includes end portions 504 and 506 each of which have beveled surfaces 508 (FIGS. 8, 10 and 12) created or formed into the end surfaces. The beveled surfaces help to provide a smooth concrete surface under the end portions of the float 502 during operation.

The engagement structure 252 of the float (FIGS. 8-9) includes a channel 510. The channel extends substantially the entire length of the float, for example when the channel was generated by way of extrusion of the float. The channel can take any number of forms desired for suitable support of the means for controlling the float. In the present example, the channel is defined in part by first and second lips or shoulders 512 and 514 extending longitudinally with the channel and defining a longitudinal opening or entrance to the cavity defined by the channel 510. The first and second lips or shoulders 512 and 514 extend parallel to each other and their upper surfaces define a plane, and they terminate at oppositely-facing points.

The float assembly includes a channel cover 516 (FIG. 9). The channel cover covers all or part of the channel, as desired, and helps to reduce the possibility of concrete, debris or other foreign material from entering the channel or from intruding under the channel cover. The channel cover in the present example extends the entire length of the float except for any portion or portions desired for accommodating a pivot engagement structure or other means for helping to control or manipulate the float. The channel cover is formed so as to provide a reliable interference fit with the lips or shoulders 512 and 514 of the channel, and may include respective overlay structures 518 and 520 over the upper surfaces of the lips or shoulders 512 and 514. In the present example, the channel cover is held in place by longitudinally extending ribs 522 and 524 having outwardly facing surfaces forming grooves conforming to or engaging with the oppositely-facing points or convex surfaces on the lips or shoulders. The channel cover may be press fit into the channel or slid longitudinally along the top of the channel to the desired position.

The present float assembly 500, as well as the previously-described float 200 as well as other float configurations can include end covers or end caps. End covers can help to minimize concrete, debris or other foreign material from intruding from the float edges, or getting on the upper surface of the float. In the present example, end caps 530 and 532 (FIG. 6) are included in the float assembly. The end caps can take a number of configurations, and in the present example extends around the end portions of the float from an end or termination 534 of a first rail 535 having the square edge portion 210 to the end or termination 536 of a second rail 537 having the ramp portion 226 (FIGS. 7 and 8). In the illustrated configurations, each end cap starts and ends at the respective ends of the respective rails 535 and 537, for example to have continuity of walls encircling or enclosing the area of the upper surface of the float. Each end cap follows the radiused curvature of the respective end portion of the float 502 (or a straight wall if the float has straight end walls as in 200), and includes a substantially vertical wall portion 540 when viewed in end elevation view (FIGS. 6 and 10) and an upper sloping wall portion 542. In the present example, the upper sloping wall portion terminates at a top portion 544 extending at approximately the same level as the tops of the rails at the tops of the upper walls 222 and 244.

The end caps are reliably supported on the ends of the float so that they remain in place during normal use, and in a way so as to minimize intrusion of concrete, water or other material from the float edges. In the present examples, the end caps are interference fit or pressure fit onto the end surfaces of the float, for example so as to have a desirable seal around the boundary between the end caps and the respective adjacent float surfaces. The end caps are molded, printed or otherwise formed from a suitable plastic or other material to have the desired configuration.

The float ends and the adjacent end cap surfaces have different profiles between the ends or termination points 534 and 536, but in the present examples, a concrete finishing surface at a float end and the adjacent end cap surface have portions where their profiles are the same or substantially the same. In the present examples, central portions of the profiles are the same or substantially the same, while end portions of the profiles are different. In the illustrated example, a central portion of the profile of the concrete finishing surface of the end of the float, between point 546 and point 548 (FIG. 10), and the profile of the adjacent surface of the end cap are the same or substantially the same, and the profile of the adjacent surface of the end cap follows the profile of the concrete finishing surface of the central portion of the end of the float. Because the present end caps are substantially identical, only one will be described herein. Outward of the central portion of the end of the float, the finishing surface profile of the end of the float and the profile of the closest adjacent surface of the end cap are different, and in the present examples, opposite end portions of an end cap are both different in profile relative to the respective adjacent surface profiles of the end of the float. In the present examples, because the floats are asymmetric along a longitudinal centerline with respect to the longitudinal edge portions, the profile differences between the portions of the float edge portions and the respective end cap profiles are not identical. However, both of the end cap profiles corresponding to the float end portions are different from the profiles of the corresponding portions of the float finishing surface.

