WO2014015375A1

WO2014015375A1 - Collapsible void former

Info

Publication number: WO2014015375A1
Application number: PCT/AU2013/000820
Authority: WO
Inventors: Phillip Graham Calow
Original assignee: Novaplas Pty Ltd
Priority date: 2012-07-23
Filing date: 2013-07-23
Publication date: 2014-01-30

Abstract

A void former (10) for formation of a void within material, such as for example settable material such as concrete. The void former (10) comprises a body (11) typically formed of plastics material. The body (11) is movable from a collapsed condition to an assembled condition in which defines a hollow spherical body for use in formation of a void. More particularly, the body (11) comprises two portions (13, 15) hingedly interconnected by hinge (17) for pivotal movement between the collapsed and assembled conditions. When the body (11) is in the collapsed condition, the two portions (13, 15) are disposed on opposed sides of the hinge (17). A retaining means (41) is provided for the retaining the two portions (13, 15) in the assembled condition. The void former (10) is configured so that identical void formers can nest in the collapsed condition one within another in a stack. The nesting arrangement facilitates stacking of the identical void formers (10) in a compact arrangement, thereby affording a space reduction when storing and transporting the void formers.

Description

Collapsible Void Former

TECHNICAL FIELD

[0001] The present invention relates to a void former for formation of a void within material, such as for example settable material such as concrete.

[0002] The invention is particularly applicable to void formers for use in the production of reinforced concrete slabs to create voids in the central region of the concrete slabs where there is no need for the volume of concrete that is mainly required at the outer faces of a slab.

[0003] The invention also relat es to production of concrete elements, including concrete slabs and other concrete structures, and concrete components of structures.

[0004] The invention also relates to a method of production of concrete elements.

[0005] The invention may, however, have application to formation of voids in other materials.

BACKGROUND ART

[0006] The following discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application.

[0007] The invention has been devised particularly as a void former for formation of voids in poured concrete during the production of concrete slabs. Accordingly, the invention will now be discussed in relation to such an application.

[0008] Typically, voids have been created in concrete slabs by casting in foamed plastic or blow moulded spheres or other essentially cubic void forming shapes.

[0009] One commonly used void former is a blow moulded sphere which is a one piece hollow sphere with irregular wall thickness due to the moulding process.

[0010] Another known void former is produced from foamed plastic to any shape (whether spherical or otherwise cubic) and is solid throughout. [0011] All of the above-mentioned void formers being of considerable volume present logistics and storage problems.

[0012] It is against this background that the present invention has been developed.

[0013] It is an object of the present invention to overcome, or at least ameliorate one or more of the deficiencies of the prior art mentioned above, and or to provide the customer with advantages and a commercial choice.

SUMMARY OF INVENTION

[0014] According to a first aspect of the invention there is provided a void former comprising at least a first portion and a second portion coupled one to another for selective movement from a collapsible condition into an assembled condition, wherein in the collapsed condition the at least first and second portions define a compact arrangement for transportation and storage and wherein in the assembled condition the at least first and second portions cooperate to define a hollow body.

[0015] With this arrangement, the void former can be considered to have collapsed and assembled conditions corresponding to the collapsed and assembled conditions of the at least a first portion and a second portion,

[0016] Preferably, the at least first and second portions comprise two portions coupled together.

[0017] Preferably, the hollow body is configured as a sphere. In this arrangement, the two portions are each configured as a hemispherical portion.

[0018] Preferably, the coupling comprises a hinged connection. Specifically, the at least first and second portions are hingedly connected one to another for pivotal movement from the collapsed condition to the assembled conditioned. Where the at least first and second portions comprise two portions, the latter are hingedly connected.

[0019] Preferably, the void former further comprises a retaining means for retaining the at least first and second portions in the assembled condition.

[0020] Preferably, the at least first and second portions are each provided with an abutment section, whereby the abutment section on one portion is adapted to abut with a counterpart abutment section on another portion when in the assembled condition. [0021] Preferably, engagement between the abutment sections establishes a seal to prevent, or at least inhibit, ingress of material (such as, for example, concrete) into the hollow interior of the sphere.

[0022] Preferably, the abutment sections are configured to present a relatively smooth exterior transition between the first and second portions when in the assembled condition. Such an arrangement is advantageous, as a relatively smooth transition between the first and second portions when in the assembled condition may assist in avoiding the creation of stress raisers in the material in which the assembled void former is used. The presence of stress raisers attributable to the presence of the void former is undesirable as they can lead to crack propagation within the material.

[0023] Where the at least first and second portions comprise two portions, the two abutment sections are adapted to abut when the two portions are in the assembled condition.

