Patent Description:
The erection of building structures is a complex engineering process involving many stages.

Typically, before any building structure may be erected, preparatory work is require to ensure that adequate support for the building is provided both during, and after, completion of the building.

In particular, when considering the type of foundations that should be built, a number of parameters must be taken into consideration, including not only the type of building, but also environmental parameters including, for example, the type of soil.

In particular, clay soils can be prone to expansion and shrinkage (also known as "heave") depending on the moisture content of the soil. As such, it is common, prior to laying concrete for construction of the building, to seek to protect the building from potential heave by lining certain areas of the ground with one or more layers of compressible material, such as, for example, expanded polystyrene materials such as Cellcore™. These materials are typically referred to as void formers.

A problem with conventional void formers, and in particular with cellular or honeycomb structures, is their bulky nature. These products typically have a defined shape and a volume, and may have a typical thickness in the region of <NUM>. Thus, their deployment to a construction site can be costly in terms of transport, and their storage on site may be inconvenient or impractical in terms of space usage. Another problem includes their relative fragility during handling and/or deployment.

<CIT>) discloses a panel for use in a drop ceiling system, wherein the ceiling system includes stringers and cross-members defining areas therebetween for support of the panels wherein the panels include at least one planar sheet of material secured to a reinforcement member having channels formed therein to extend in at least one direction relative to the sheet material.

<CIT>) discloses a multi-layered insulation apparatus having a collapsed configuration in which one dimension of the insulation is minimized to reduce the volume for storage, and an expanded configuration in which the dimension is maximized to separate outer layers of the insulation.

It is an object of the present invention to obviate and/or mitigate the limitations and/or disadvantages associated with the prior art and/or with conventional systems.

According to a first aspect there is provided a building apparatus comprising:.

The first layer and/or the second layer, preferably the first layer and the second layer, may be a self-supporting and/or or a rigid layer. The first layer may comprise or may be a sheet or a board. The second layer may comprise or may be a sheet or a board.

Typically, the first layer and/or the second layer may be made of a lightweight material, e.g. a polymeric material. By such provision, the apparatus may be easy to transport and/or deploy. The first layer and/or the second layer may comprise or may be made from a plastic material such as polypropylene, polyethylene, polyvinylchloride, polycarbonate, a polyester, or the like.

Typically, the first layer and/or the second layer may have a structure providing a low density and semi-rigid properties. For example, the first layer and/or the second layer may have a fluted sheet structure. The first layer and/or the second layer may be made of fluted polypropylene board.

The first layer and/or the second layer may have a thickness in the range of about <NUM>-<NUM>.

The first layer may have a thickness in the range of about <NUM>-<NUM>, typically about <NUM>. The first layer may, in use, e.g. after deployment, be an upper layer.

The second layer may have a thickness in the range of about <NUM>-<NUM>, typically about <NUM>. The second layer may, in use, e.g. after deployment, be a lower layer, e.g. a layer facing the ground.

Typically, in the first or stowed configuration, the first layer and the second layer may be substantially adjacent to each other. By such provision, in the first or stowed configuration, e.g. before deployment, such as during transport and/or storage, the apparatus may be compact and/or may optimise space efficiency.

In the second or deployed configuration, the first layer and the second layer may be provided substantially parallel to each other.

In the second or deployed configuration, the first layer and the second layer may be substantially distal from each other. Typically, first layer and the second layer may be spaced apart by the at least one connecting element.

In the second or deployed configuration, the first layer and the second layer may separated by a predetermined distance. In the second or deployed configuration, the at least one connecting element may provide or may define a gap between the first layer and the second layer. In the second configuration, the apparatus may represent or and be termed a void former.

In the first or stowed configuration, the apparatus may have first thickness. The first thickness may be defined by a distance between an outside surface of the first layer and second layer in the first or stowed configuration.

In the second or deployed configuration, the apparatus may have a second thickness. The second thickness may be defined by a distance between an outside surface of the first layer and second layer in the second or deployed configuration.

The second thickness may be greater than the first thickness.

Typically, in the first or stowed configuration, the apparatus may have a thickness in the range of about <NUM>-<NUM>, e.g. about <NUM>-<NUM>, e.g. about <NUM>.

Typically, in the second or deployed configuration, the apparatus may have a thickness in the range of about <NUM>-<NUM>, e.g. about <NUM>-<NUM>, e.g. about <NUM>-<NUM>, e.g. about <NUM>, <NUM> or <NUM>. It will be appreciated that the overall thickness of the apparatus in the second or deployed configuration may be selected to account for the particular requirements at the intended deployment site. For example, if the ground is such that a small degree of heave is expected, then a lower thickness of the apparatus in the second or deployed configuration may be adequate. However, if the ground is such that a large degree of heave is expected, then a larger thickness of the apparatus in the second or deployed configuration may be preferable, as a larger gap between the first layer and the second layer may be able to "absorb" a greater level of ground heave. Typically, the apparatus may comprise a plurality of connecting elements.