The surface profile of the illustrated end cap that is described herein relative to the adjacent surface of the concrete finishing surface of the float is the lower-most, downward facing portion of the end cap. As illustrated in FIGS. 13-14, an outwardly-facing portion 550 of the end of the float, for example facing to the left as viewed in those figures, is covered by the adjacent portion of the end cap, and the lower-most surface 552 of the end cap adjacent the concrete finishing surface at the end of the float are flush with each other or coincident. The adjacent portions of the lower-most surface of the end cap and the concrete finishing surface between the points 546 and 548 are flush with each other and coincident, and that portion of the end cap covers the outwardly facing surface 550 of the end of the float. That relationship extends between the points 546 and 548. In the region between the points 546 and 548, the downwardly-facing surface 552 of the end cap is an outward extension of the adjacent concrete finishing surface. Outside of the region between the points 546 and 548, the downwardly-facing surface of the end cap covers less and less of the outwardly-facing surface 550. Therefore, outside of the region between the points 546 and 548, the profile of the end cap is different from the profile of the most closely adjacent concrete finishing surface on the end of the float. In other words, between the endpoint 546 and the end of the rail 535, the profiles are different. Additionally, between the endpoint 548 and the end of the rail 537, the profiles are different. Alternatively, one of the regions outside the endpoints 546 and 548 can have their profiles different, and the profiles of the other region can be the same, as desired. In the illustrated configuration, over 50% of the perimeter of the end cap between the rails 535 and 537 has the same profile as the adjacent finishing surface, for example because the lower surface of the end cap is flush with the adjacent surface of the bevel surface 508. In other words, less than 50% of the perimeter of the end cap between the rails has a different profile than the adjacent finishing surface.

The profiles between the end cap and the finishing surface can be shown as being the same or different using tangents to the respective surfaces. If appropriate tangents are substantially the same in a selected area or region, the profiles in that selected area are substantially the same, whereas profiles in a selected area may be different if appropriate tangents are different. Viewing the end of the float assembly from a generally end view can indicate the similarity or dissimilarity of the profiles. For example, viewing the combined float and end cap toward the end of the float assembly in a direction parallel to a concrete surface on which the float would be resting, for example surface 400 in FIG. 4, tangents can be evaluated by taking a viewing direction 560 normal to an edge of the float forming the finishing surface (FIG. 9). Each viewing direction 560, 562 and 564 is taken normal to the outwardly- facing edge of the float, to accommodate any possible curvature such as the radiused edge as viewed in plan view in FIG. 7. The term “normal” in the present context is taken to be normal to the edge of the float when viewed in plan view in FIG. 7, even if the end surface 550 (FIG. 13) is not precisely vertical as viewed in FIG. 13. To select a tangent, a point is selected at the finishing surface for the selected viewing direction. For example, a point 566 (FIG. 10) is selected as the point of intersection between the normal line 562 and the finishing surface, and the tangent to that point is taken, represented at 568. To determine a tangent for the adjacent surface of the end cap, a vertical line 570 intersecting the point 566 is taken to select an adjacent point on the end cap. The vertical line 570 is substantially normal to a concrete surface on which the float can rest. A point 572 is selected on an adjacent surface of the end cap for determining a tangent. The point 572 may or may not be on the vertical line 570, but the point 572 is selected based on a projection of the line 570 as viewed in the normal direction 562 to intersect the adjacent surface of the end cap. For example, if the closest end cap surface is recessed inward from the surface 550, or extends outwardly of the surface 550, the selected point 572 would not be on the vertical line 570, but a projection of the vertical line 570 would intersect the selected point 572, such as a plane containing the vertical line 570 and the normal line 562. Using the selected point 572, a tangent line 574 (FIG. 10) can be generated representing a portion of a profile for the end cap as viewed from the normal direction 562. Because the points 566 and 572 are essentially next to each other, and the surface of the end cap and the adjacent surface of the concrete finishing surface are substantially flush, the tangent lines 568 and 574 are substantially parallel, are not spaced apart, do not intersect, and would not form an angle. Many points on projections of vertical lines such as 570 will produce tangent lines that are parallel to each other, which means the profiles corresponding to such tangent lines are substantially the same. For example, the tangent lines and therefore the profile portions of the float end and the end cap are substantially the same between the points 546 and 548.