[0024] The abutment sections may be configured for mating engagement. In an embodiment of the invention, one abutment section may be configured as a male section and the other abutment section may be configured as a corresponding female section. The male section may comprise a rib and the female section may comprise a channel, wherein the rib is receivable within the channel when the abutments sections are in mating engagement.

[0025] When configured for mating engagement, the abutment sections may contribute to the structural rigidity of the assembled void former by providing a physical interconnection between the two portions in the assembled condition to inhibit sideways displacement therebetween.

[0026] Preferably, the retaining means is associated with the abutments sections.

[0027] The retaining means may comprise one or more tab locks each comprising a locking tab adapted to be received in a mating locking aperture for locking engagement therewith.

[0028] Preferably, the one or more tab locks are incorporated in the abutment sections. [0029] It is a particular feature of the hinged coupling between the two portions that it maintains alignment between the two portions as they are moved into the assembled condition for engagement of the retaining means.

[0030] When configured for mating engagement, the abutment sections may also assist in guiding the first and second potions into position to assume the assembled condition.

[0031] Preferably the two portions are of the same configuration, apart from the counterpart abutment sections when configured for mating engagement.

[0032] Where the at least first and second portions comprise two portions, the two portions are hingedly connected together by a hinge between the abutment flanges.

[0033] Preferably, the two portions when in the collapsed condition are disposed on opposed sides of the hinge with the abutment sections in a common plane.

[0034] Preferably, the void former is configured so that identical void formers can nest one within another in a stack when the at least first and second portions are in the collapsed condition. This provides a compact arrangement.

[0035] Where the at least first and second portions comprise two portions, the two portions are hingedly connected together by a hinge disposed between the abutment flanges.

[0036] Preferably, the void former is of one-piece construction; that is, the at least first and second portions are integrally connected together for as a unit when in either the collapsed or assembled condition.

[0037] Preferably, the void former comprises a body of plastics material, the body defining the at least first and second portions are integrally connected together.

[0038] According to a second aspect of the invention there is provided a void former comprising a body of plastics material, the body comprising two portions hingedy connected together for selective movement from a collapsible condition into an assembled condition, and retaining means for retaining the two portions in the assembled condition, wherein in the collapsed condition the portions define a compact arrangement for transportation and storage and wherein in the assembled condition the cooperate to define a hollow body. [0039] According to a third aspect of the invention there is provided a concrete structure comprising a body of concrete and a plurality of void formers within the body of concrete, the void formers being in accordance with the first or second aspect of the invention.

[0040] The concrete structure may be of any appropriate form; for example, a concrete slab, a concrete element such as a bridging span, or a concrete beam. The concrete structure may be pre-fabricated or poured on site.

[0041] According to a fourth a aspect of the invention there is a method of forming a concrete structure using void formers according to the first or second aspect of the invention.

[0042] According to a fifth aspect of the invention there is a method of forming a concrete structure using void formers according to the first or second aspect of the invention, the method comprising transporting the void formers to a site of intended use with the at least first and second portions being in the collapsed condition, moving the first and second portions into the assembled condition to define a plurality of hollow bodies, placing the hollow bodies in position, and pouring concrete whereby the hollow bodies displace some of the poured concrete to form voids in the poured concrete.

[0043] According to a sixth aspect of the invention there is a method of forming a concrete structure using void formers according to the second aspect of the invention, the method comprising transporting the void formers to a site of intended use with the portions being in the collapsed condition, moving the portions into the assembled condition to define a plurality of hollow bodies, placing the hollow bodies in position, and pouring concrete whereby the hollow bodies displace some of the poured concrete to form voids in the poured concrete.

[0044] According to a seventh aspect of the invention there is a method of forming a concrete structure using at least one collapsible void former having a collapsed condition defining a compact arrangement for transportation and storage and an assembled condition defining a hollow body, the method comprising transporting the void former to a site of intended use in the collapsed condition, moving the void former into the assembled condition to define a hollow body, placing the hollow body in position, and pouring concrete whereby the hollow body displace some of the poured concrete to form a void in the poured concrete. [0045] According to an eighth aspect of the invention there is a method of forming a concrete structure using a plurality of collapsible void formers each having a collapsed condition defining a compact arrangement for transportation and storage and an assembled condition defining a hollow body, the method comprising transporting the void formers to a site of intended use in the collapsed condition, moving the void formers into assembled conditions to define a plurality of hollow bodies, placing the hollow bodies in position, and pouring concrete whereby the hollow bodies displace some of the poured concrete to form voids in the poured concrete.