The first layer and the second layer may have a length and/or a width, typically a length and a width.

The connecting elements may extend substantially parallel to each other along a dimension of the first layer and of the second layer, e.g. along a width thereof.

The connecting elements may be regularly spaced apart and/or may be disposed at regular intervals.

Typically, the connecting elements may be spaced apart by a distance in the range of about <NUM>-<NUM>, e.g. about <NUM>-<NUM>, e.g. about <NUM>.

The connecting elements may comprise a first portion configured to connect to the first layer, a second portion configured to connect to the second layer, and a third or intermediate portion provided between the first portion and the second portion.

Advantageously, the first portion may be hingedly connected to the third or intermediate portion. Advantageously also, the second portion may be hingedly connected to the third or intermediate portion.

In the first or stowed configuration, the third or intermediate portion may be provided substantially parallel to the first layer and/or to the second layer.

In the second or deployed configuration, the third or intermediate portion may be provided substantially transverse, typically substantially perpendicular, to the first layer and/or to the second layer. Thus, in the second or deployed configuration, the connecting elements may act as spacers between the first layer and the second layer.

In the second or deployed configuration, the apparatus, e.g. the connecting elements, e.g. third portion thereof, may be capable of bearing a load. For example, in the second or deployed configuration, the apparatus may be capable of withstanding a force applied on the first layer or on the second layer, e.g. on an outer surface thereof, of at least <NUM> kN/m<NUM>, e.g. at least <NUM> kN/m<NUM>,typically up to about <NUM> kN/m<NUM>, without collapsing. This is advantageous as this may allow the apparatus to bear a load applied thereon after deployment, for example the weight of a construction material, typically cement or concrete. Thus, upon deployment of the apparatus, cement of concrete may be poured onto an upper surface of the apparatus, and the upper surface of the apparatus may provide or may define a support surface for the concrete or cement.

In the second or deployed configuration, the apparatus may be configured to collapse, fail or crush when subjected to a threshold load, e.g. when applied to the first layer or the second layer, being greater than about <NUM> kN/m<NUM>, e.g. greater than about <NUM> kN/m<NUM>, typically greater than about <NUM> kN/m<NUM>.

Typically, without wishing to be bound by theory, application of a force greater than the threshold load on the first layer or the second layer, e.g. in a direction transverse, e.g. perpendicular to the first layer or the second layer, may cause the connecting elements, e.g. third or intermediate portion thereof, to fail, break or collapse. This may be advantageous in order to absorb any heave from the ground, e.g. from a clay soil that may cause application of an upwards force on a lower surface of the apparatus, thus protecting a building from potential damage.

The first portion and the third or intermediate portion of at least one connecting element may be made from separate parts. In such instance, the connecting element(s) may comprise a first hinged connection, e.g. a first hinge, between the first portion and the third or intermediate portion.

Alternatively, the first portion and the third or intermediate portion may be made from a single piece. In such instance, the first hinged connection between the first portion and the third or intermediate portion may be provided by a structural arrangement of the connecting element, e.g. a first longitudinal score or cut in the connecting element. The portion of the connecting element between the first score or cut and a first longitudinal edge may define the first portion.

The second portion and the third or intermediate portion of at least one connecting element may be made from separate parts. In such instance, the connecting element(s) may comprise a second hinged connection, e.g. a second hinge, between the second portion and the third or intermediate portion.

Alternatively, the second portion and the third or intermediate portion may be made from a single piece. In such instance, the second hinged connection between the second portion and the third or intermediate portion may be provided by a structural arrangement of the connecting element, e.g. a second longitudinal score or cut in the connecting element. The portion of the connecting element sheet between the second score or cut and the second longitudinal edge may define a/the second portion.

Advantageously at least one connecting element, e.g. each connecting element, may be made from a single or integral piece. In such instance, there may be provided a first longitudinal score or cut configured to provide a first hinged connection between the first portion and the third or intermediate portion, and a second longitudinal score or cut configured to provide a second hinged connection between the second portion and the third or intermediate portion.

The at least one connecting element may comprise a first face and a second face. When the at least one connecting element is made from a single or integral piece, the first longitudinal score or cut may be provided on the first face, and the second longitudinal score or cut may be provided on the second face. By such provision, the first hinge and the second hinge may be configured to hinge or fold in opposite directions.

As described above, the connecting elements may comprise a first portion configured to connect to the first layer, a second portion configured to connect to the second layer, and a third or intermediate portion provided between the first portion and the second portion.

Typically, the first portion may be configured to connect to the first layer via the first face of the first portion. The second portion may be configured to connect to the second layer via the second face of the second portion. In other words, the first portion and the second portion may be configured to connect to a respective layer via opposite faces of the connecting element(s).