Considering the viewing direction 560, a point 576 is selected on a vertical line 578 for a tangent line 580 (FIG. 10). Projecting the vertical line 578 onto the end cap along the viewing direction 560, a point 582 is selected for the tangent for the adjacent surface of the end cap. The point 582 is selected based on the closest surface portion of the end cap to the corresponding point 576 on the vertical line 578, which in the present case may be on an at least partially downwardly-facing surface on the end cap. In the present example, the point 582 may be selected to be on an interior edge portion of the end cap similar to point 572 (FIG. 13), or other points on the surface 552, based on which ever portion of the end cap is closest to the point 576 on the finishing surface and on the projection of the vertical line 578. Using the selected point 582, a tangent line 584 can be generated representing a portion of the profile of the end cap as viewed from the normal direction 560. The tangent lines 580 and 584 are not parallel, are spaced apart, and in a two-dimensional projection of the two tangent lines, the tangent lines would intersect and form an angle with respect to each other. It is noted that if the end cap surface was recessed inward from the end surface of the float, as viewed in plan view in FIG. 7, the tangent lines may not intersect in three dimensions, but when projected onto a two-dimensional plane such as that represented in FIG. 10, they would intersect and form an angle with respect to each other. Therefore, the portions of the float profile and the end cap profile in the area of the points 576 and 582 are not the same, and similarly tangent lines representing the profiles in each direction from the respective points 576 and 582 would also be different. The end cap profile diverges away from the point 546 and continues diverging away from the point 546 beyond the point 582 at the vertical line 578. Therefore, the end cap profile from the end of the end cap to the point approximately at 546 is different from the corresponding profile for the float, and therefore the end cap profile is different from the float profile for the end of the finishing surface.

Similar comments apply for the other portion of the end of the float, corresponding to the ramp 226, and the adjacent end portion of the end cap. A vertical line 586 contains a point 588 on the finishing surface and can be used to select a point 590 on the closest-most lower-facing surface on the end cap. The finishing surface tangent line 592 and the end cap tangent line 594 are nonparallel, and their projection on a two-dimensional plane have them intersect to form an angle with respect to each other. Therefore, the portions of the float profile and the end cap profile in the area of the points 588 and 590 are not the same, and similarly tangent lines representing the profiles in each direction from the respective points 588 and 590 would also be different. The end cap profile diverges away from the point 548 beyond the point 548 and continues diverging beyond the point 590 on the projection of the vertical line 586. Therefore, the end cap profile from the end of the end cap to the point 548 is different from the corresponding profile for the finishing surface, and therefore the profile for the end cap is different from the profile for the finishing surface. Profiles of the end cap portions near the ends of the end caps reduce the possibility that the concrete surface is marred by surfaces on the end caps as the float is moved.

As with the float 200, end caps for the float 500 are optional and may be omitted.