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Further features of the present invention are more fully described in the following description one non-limiting embodiment thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

Figure 1 is a schematic perspective view of the embodiment of the void former according to the invention, the void former being shown in an assembled condition;

Figure 2 is a schematic perspective view from above of the void former in a collapsed condition;

Figure 3 is a schematic perspective view from below of the void former in the condition shown in Figure 2;

Figure 4 is a perspective view of the void former moving from the collapsed condition towards the assembled condition;

Figure 5 is a plan view of the void former in the collapsed condition;

Figure 6 is a side view of the void former in the collapsed condition

Figure 7 is an end view the void former in the collapsed condition;

Figure 8 is a fragmentary view of the void former moving from the collapsed condition towards the assembled condition; Figure 9 is a section on line 9-9 of Figure 8 illustrating in particular abutment sections of the void former configured for mating engagement;

Figure 10 is a section on line 10-10 of Figure 8 illustrating in particular a tab lock associated with the abutments sections; and

Figure 11 is a schematic view of a plurality of identical void formers nested one within another to assume a compact arrangement.

[0047] In the drawings like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention.

DESCRIPTION OF EMBODIMENTS

[0048] Referring to the drawings, there is shown a void former 10 comprising a body 1 formed of plastics material such as, for example, a recycled polyolefin (such as polyethylene or polypropylene). Other suitable materials, plastics or otherwise, can of course be used to form the body 11. - ^'

[0049] As will be explained in detail later, the body 11 is movable from a first collapsed condition (as shown in Figures 2, 3, and 5, 6 and 7) to an assembled condition (as shown in Figure 1 ). In the assembled condition, the void former 10 defines a hollow body 12 for use in formation of a void in poured concrete. In the arrangement illustrated, the hollow body 12 is configured as a sphere.

[0050] The body 11 comprises two portions 13, 15 coupled together. In the arrangement shown, the two portions 13, 15 are hingedly connected by hinge 17 for pivotal movement between two conditions corresponding to the collapsed and assembled conditions of the body 11.

[0051] Each portion 13, 15 comprises a central section 21 of hollow construction and a peripheral abutment section 23. The central section 21 comprises a wall 25 of domed configuration defining an open interior 27. In the arrangement illustrated the domed configuration of the wall 25 is hemi-spherical to correspond with the spherical configuration of the body 1 , as will become more apparent later. The wall 25 has a perimeter edge 28 which defines an opening 29 communicating with the open interior 27. The peripheral abutment section 23 is integral with, and extends around, the perimeter edge 28.

[0052] Trie hinge 17 extends between the peripheral abutment sections 23 of the two portions 13, 15.

[0053] When the body 11 is in the collapsed condition, the two portions 13, 15 are disposed on opposed sides of the hinge 17 with the abutment sections 23 in a common plane, as best seen in Figures 5 and 6.

[0054] When the body is in the assembled condition, the two portions 13, 15 are together, with their respective abutment sections 23 in abutting engagement, as will be described in more detail later and as shown in Figure . With this arrangement, the two portions 13, 15 cooperate to define a void-forming sphere which is hollow and which has a closed interior. The engagement between the abutment sections 23 establishes a seal to prevent, or at least inhibit, ingress of concrete into the hollow interior of the sphere.

[0055] In this embodiment, the abutment sections 23 are configured to present a relatively smooth exterior transition between two portions 13, 15 when in the assembled condition. Such an arrangement is advantageous, as a relatively smooth exterior transition between two portions 13, 15 when in the assembled condition may assist in avoiding the creation of stress raisers in concrete in which the assembled void former is used. The presence of stress raisers attributable to the presence of the void former is undesirable as they can lead to crack propagation within the concrete.

[0056] The abutment sections 23 are configured for mating engagement. In the arrangement illustrated, one abutment section 23a is configured as a male section 32 and the other abutment section 23b is configured as a corresponding female section 33. The male section 32 comprise a rib 35 and the female section 33 comprise a channel 37, wherein the rib 35 is receivable within the channel 37 when the abutments sections 23 are in mating engagement.

[0057] With this arrangement, the abutment sections 23 contribute to the structural rigidity of the assembled void former 10 by providing a physical interconnection between the two portions 13, 15 in the assembled condition to inhibit sideways displacement therebetween. Further, engagement between the rib 35 and the channel 37 contributes to establishment of the seal to prevent, or at least inhibit, ingress of concrete into the hollow interior of the sphere.