The first portion and/or the second portion may be configured to connect to a respective layer by conventional attachment means, e.g. by using an adhesive, or by welding such as ultrasonic welding, laser welding, solvent welding, etc..

In the first or stowed configuration, the first portion may overlap or may be folded over the third or intermediate portion of at least one connecting element. The first portion and the third or intermediate portion may be substantially parallel to each other and/or parallel to the first layer and/or the second layer.

In the first or stowed configuration, the second portion may overlap or may be folded over the third or intermediate portion of at least one connecting element. The second portion and the third or intermediate portion may be substantially parallel to each other and/or parallel to the first layer and/or the second layer.

Alternatively, in the first or stowed configuration, the first portion may not overlap or may not be folded over the third or intermediate portion of at least one connecting element. The first portion may extend in substantially the same direction as the third or intermediate portion. The first portion and the third or intermediate portion may be substantially parallel to each other and/or parallel to the first layer and/or the second layer.

In the first or stowed configuration, the second portion may not overlap or may not be folded over the third or intermediate portion of at least one connecting element. The second portion may extend in substantially the same direction as the third or intermediate portion. The second portion and the third or intermediate portion may be substantially parallel to each other and/or parallel to the first layer and/or the second layer.

In the second or deployed configuration, the third or intermediate portion may be substantially perpendicular to the first portion and/or substantially perpendicular to the first layer and/or the second layer.

In the second or deployed configuration, the third or intermediate portion may be substantially perpendicular to the second portion and/or substantially perpendicular to the first layer and/or the second layer.

At least one connecting element, e.g. each connecting element, may be a self-supporting and/or or a rigid layer. At least one connecting element, e.g. each connecting element, may comprise or may be a sheet or a board.

Typically, at least one connecting element, e.g. each connecting element, may be made of a lightweight material, e.g. a polymeric material. By such provision, the apparatus may be easy to transport and/or deploy. At least one connecting element, e.g. each connecting element, may comprise or may be made from a plastic material such as polypropylene, polyethylene, polyvinylchloride, polycarbonate, a polyester, or the like.

Typically, at least one connecting element, e.g. each connecting element, may have a structure exhibiting a low density and semi-rigid properties. For example, at least one connecting element, e.g. each connecting element, may have a fluted sheet structure. At least one connecting element, e.g. each connecting element, may be made of fluted polypropylene board.

At least one connecting element, e.g. each connecting element, may have a thickness in the range of about <NUM>-<NUM>, typically about <NUM>. It will be appreciated that the thickness of the at least one connecting element may be selected so as to be associated with a desired threshold load above which the apparatus may be configured to collapse, fail or crush, in its deployed configuration. Typically, the thicker the at least one connecting element, the greater the threshold load.

The apparatus may comprise at least one locking element configured to maintain the apparatus in the second or deployed configuration.

Typically, the apparatus may comprise a plurality of locking elements.

The locking elements may be disposed at or near an edge of the first layer or second layer. Typically, the locking elements may be disposed at or near two opposing edges of the first layer or second layer.

The locking elements may be provided in pairs.

Two adjacent connecting elements may define a channel therebetween. There may be provided a plurality of channels, each channel being defined by the space between adjacent connecting elements.

One or more elements may be provided in a respective channel between two adjacent connecting elements. Typically, a pair of locking elements may be provided in a respective channel between two adjacent connecting elements. Each locking element of a pair may be disposed at or near an end region of a respective channel, e.g. at or near an edge of the first layer or second layer.

Advantageously, there may be provided at least one locking element, e.g. a pair of locking elements, in each channel between adjacent connecting elements. By such provision, maximum stability and/or strength may be provided.

The locking elements may be regularly spaced apart and/or may be disposed at regular intervals.

The locking elements may comprise a first portion configured to attach to the first layer, and a second portion hingedly connected to the first portion.

In the first or stowed configuration, the second portion of the locking elements may be provided substantially parallel to the first layer and/or to the second layer.

In the second or deployed configuration, the second portion of the locking elements may be provided substantially transverse, typically substantially perpendicular, to the first layer and/or to the second layer.

In the second or deployed configuration, the locking elements, e.g. second portions thereof, may extend substantially parallel to each other along a dimension of the first layer and of the second layer, e.g. along a length thereof.

Advantageously, a width of the locking elements may be substantially equal to or marginally less than the width of a respective channel. By such provision, in the second of deployed configuration, the provision of a locking element on either side of a connecting element may prevent the connecting element from reverting to its first or stowed configuration, thus "locking" the connecting element in its second of deployed configuration.

The height of the locking elements may typically be less than the height of the gap between the first layer and the second layer in the second or deployed configuration.

The at least one locking element may comprise a third portion hingedly connected to the second portion. Thus, the second portion may be provided between the first portion and the third portion. Advantageously, the third portion may be configured to engage the second layer in the second or deployed configuration.

