Filler Member

This invention concerns filler members, filler members for use within concrete slabs, and also concrete slabs incorporating such filler members.

When using concrete slabs in construction, it may be required to have a relatively thick slab and/or to cover a wide span. Problems can be encountered in either or both of these instances, due to the weight of the concrete slabs. In view of this, filler structures have been proposed to be incorporated within the slab. One prior proposal has been to provide a plurality of individual hollow plastic spheres, retained within a metal cage. Such a structure is not however particularly easy to handle, and is also potentially dangerous to walk upon.

According to the present invention there is provided a filler member, the member comprising a framework and a plurality of closed hollow members integrally formed with the framework, the member being beatable wholly within a concrete slab, with the hollow members defining hollow voids.

The interiors of adjacent hollow members may be interconnected. Connecting pipes may extend between adjacent hollow members.

The filler member may be formed in two parts, with the two parts engageable together to define the hollow members. The two parts may be substantially identical. Interconnecting formations may be provided to permit inter- engagement between the two parts.

The hollow members may be spheres.

The filler member may be configured such that the hollow members are arranged generally in line.

The framework may extend outwardly on all sides a little way beyond the hollow members.

In one embodiment spacer formations are provided between two or more of the hollow members to permit the filler member to be cut to a required size between said hollow members, without cutting into the hollow members.

Connection formations may be provided on the outside of the filler member to permit connection to other filler members. Connection formations may be provided on some or all of the external sides of the filler member. The connection formations may have a dovetail cross section.

Interconnecting formations may be provided for interconnecting the interior of the hollow members in adjacent filler members.

The filler member may be made of plastics material, such as polypropylene or polyethylene.

The filler member may be of sufficient strength such that a person can walk thereon substantially without causing damage thereto.

Outer surfaces of the filler member may have an anti-slip formation, which may be moulded thereon.

The invention further provides a concrete slab incorporating one or more filler members according to any of the preceding ten paragraphs.

The concrete slab may include means for directing air into or out of the interiors of the hollow members.

The concrete slab may include line means extending through the interiors of the hollow members in a loop such that services may be provided in the concrete slab as required.

Embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings, in which:-

Fig. 1 is a diagrammatic perspective view of a first filler member according to the invention;

Fig. 2 is a shaded version of Fig. 1 ;

Fig. 3 is a diagrammatic exploded view of the filler member of Fig. 1 ;

Fig. 4 is a shaded view similar to Fig. 3;

Fig. 5 shows two interconnected filler members of the type shown in Fig. 1 ;

Fig. 6 is a similar view to Fig. 1 but of a second filler member according to the invention;

Fig. 7 is a similar view to Fig. 3 but of the filler member of Fig. 6; and

Fig. 8 is a similar view to Fig. 5 but of two interconnected third filler members according to the invention.

Figs. 1 to 5 of the drawings show a first filler member 10. The filler member 10 includes a framework 12 in which is located five in line hollow spheres 14. The spheres 14 are located wholly within the framework 12 such that the latter extends beyond these spheres 14 a short way in all directions.

The framework 12 comprises side members 16, defining upper and lower rows of rounded square openings 18. Similar end members 20 are provided, each defining two rows of two openings 22. The side members 16 and end members 20 are interconnected by longitudinal and transverse webs 24, 26 which divide the spheres 14 into equal quarters.

The filler member 10 is formed in two identical parts 28, each defining lower and upper halves, as shown in the drawings, of the spheres 14 and the framework 12. The parts 28 are engageable together with interconnecting formations 30 in the form of upstanding male members 32 engageable in corresponding female socket members 34.

Connection formations 36 are provided on each end of the framework 12. The formations 36 are in the form of dovetail cross section projections 38 which are engageable in dovetail cross section slots 40. The connection formations 36 enable two filler members 10 to be interconnected end to end as shown in Fig. 5, and obviously further filler members 10 could be joined to these two members 10.

A number of modifications may be made without departing from the scope of the invention. For instance, connection formations can also be provided on the sides, and also top and bottom of the framework 12 to permit interconnection to other filter member 10 on all sides.

A spacer structure or structures could be provided within a filler member to permit cutting of the member to a required length. The structure could be in the form of a double web between adjacent spheres, at which double web the filler member could be cut so as to provide a web on the outside of each adjacent sphere.

The filler member 10 is formed by moulding a plastics material such as polypropylene or polyethylene. The two parts 28 are each moulded

separately, and subsequently joined together. This means that the difficulties usually encountered in moulding spheres are not encountered.

Various other modifications may be made without departing from the scope of the invention. For instance, the filler member could be made from different materials and/or by different methods. The filler member may take a different form. Hollow members other than spheres could be provided.

In use, the filler member or members 10 are located within a concrete mould during manufacture of a slab. The filler member or members 10 may be connected to other filler members by the connection formations. The filler member or members 10 may be supported on wires or other support structures within the mould. Concrete is then poured into the mould to fully surround and encapsulate the filler member or members 10. The hollow spheres 14 thereby provide voids in the concrete slab thus formed.

There is thus described a filler member usable within concrete slabs which provides for a number of advantages. The filler member can readily be formed of plastics material, and the two part construction enables relatively straightforward moulding techniques to be used. The filler member is such that if required it can be walked upon by a person. The filler member or members reduce the overall floor slab weight whilst maintaining its biaxial strength. Such filler members can be inexpensively and robustly manufactured to a uniform and consistent design, thereby using less materials and producing less wastage than in previous proposals. The outer surfaces of the framework 12 are provided with an anti slip formation to assist walking thereon.

Figs. 6 and 7 show a second filler member 42 which is similar in most respects to the filler member 10 and the same reference numerals have been used for corresponding features. Here the interior of each of the spheres 14 is interconnected to adjacent such spheres 14 by connecting pipes 44, formed

by semicircular section formations on each of the parts 28. Interconnecting pipes 46 are provided at each end of the members 42 for interconnecting the spheres 14 to corresponding spheres 14 in adjacent such filler members 42. Again the interconnecting pipes 46 are formed by semicircular section formations on each of the parts 28.

In use air could be blown through the connecting and interconnecting pipes 44, 46 through the floor slabs in which the members 42 are located, or sucked out thereof. This means that in warm weather warm air from rooms above or below the floor slab can be pumped through the pipes 44, 46 into the slab. Conversely in colder weather air could be pumped out of the floor slab through the pipes 44, 46 to provide warming air in the rooms. In this way the floor slab can act as a heat sink.

Fig. 8 shows two third filler members 48 interconnected in a similar manner to the filler members 10 in Fig. 5. The third members 48 are similar to both the first and second members 10, 42, and similar reference numerals are used. Again connecting and interconnecting pipes 44, 46 are provided to interconnect interiors of the spheres 14, and if required air can be pumped therethrough.

A line means 50 which could be a wire, chain, strong, rope or other line means, extends through the pipes 44, 46 and will be provided extending through the pipes 44, 46 in adjacent such members 48. The line means is provided as a loop extending through the slab.

The line means 50 enables services such as electric wires or other cabling to conveniently be installed in a slab which may form the ceiling or floor of a room. A hole can be drilled to provide an opening into the slab where such a connection is required, and the closest part of the loop of line means 50 can be located. A relevant cable such as an electric cable, computer cable or otherwise can then be attached to the line means 50 and

pulled to this opening through the respective members 48 to enable a connection to be made.

This means that a connection can be made through the slab, be it a ceiling, floor or otherwise, without for instance having to form a groove to locate cabling across a face of the slab.

Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.