WAFFLE POD SPACING METHOD AND APPARATUS IN A CONCRETE SLAB

Cross-Reference to Related Applications

The present application claims priority from Australian Provisional Patent Application No 2007904835 filed on 5 September 2007, the content of which is incorporated herein by reference.

Introduction to the Invention

This invention relates to waffle pod technology and in particular, to the use of expanded polystyrene foam (EPS) waffle pods and methodologies and apparatus for connecting and spacing adjacent pods into a waffle pod matrix.

Background to the Invention

The use of waffle pod construction techniques in the pouring of concrete slabs is a common and well understood construction technique; however, current waffle pod apparatus and methodologies available generally require concrete workers to place a plurality of pods in a simple matrix and subsequently insert spacers or other forms of alignment tools to ensure the pods and a given matrix are separated and held in the correct juxta position prior to the pouring of a concrete slab.

To date, there have been many proposals to accommodate the requirement to space the individual pods including the provision of platform elements and connectors adapted for fitting between adjacent pods and holding said pods in a favourable juxta position. However, the prior art spacing devices often require the use of dedicated spacer pods with interlocking and interconnecting features or alternatively, require the spacers to be laid down first in the correct matrix orientation with the pods subsequently placed onto the spacers. These systems are time consuming and laborious and subject to errors and do not provide the optimal use of the waffle pod construction potential.

Other spacer designs include plastic spacers that sit on the ground but do not lock together in any particular way but just function as a chair or support for reinforcement bar or mesh used in conjunction with the waffle pods.

One object of the invention is to provide an improved waffle pod spacing methodology and apparatus.

Statements of the Invention In a first aspect the invention provides a method of connecting and holding a plurality of individual waffle pods in a matrix said method comprising the steps of

placing two or more of said waffle pods in position and subsequently joining adjacent waffle pods together from above using a spacer means characterised in that said spacer means engages the respective tops of adjacent waffle pods by piercing the respective tops of adjacent pods. The spacers are preferably used to pierce the pods from the top of said pods.

The pods are most preferably expanded polystyrene foam (EPS) blocks. The spacers are most preferably formed of a tough plastic or synthetic wire with sharpened tips adapted for piercing said polystyrene.

The spacers may include two or more piercing arms separated by a spacing bridge.

The spacers may be formed of metal, plastic or any other form of material capable of holding a piercing edge on said piercing arm sufficient to allow said arm to be inserted into the pods.

In another aspect the invention provides a waffle pod spacer comprising a spacing bridge and two or more piercing arms positioned adjacent said bridge and being adapted for insertion into adjacent waffle pods by piercing said pods.

Detailed Description of the Invention

The invention will now be described with reference to Figures 1, 2, 3 and 4 with Figure 1 showing a plan view of a small matrix of six pods joined together by the spacer devices of the invention.

Figure 2 shows a side view with the spacer means piercing and inserted through the top of the pod.

Figure 3 shows a side end elevation of a waffle pod with the spacer means inserted.

Figure 4 shows two waffle pods joined together by the spacing means of the invention.

Figure 5 shows a spacer in elevation view with a cross-section. Referring firstly to Figure 1, the methodologies and apparatus of the invention have been applied to a small matrix of pods where a top view showing six pods placed side by side, reveals the spacers 3 of the invention which have been positioned from the top 2 and pushed down into the fabric of the waffle pod 1 as a piercing action commencing at the top of the pods.

Figure 2 shows a side view where the piercing arm 4 of the spacer 3 has been inserted through the top 2 of the pod 1.

Figure 3 shows a side end elevation of a single pod 1 where the spacer 3 has been inserted via the top 2 of the pod with the piercing arm 4 being inserted into the pod.

Figure 4 shows a view of two adjacent pods 1 sitting side by side where the spacer 3 has been inserted with the piercing amis 4 being inserted into the top 2 of the adjacent pods 1. The spacer 3 can be seen to clearly incorporate a bridge 5 which serves to form a definitive spacing element of the spacer and serves to provide a minimum spacing distance between adjacent pods.

Referring now to Figure 5, a view of the spacer is provided in elevation or side view with a representation of the cross-section also indicated. The spacer can be seen to be formed of a unitary wire-like bent formation comprising an inverted bridge 5, which rises up at either side with upward projecting spacer arm 6, where the space provided by the inverted bridge allows for the spacing between adjacent pods fitted or held in place with this spacer. The upward projecting spacer arms terminate in transverse projection 7, moving out either side of the space formed by the inverted bridge with transverse projections themselves terminating in a downwardly directed piercing arms, so as to form a generally parallel array of upward and downward components to the spacer, which allow for a highly simplified and effective spacing device which can be manufactured from wire of either metallic composition or alternatively, similar synthetic or plastic products capable of being formed into similar shapes whilst adopting the resilience and ability to hold a sharpened point to the piercing arms such that the spacers can be readily pushed into adjacent pods so as to serve as an alignment and holding means for adjacent pods.

The invention provides for the first time, a highly simplified methodology and apparatus for assembling and holding a plurality of waffle pods in a distinct matrix ready for pouring of a concrete slab. The methodology and apparatus of the invention is particularly adapted for use on expanded polystyrene waffle pods which are easily pierced by the spacers of the invention. The spacers have been specifically designed to readily pierce the expanded polystyrene pods after they have been placed into the approximate position to form a matrix and provide an automatic mechanism for spacing the pods at the desired distance. In particular, the spacers of the invention are adapted for retrospective fitting by piercing the top surfaces of adjacent pods. The methodologies and spacers of the invention are particularly adapted for use with commonly available waffle pods without requiring a redesign or change or the use of a dedicated waffle pod product.

The process and methodologies of the invention allow the waffle pods to be quickly placed onto a working site and without the need for detailed measurements and prior positioning of spacers or other systems, the pods can be methodically connected together by the ready and rapid piercing of spacers which move the individual waffle pods into the correct and precise juxta position and thereby provide a ready, quick, accurate means of laying out a waffle pod matrix.

The spacers of the invention can be made from metal, wire, plastic or any other material capable of exhibiting the necessary strength and sharpness to achieve the piercing objective. The methodologies and apparatus of the invention make full use of the integrity and composite materials of the expanded polystyrene waffle pods which can be easily pierced into the wall at the top thereby allowing spacers to hold the pods in place. The piercing of the pods in their manner of the invention allows concrete workers to place the pods in any position without having to be restricted by other systems that only allow the use of dedicated or particular spacers at certain positions and orientations on the pod.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.