The height of the locking elements, e.g. second portion thereof, may be approximately equal to, or marginally less than, the height of the gap between the first layer and the second layer in the second or deployed configuration. This may provide additional strength and structural integrity in the deployed configuration.

The second portion of the at least one locking element may comprise an aperture or opening configured to allow a user to move and/or deploy the at least one locking element. For example, the aperture or opening may be sized to allow a digit or a tool to be inserted therein in order to move, e.g. pull, the locking element and deploy it between two adjacent connecting elements.

At least one locking element, e.g. each locking element, may be a self-supporting and/or or a rigid layer. At least one locking element, e.g. each locking element, may comprise or may be a sheet or a board.

Typically, at least one locking element, e.g. each locking element, may be made of a lightweight material, e.g. a polymeric material. By such provision, the apparatus may be easy to transport and/or deploy. At least one locking element, e.g. each locking element, may comprise or may be made from a plastic material such as polypropylene, polyethylene, polyvinylchloride, polycarbonate, a polyester, or the like.

Typically, at least one locking element, e.g. each locking element, may have a structure exhibiting a low density and semi-rigid properties. For example, at least one locking element, e.g. each locking element, may have a fluted sheet structure. At least one locking element, e.g. each locking element, may be made of fluted polypropylene board.

At least one locking element, e.g. each locking element, may have a thickness in the range of about <NUM>-<NUM>, typically about <NUM>.

Advantageously, at least one connecting element, e.g. each connecting element, may comprise a third hinged connection. Typically, when the at least one connecting element is made from a single or integral piece, the third hinged connection may be provided by a third longitudinal score or cut, advantageously on the second face of the at least one connecting element. Typically, the third longitudinal score or cut may be provided between the first longitudinal score or cut and the second third longitudinal score or cut. The third longitudinal score or cut may be provided near or adjacent the first longitudinal score or cut such that the portion of the at least one connecting element between the first longitudinal score and the third longitudinal score may define a fourth portion. The fourth portion may be provided between the first portion and the third or intermediate portion.

The first longitudinal score or cut and the third longitudinal score or cut may define a "double hinge", wherein the first hinged connection and the third hinged connection hinge in opposite directions.

Advantageously, the provision of a third hinged connection near the first hinged connection may allow the at least one connection element to extend in a flatter or more compact configuration when stretched out and/or when positioned against one or more adjacent locking elements either during manufacture, in the second or deployed configuration, or both.

According to a second aspect there is provided a method for manufacturing.

The method may comprise preparing the at least one connecting element.

The method may comprise providing a connecting element sheet. The method may comprise cutting the sheet in a quadrilateral shape, e.g. a rectangular shape. The connecting element sheet may have a size of about <NUM> x <NUM>. The connecting element sheet may have a thickness of about <NUM>.

The method may comprise providing a first longitudinal score or cut on a first face of the connecting element sheet, e.g. about <NUM> from a first longitudinal edge thereof. The portion of the connecting element between the first score or cut and the first longitudinal edge may define a/the first portion.

The method may comprise providing a second longitudinal score or cut on a second face of the connecting element sheet, e.g. about <NUM> from a second longitudinal edge thereof. Thus, the first and second longitudinal scores or cuts may be provided about <NUM> from respective opposite longitudinal edges of the connecting element sheet. The portion of the connecting element sheet between the second score or cut and the second longitudinal edge may define a/the second portion.

The method may comprise creating a third longitudinal score or cut on the second face of the connecting element sheet, e.g. about <NUM> from the first longitudinal edge thereof. Thus, the third longitudinal score or cut may be provided about <NUM> from the first longitudinal score or cut, on an opposite face of the connecting element sheet. The portion of the connecting element sheet between the first longitudinal score or cut and the third longitudinal edge may define a/the fourth portion. Thus, the proximal first and third longitudinal scores or cuts may define a "double hinge".

At least one connecting element, e.g. each connecting element, may be made of fluted polypropylene board.

The method may comprise preparing at least one locking element.

The method may comprise providing a locking element sheet. The method may comprise cutting the sheet in a quadrilateral shape, e.g. a rectangular shape. The locking element sheet may have a size of about <NUM> x <NUM>. The locking element sheet may have a thickness of about <NUM>.

The method may comprise providing a first longitudinal score or cut on a first face of the locking element sheet, e.g. about <NUM> from a first longitudinal edge thereof.

The method may comprise creating a first notch at or near a first corner of the locking element sheet including the first longitudinal edge. The first notch may have a size of about <NUM> x <NUM>, typically about <NUM> along the first longitudinal edge x <NUM> along an edge perpendicular to the first longitudinal edge.

The first layer may have a size of about <NUM> x <NUM>. The first layer may have a thickness of about <NUM>.