[0058] In the arrangement shown, the rib 35 and the channel 37 do not extend entirely around the perimeter edge 28 of the respective wall 25. Specifically, there is a portion 38 of abutment section 23a at which there is no rib 35, and a portion 39 of abutment section 23b at which there is no channel. The two portions 38, 39 are adjacent the hinge 17. With this arrangement, the portions 38, 39 of the abutment sections 23a, 23b merely abut in face-to-face engagement without any interconnection. The end sections 35a of the rib 35 adjacent the portion 38 of abutment section 23a are tapered or otherwise configured to provide a smooth transition to the portion 38, as shown in Figure 6. This configuration may assist in facilitating a smooth and guided entry of the rib 35 into the channel 37 as the two portions 13, 15 are pivoted towards each other to assume the assembled condition.

[0059] A retaining means 41 is provided for the retaining the two portions 13, 15 in the assembled condition. The retaining means 41 may take any suitable form. In the arrangement shown, the retaining means 41 is associated with the abutments sections 23. More particularly, the retaining means 41 comprises a plurality of tab locks 43 associated with the abutments sections 23. Each tab lock 43 comprises a locking tab 45 and a mating locking aperture 47, the arrangement being that the locking tab 45 is adapted to be received in the mating locking aperture 47 for locking engagement therewith in the manner of a click-lock connection. The locking tabs 45 are disposed at spaced locations on the rib 35 and the mating locking apertures 47 are associated with the channel 37 (as best seen in Figure 10), whereby the locking tabs 45 are adapted to engage in the locking apertures upon insertion of the rib 35 into the channel 37.

[0060] The void former 10 is configured so that identical void formers can nest one within another in a stack 50 when the two portions 13, 15 of each void former are in their respective collapsed conditions, as shown in Figure 11. In the nesting arrangement, the central sections 21 of one void former 10 receive the counterpart central sections 21 of the identical void former 10 immediately above it in the stack 50 through the openings 29 therein. In other words, the void formers 10 are stacked with the central sections 21 one partly inside another. [0061] The nesting arrangement facilitates stacking of the identical void formers in a compact arrangement (as depicted in Figure 11), thereby affording a space reduction when storing and transporting the void formers.

[0062] The identical void formers 10 are stored and transported in a nested arrangement. When required for use, the void formers 10 delivered to the site of intended use and each is assembled into the void forming sphere as shown in Figure 1. In assembling each void former 10, an operator simply folds the two portions 13, 15 about hinge 17 from the collapsed condition into the assembled condition. As the two portions 13, 15 approach the assembled condition, the various locking tabs 45 engage their respective mating locking apertures 47 to clip the two portions together in the assembled condition.

[0063] It is a particular feature of 'the hinged coupling between the two portions 13, 15 that the latter remain together and thereby can be handled as a unit in the collapsed condition. Further, the hinged coupling serves to maintain alignment between the two portions 13, 15 as they are moved into the assembled condition, thereby ensuring that the various locking tab 45 and mating locking aperture 47 are guided into registration with each other.

[0064] The assembled void formers 10 can then be used in the normal way in the production of a concrete slab. This typically involves placement of an array of the assembled void formers 10 between reinforcement layers (typically reinforcement mesh of known kind) and then pouring of concrete to produce the reinforced concrete slab. The void formers 10 serve to displace poured concrete and establish voids with the concrete.

[0065] From the foregoing, it is evident that the present invention provides a simple yet highly effective way of providing a void former which can cooperate with identical void formers to afford space reduction for storage and transportation.

[0066] It should be appreciated that the scope of the invention is not limited to the scope of the embodiment described.

[0067] While the present invention has been described in terms of a preferred embodiment in order to facilitate better understanding of the invention, it should be appreciated that various modifications can be made without departing from the principles of the invention. Therefore, the invention should be understood to include all such modifications within its scope.

[0068] Reference to positional descriptions, such as "upper", "lower", "top" and "bottom", are to be taken in context of the embodiments depicted in the drawings, and are not to be taken as limiting the invention to the literal interpretation of the term but rather as would be understood by the skilled addressee.

[0069] Throughout this specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

Claims

1. A void former comprising at least a first portion and a second portion coupled one to another for selective movement from a collapsible condition into an assembled condition, wherein ih the collapsed condition the at least first and second portions define a compact arrangement for transportation and storage and wherein in the assembled condition the at least first and second portions cooperate to define a hollow body.

2. The void former according to claim 1 wherein the at least first and second portions comprise two portions coupled together.

3. The void former according to claim 1 or 2 wherein the hollow body is configured as a sphere.

4. The void former according to claim 2 or 3 wherein the two portions are each configured as a hemispherical portion.

5. The void former according to any one of the preceding claims wherein the first portion and a second portion are hingedly coupled one to another.