Other exposed perimeter edges of the float can be protected or covered with added materials, with or without the presence of end caps. However, protection by the end caps can be supplemented with protection of other perimeter edges of the float. In one example, the edge rails 535 and 537 (FIGS. 7 and 9) that extend longitudinally from one end of the float to the other end of the float may include rail protectors 600 and 602, respectively. Though they can be different, each rail protector is an identical mirror image of the other, and only one rail protector will be described further. The rail protector 600 includes an internal surface 604 that preferably conforms to the outer profile of the edge rails 535 on which it is placed. The outer surface of the protector can take any number of configurations. The rail protector 600 is formed as a channel, which in the illustrated configuration includes in cross section free end surfaces that are tapered, to reduce the size of the transition from the surface of the rail protector to the adjacent surface of the rail.

The rail protector forms as close a fit as possible to the rail edge. In one configuration, the rail protector is applied with an interference fit, and optionally may include an additional securement material such as adhesive or the like, for example on the interior surface of the rail, to securely cover the surface. The rail protector can be extruded from a suitable material and securely applied to the rail edge so that it can withstand normal use and cleaning on a construction site, including contact with or intrusion by water, wet concrete, impact from tools and the like, and pressure washing. Each rail protector can be formed as a single piece or combined from multiple pieces. Multiple pieces can be installed discreetly or they may be bonded, glued, adhered, welded or otherwise fixed together on the rail edge. End portions of the rail protector can also be formed integral with an end cap, or the rail protector can be bonded, glued, adhered or welded or otherwise secured to an end cap, to form a continuous protection against intrusion of material from the edges of the float.

In use, the float assembly 100, with a float 200 or 500, is placed on a concrete surface, for example concrete surface 400 (FIGS. 3-4), and the handle (not shown) is turned to increase the outbound angle of the float 200, 500 a desired amount. The description of the use of the float assembly 100 applies equally to the use of a float assembly including the float 500. The float is pushed in the direction of the arrow 402 over the concrete surface as far as the assembly can reach. At the end of the span or track over the concrete surface, the handle is turned to flatten the float so that the finishing surface 202 contacts the concrete surface, as illustrated schematically in FIG. 4. The float is illustrated in FIGS. 3-5 slightly raised from the concrete surface for clarity, but it is understood that a substantial portion of the finishing surface 202 of the float would rest on and contact the surface of the concrete in the orientation shown in FIG. 4, and the relevant parts would contact the concrete surface in the orientations shown in FIGS. 3 and 5. As the float is pulled back in the direction of arrow 404, the sealing portion formed by the first boundary portion 204 of the float helps to seal the concrete surface while the finishing surface 202 smooths the concrete surface. At any portion of the concrete surface that might be raised, the handle of the float assembly can be turned to increase the angle of the float relative to the concrete surface at or during the pullback, for example as illustrated in FIG. 5. The float angle can be increased to a desired angle, and as illustrated in FIG. 5, the float angle is increased until the straight surface portion 238 rests on the surface 406 of the concrete, and the cutting edge 228 can contact the concrete surface. As the float assemblies pulled back with the cutting edge 228 against the concrete surface, the float can cut a raised portion 408 to smooth the surface.

Additional concrete can rise up the first wall 242 and possibly the second wall 244, and be pulled along the concrete with the float 200. Additional concrete can also be left in any cavity or low portion in the concrete surface such as illustrated at 410.

The sequence of steps using the float assembly 100 to finish the concrete surface includes pushing the float 200 outward as illustrated in FIG.

3 and back as illustrated in FIG. 4. The out and back movement of the float can occur a number of times until the desired finish or texture is produced in the surface of the concrete. At any time in the pullback, the float angle can be increased to a desired angle greater than zero relative to the concrete surface, as illustrated in FIG. 5, and the ramp 226 and/or the cutting edge 228 can finish the adjacent portion of the concrete surface as desired. The increased float angle can be used to cut concrete from raised portions of the surface, or to deposit excess concrete in a low spot such as 410.

Having thus described several exemplary implementations, it will be apparent that various alterations and modifications can be made without departing from the concepts discussed herein. Such alterations and modifications, though not expressly described above, are nonetheless intended and implied to be within the spirit and scope of the inventions. Accordingly, the foregoing description is intended to be illustrative only.