The method may comprise providing a first connecting element. The method may comprise connecting a/the first face of the first portion of the first connecting element to the first layer, e.g. using ultrasonic welding. There may be provided a plurality of welds along the first portion, e.g. about <NUM> long and/or disposed at about <NUM> intervals.

The method may comprise providing a template. The template may define one or more locations to position one or more connecting elements on the first layer. By such provision, consistent and reliable positioning of the connecting elements may be achieved, thus ensuring effective assembly of the apparatus.

The method may comprise providing a second connecting element. The second connecting element may be provided parallel to the first connecting element at a predetermined distance therefrom. In an embodiment, the second connecting element may be provided about <NUM> from the second connecting element. The template may provide or may define an interval of about <NUM> between adjacent connecting elements.

The method may comprise connecting a/the first face of the first portion of the second connecting element to the first layer, e.g. using ultrasonic welding, e.g. similarly to the first connecting element.

The method may comprise connecting a/the first portion of further connecting elements to the first layer, e.g. using ultrasonic welding. In an embodiment, there may be provided eight connecting elements.

The method may comprise folding the first connecting element, e.g. over the first hinge and second hinge thereof.

The method may comprise providing a first locking element. The method may comprise connecting a/the first portion of the first locking element to the first layer, e.g. using ultrasonic welding. The first locking element may be provided between two adjacent connecting elements, e.g. between the first and the second connecting element, and may be provided near a first edge of the first layer e.g. about <NUM>-<NUM>, typically about <NUM> from the first edge.

The method may comprise providing a second locking element. The method may comprise connecting a/the first portion of the second locking element to the first layer, e.g. using ultrasonic welding. The second locking element may be provided between two adjacent connecting elements, e.g. between the first and the second connecting element, and may be provided near a second edge of the first layer opposite the first edge, e.g. about <NUM>-<NUM>, typically about <NUM> from the second edge.

The first and second locking elements may define a first pair of locking elements.

The method may comprise folding the second connecting element, e.g. over the first hinge and second hinge thereof. The method may comprise folding the second connecting element, e.g. over the first hinge and second hinge thereof, at least partially over the first pair of locking elements.

The method may comprise providing at least one further locking element, e.g. a second pair of locking elements. The method may comprise connecting a/the first portion of the at least one further locking element, e.g. of each of the second pair of locking elements, to the first layer, e.g. using ultrasonic welding.

The method may comprise repeating folding an adjacent connecting element, and connecting a further pair of locking elements, as described above, for example until the last connecting element is reached and/or until each space between adjacent connecting elements has been provided with at least one, e.g. a pair of, locking elements.

The method may comprise providing each connecting element such that its first face faces towards the first layer and/or such that at least a portion of the first face of its intermediate portion and/or second portion overlaps or extends over an adjacent locking element or pair of locking elements. Advantageously, the provision of a third longitudinal score of cut on the second face near the first longitudinal score of cut on the first face, provides a double hinge region which allows the connecting element to remain flat and/or parallel to and adjacent a locking element or pair of locking elements when overlaping or extending over such. This is advantageous as it may allow the second layer to be placed flat and/or flush against the second face of the second portion for subsequent attachment, e.g. welding.

The method may comprise providing the second layer. The method may comprise connecting the second face of a/the second portion of at least one, preferably of each, connecting element, to the second layer, e.g. using ultrasonic welding. There may be provided a plurality of welds along the second portion, e.g. about <NUM> long and/or disposed at about <NUM> intervals.

The method may comprise bringing the first layer and second layer in proximity with each other, thus providing the apparatus in its first or stowed configuration.

In one embodiment, the method may comprise bringing the first layer and second layer in proximity with each other such that the first face of the/each connecting element, e.g. the first face of each of the first portion, intermediate portion and second portion, faces towards the first layer and/or such that at least a portion of the first face of its intermediate portion and/or second portion overlaps or extends over an adjacent locking element or pair of locking elements. Advantageously, this configuration may provide a thinner and/or more compact size or thickness in the first or stowed configuration.

In another embodiment, the method may comprise bringing the first layer and second layer in proximity with each other such that the first hinged connection and the second hinged connection of the/each connecting element are folded over. The method may comprise bringing the first layer and second layer in proximity with each other such that at least a portion of the second face of the intermediate portion faces and/or overlaps at least a portion of the second face of the first portion, and/or such that at least a portion of the first face of the intermediate portion faces and/or overlaps at least a portion of the first face of the second portion. Advantageously, this configuration may provide a degree of "spring" in the apparatus when provided in its stowed configuration, which may cause the apparatus, upon deployment, to partially unfold upon deployment into or towards its deployed configuration.

The method may comprise securing, e.g. temporarily securing such as using adhesive tape, Velcro®, or the like, the apparatus in its first or stowed configuration. This may conveniently allow a user to store the apparatus and/or transport the apparatus to a deployment site whilst in its first or stowed configuration.