6. The void former according to any one of claims 2 to 4 wherein the at least first and second portions are hingedly connected one to another for pivotal movement from the collapsed condition to the assembled conditioned.

7. The void former according to claim 6 wherein the at least first and second portions comprise two portions and wherein the two portions are hingedly connected together.

8. The void former according to any one of the preceding claims further comprising a retaining means for retaining the at least first and second portions in the assembled condition.

9. The void former according to any one of the preceding claims wherein the at least first and second portions are each provided with a abutment section, whereby the abutment section on one portion is adapted to abut with a counterpoint abutment section on another portion when the portions are in the assembled condition.

10. The void former according to any one of claims 1 to 8 wherein the at least first and second portions comprise two portions and wherein each portion is provided with an abutment section, the two abutment sections being adapted to abut when the two portions are in the assembled condition.

11. The void former according to claim 10 wherein engagement between the abutment sections establishes a seal to prevent, or at least inhibit, ingress of material.

12. The void former according to claim 10 or 11 wherein the abutment sections are configured to present a relatively smooth exterior transition between the first and second portions when in the assembled condition.

13. The void former according to any one of the preceding claims wherein the abutment sections are configured for mating engagement.

14. The void former according to claim 3 wherein one abutment section is configured as a male section and the other abutment section is configured as a corresponding female section.

15. The void former according to claim 14 wherein the male section comprises a rib and the female section comprises a channel, wherein the rib is receivable within the channel when the abutments sections are in mating engagement.

16. The void former according to any one of claims 8 to 15 wherein the retaining means is associated with the abutments sections.

17. The void former according to any one of claims 8 to 16 wherein the retaining means comprises one or more tab locks each comprising a locking tab adapted to be received in a mating locking aperture for locking engagement therewith.

18. The void former according to claim 17 wherein the one or more tab locks are incorporated in the abutment sections.

19. The void former according to any one of claims 10 to 18 wherein the two portions are hingedly connected together by a hinge between the abutment sections.

20. The void former according to claim 19 wherein two portions when in the collapsed condition are disposed on opposed sides of the hinge with the abutment sections in a common plane.

21. The void former according to any one of the preceding claims wherein the void former is configured so that identical void formers can nest one within another in a stack when the at least first and second portions are in the collapsed condition.

22. The void former according to any one of the preceding claims wherein the at least first and second portions are integrally connected together for as a unit.

23. The void former according to any one of the preceding claims comprising a body of plastics material, the body defining the at least first and second portions are integrally connected together.

24. A void former comprising a body of plastics material, the body comprising two portions hingedly connected together for selective movement from a collapsible condition into an assembled condition, and retaining means for retaining the two portions in the assembled condition, wherein in the collapsed condition the portions define a compact arrangement for transportation and storage and wherein in the assembled condition the cooperate to define a hollow body.

25. A concrete structure comprising a body of concrete and a plurality of void formers within the body of concrete, each void former being in accordance with any one of the preceding claims.

26. A method of forming a concrete structure using void formers according to any one of claims 1 to 24.

27. A method of forming a concrete structure using void formers according to any one of claims 1 to 24, the method comprising transporting the void formers to a site of intended use with the at least first and second portions being in the collapsed condition, moving the first and second portions into the assembled condition to define a plurality of hollow bodies, placing the hollow bodies in position, and pouring the concrete whereby the hollow bodies displace some of the poured concrete to form voids in the poured concrete.

28. A method of forming a concrete structure using void formers according to the claim 24, the method comprising transporting the void formers to a site of intended use with the portions being in the collapsed condition, moving the portions into the assembled condition to define a plurality of hollow bodies, placing the hollow bodies in position, and pouring the concrete whereby the hollow bodies displace some of the poured concrete to form voids in the poured concrete.

29. A method of forming a concrete structure using at least one collapsible void former having a collapsed condition defining a compact arrangement for transportation and storage and an assembled condition defining a hollow body, the method comprising transporting the void former to a site of intended use in the collapsed condition, moving the void former into the assembled condition to define a hollow body, placing the hollow body in position, and pouring concrete whereby the hollow body displace some of the poured concrete to form a void in the poured concrete.

30. A method of forming a concrete structure using a plurality of collapsible void formers each having a collapsed condition defining a compact arrangement for transportation and storage and an assembled condition defining a hollow body, the method comprising transporting the void formers to a site of intended use in the collapsed condition, moving the void formers into assembled conditions to define a plurality of hollow bodies, placing the hollow bodies in position, and pouring concrete whereby the hollow bodies displace some of the poured concrete to form voids in the poured concrete.