The method may be automated and/or may be controlled by a computer.

According to a third illustrative example not forming any part of the claimed invention, there is provided a kit of parts for providing an apparatus according to the first aspect, the kit of parts comprising:.

Typically, the kit of parts may comprise a plurality of connecting elements, e.g. about eight connecting elements.

The kit of parts may further comprise at least one locking element. Typically, the kit of parts may comprise a plurality of locking elements or pairs of locking elements, e.g. about seven pairs of connecting elements.

According to a fourth aspect there is provided a method for installing a building apparatus, the method comprising:.

The method may comprise deploying the at least one locking element. The method may comprise deploying at least one locking element such that the second portion thereof is substantially perpendicular to the first layer and second layer and/or to the at least one connecting element, preferably substantially perpendicular to the first layer and second layer and to the at least one connecting element.

The method may comprise deploying the at least one locking element such that a third portion thereof engages the second layer in the second or deployed configuration.

For the avoidance of doubt, any feature described in respect of any aspect of the invention may be applied to any other aspect of the invention, in any appropriate combination. For example, features of an apparatus may be applied to a method, and vice versa.

The present invention will now be further described in detail and with reference to the figures in which:.

<FIG> shows a building apparatus <NUM> according to a first embodiment. In <FIG>, the apparatus <NUM> is shown in its deployed configuration. The apparatus <NUM> is typically a void former for use in construction.

The apparatus <NUM> has a first layer <NUM> made of a <NUM> thick fluted polypropylene sheet; and a second layer <NUM> made of a <NUM> thick fluted polypropylene sheet.

The apparatus has a plurality, in this embodiment eight, connecting elements <NUM> configured to connect the first layer <NUM> and the second layer <NUM>.

In <FIG>, the apparatus <NUM> is shown in its deployed configuration in which the connecting elements <NUM> are in their deployed state so as to maintain the first layer <NUM> and the second layer <NUM> in a distal relationship from each other.

The apparatus also has one or more stowed configurations, as shown in <FIG> and <FIG>, in which the connecting elements are in a stowed state and the first layer <NUM> and the second layer <NUM> are in a proximal relationship.

The first layer <NUM> and second layer <NUM> are made of a lightweight material which would not be normally sufficiently strong to withstand a significant load. However, as explained below in more detail, the construction of the apparatus <NUM> is such that, once deployed as shown in <FIG>, the void former <NUM> is able to withstand the weight of one or more operators and/or the weight of cement being poured on the void former. Typically, the void former <NUM> may be able to withstand a weight of about <NUM> to <NUM> kN/m<NUM> , typically about <NUM> kN/m<NUM>, without collapsing or failing. Thus, upon deployment of the void former <NUM>, cement of concrete may be poured onto an upper surface of the void former <NUM>, and the upper surface of the first sheet <NUM> may provide or may define a support surface for the concrete or cement.

The connecting elements <NUM> are configured to connect the first layer <NUM> and the second layer <NUM>, and to provide a predetermined distance between the first sheet <NUM> and the second sheet <NUM>, in the deployed configuration, in this embodiment a distance of about <NUM>.

In this embodiment, the connecting elements <NUM> are made of a <NUM> thick fluted polypropylene sheet.

As shown in <FIG> and <FIG>, the first layer <NUM> and the second layer <NUM> have length L and/or a width W. The connecting elements <NUM> extend substantially parallel to each other along a width W of the first layer <NUM> and of the second layer <NUM>.

The connecting elements <NUM> are disposed at regular intervals, in this embodiment at a distance of about <NUM>.

As best shown in <FIG>, the connecting elements <NUM> each have a first portion <NUM> configured to connect to the first layer <NUM>, a second portion <NUM> configured to connect to the second layer <NUM>, and a third or intermediate portion <NUM> provided between the first portion <NUM> and the second portion <NUM>. <FIG> shows a side view of the connecting element <NUM> before attachment to the first layer <NUM> and second layer <NUM>. <FIG> shows a cross-section view, and <FIG> a side view, of the connecting element <NUM> when attached to the first layer <NUM> and second layer <NUM>, in the deployed configuration.

Advantageously, the first portion <NUM> is hingedly connected to the third or intermediate portion <NUM>, and the second portion <NUM> is hingedly connected to the third or intermediate portion <NUM>.

In the first or stowed configuration, as shown in <FIG> and <FIG>, the third or intermediate portion <NUM> is provided substantially parallel to the first layer <NUM> and to the second layer <NUM>.

In the deployed configuration, as shown in <FIG>, the third or intermediate portion <NUM> is provided substantially perpendicular to the first layer <NUM> and to the second layer. Thus, in the second or deployed configuration, the connecting elements <NUM> act as spacers between the first layer <NUM> and the second layer <NUM>. In the deployed configuration, as shown in <FIG>, the void former <NUM> is able to withstand the weight of one or more operators and/or the weight of cement being poured on the void former. Typically, the void former <NUM> may be able to withstand a weight of about <NUM> kN/m<NUM> without collapsing or failing. Thus, upon deployment of the apparatus, cement of concrete may be poured onto an upper layer <NUM> of the void former <NUM>, and the upper surface of the void former <NUM> may provide or may define a support surface for the concrete or cement. In the deployed configuration, the void former <NUM> is configured to collapse, fail or crush when subjected to a threshold load being greater than about <NUM> kN/m<NUM>.

Typically, without wishing to be bound by theory, application of a force greater than the threshold load on the first layer <NUM> or the second layer <NUM>, e.g. in a direction transverse, e.g. perpendicular to the first layer <NUM> or the second layer <NUM>, will cause the connecting elements <NUM> to fail, break or collapse. This may be advantageous in order to absorb any heave from the ground, e.g. from a clay soil that may cause application of an upwards force on a bottom layer <NUM> of the void former <NUM>, thus protecting a building from potential damage.

In this embodiment, each of the connecting elements <NUM> is unitary in construction and is made from a single piece.

The first portion <NUM> and the third or intermediate portion <NUM> are made from a single piece. The first hinged connection <NUM> between the first portion <NUM> and the third or intermediate portion <NUM> is provided by a first longitudinal score or cut <NUM> on the first face <NUM> of the connecting element <NUM>. Thus, the first <NUM> portion of the connecting element <NUM> extends between the first score or cut <NUM> and a first longitudinal edge 31a.

The second portion <NUM> and the third or intermediate portion <NUM> are made from a single piece. The second hinged connection <NUM> between the second portion <NUM> and the third or intermediate portion <NUM> is provided by a second longitudinal score or cut <NUM> on the second face <NUM> of the connecting element <NUM>. Thus, the second portion <NUM> of the connecting element <NUM> extends between the second score or cut <NUM> and a second longitudinal edge 32a.

Advantageously, each connecting element <NUM> also has a third hinged connection <NUM>, the purpose of which will be described later. The third hinged connection <NUM> is provided by a third longitudinal score or cut <NUM> provided on the second face <NUM>. The third longitudinal score or cut <NUM> is provided between the first longitudinal score or cut <NUM> and the second third longitudinal score or cut <NUM>, and is located near or adjacent the first longitudinal score or cut <NUM> such that the portion of the connecting elements <NUM> between the first longitudinal score <NUM> and the third longitudinal score <NUM> defines a fourth portion <NUM>. Thus, the fourth portion <NUM> is located between the first portion <NUM> and the third or intermediate portion <NUM>, as best seen in <FIG>.

The first portion <NUM> is configured to connect to the first layer <NUM> via its first face <NUM>. The second portion <NUM> is configured to connect to the second layer <NUM> via its second face <NUM>. In other words, the first portion <NUM> and the second portion <NUM> are configured to connect to a respective layer <NUM>,<NUM> via opposite faces <NUM>,<NUM> of the connecting elements <NUM>.

In this embodiment, the first portion <NUM> and the second portion <NUM> are configured to be attached to a respective layer <NUM>,<NUM> by ultrasonic welding.

The connecting elements <NUM> are typically made of a self-supporting and/or a rigid layer, e.g. a sheet or a board such as a fluted polypropylene board. In this embodiment, the connecting elements <NUM> have a thickness of about <NUM>.

As shown in <FIG>, in the first or stowed configuration, the first portion <NUM> may overlap or is folded over the third or intermediate portion <NUM> of each connecting element <NUM>, such that the first portion <NUM> and the third or intermediate portion <NUM> are substantially parallel to each other and parallel to the first layer <NUM> and the second layer <NUM>. In such instance, the second portion <NUM> also overlaps and is folded over the third or intermediate portion <NUM> of the connecting elements <NUM>, such that the second portion <NUM> and the third or intermediate portion <NUM> are substantially parallel to each other and parallel to the first layer <NUM> and second layer <NUM>. Advantageously, this configuration may provide a degree of "spring" in the void former <NUM> when provided in its stowed configuration, which may cause the void former <NUM>, upon deployment, to partially unfold upon deployment into or towards its deployed configuration.

Alternatively, as shown in the configuration of <FIG>, in the first or stowed configuration, the first portion <NUM> may not overlap or may not be folded over the third or intermediate portion <NUM> of the connecting elements <NUM>, and the first portion <NUM> extends in substantially the same direction as the third or intermediate portion <NUM>. The first portion <NUM> and the third or intermediate portion <NUM> are still substantially parallel to each other and parallel to the first layer <NUM> and to the second layer <NUM>. In such instance, the second portion <NUM> does not overlap and is not be folded over the third or intermediate portion <NUM> of the connecting elements <NUM>. The second portion <NUM> extends in substantially the same direction as the third or intermediate portion <NUM>, and the second portion <NUM> and the third or intermediate portion <NUM> are substantially parallel to each other and parallel to the first layer <NUM> and second layer <NUM>. Advantageously, this configuration may provide a thinner and/or more compact size or thickness of the void former <NUM> in the first or stowed configuration.

In the second or deployed configuration, as shown in <FIG>, <FIG>, <FIG> and <FIG>, the third or intermediate portion <NUM> is substantially perpendicular to the first portion <NUM> and second portion <NUM>, and to the first layer <NUM> and the second layer <NUM>. Thus, the intermediate portion <NUM> provides the gap between first sheet <NUM> and second sheet <NUM> and also support for any weight or force applied on the first sheet <NUM> or second sheet <NUM>.

However, without further structural feature, the void former may not be able to remain in its deployed configuration, particularly when a force is applied to the first sheet <NUM> or second sheet <NUM>.

Thus, the void former <NUM> further includes a plurality of locking elements <NUM>, best shown in <FIG>. The locking elements are configured to maintain the void former <NUM> in its second or deployed configuration. <FIG> shows a side view of the locking element <NUM> before attachment to the first layer <NUM>. <FIG> shows a cross-section view, and <FIG> a side view, of the locking element <NUM> when attached to the first layer <NUM>, in the deployed configuration.

As best shown in <FIG> and <FIG>, the locking elements <NUM> are disposed in pairs at or near the opposing side edges of the first layer <NUM> along a length thereof.

Each pair of connecting elements <NUM> defines a channel <NUM> therebetween. Thus, there are provided a plurality of channels <NUM>, each channel <NUM> being defined by the space between adjacent connecting elements <NUM>. In this embodiment, there are seven channels <NUM>.

A pair of locking element <NUM> is provided in a respective channel <NUM> between two adjacent connecting elements <NUM>, and is disposed at or near an end region of a respective channel <NUM>, that is, at or near an edge of the first layer <NUM> and second layer <NUM>.

The locking elements <NUM> are regularly spaced apart and are disposed at regular intervals, in this embodiment at <NUM> intervals.

The locking elements <NUM> each have a first portion <NUM> configured to attach to the first layer <NUM>, and a second portion <NUM> hingedly connected to the first portion <NUM> via a first cut or score <NUM>'.

In the first or stowed configuration (as shown for example in <FIG>), the second portion <NUM> of the locking element <NUM> is provided substantially parallel to the first layer <NUM>.

In the second or deployed configuration, the second portion <NUM> of the locking elements <NUM> is provided substantially perpendicular to the first layer <NUM> and to the second layer <NUM>. Thus, in the second or deployed configuration, the second portions <NUM> of the locking elements <NUM> extend substantially parallel to each other along a length of the first layer <NUM> and second layer <NUM>.

Advantageously, a width of the locking elements <NUM> is substantially equal to or marginally less than the width of a respective channel <NUM>. By such provision, in the second of deployed configuration, the provision of a locking element <NUM> on one or both sides of each connecting element <NUM> helps prevent the connecting elements <NUM> from reverting to their first or stowed configuration, thus "locking" the connecting elements <NUM> in their second of deployed configuration. Advantageously, as depicted in <FIG>, there is provided a pair of locking elements <NUM> in each channel <NUM> between adjacent connecting elements <NUM>. By such provision, maximum stability and/or strength may be provided by ensuring that at least one locking element <NUM> engages at least one side of each connecting element <NUM>, in the deployed configuration.

The height of the locking elements <NUM> is typically less than the height of the gap between the first layer <NUM> and the second layer <NUM> in the second or deployed configuration. This allows a user to "pull" the second portion <NUM> of the locking elements into their deployed configuration, upon deployment. Thus, the space between a lower end of the second portion <NUM> and the second layer <NUM> may be sufficient to allow use of a tool and/or use of a digit, e.g. finger, by a user.

The locking elements <NUM> are typically made of a self-supporting and/or a rigid layer, e.g. a sheet or a board such as a fluted polypropylene board. In this embodiment, the locking elements <NUM> have a thickness of about <NUM>.

An alternative embodiment of the locking elements, designated as <NUM>', is shown in <FIG>. The locking elements <NUM>' of <FIG> are generally similar to the locking elements <NUM> of <FIG>, like parts being denoted by like numerals, supplemented by "'". <FIG> shows a side view of the locking element <NUM> before attachment to the first layer <NUM>'. <FIG> shows a cross-section view, and <FIG> is a side view of the locking element <NUM>' when attached to the first layer <NUM>', in the deployed configuration.

The locking elements <NUM>' each have a first portion <NUM>' configured to attach to the first layer <NUM>', and a second portion <NUM>' hingedly connected to the first portion <NUM>' via a first cut or score <NUM>'.

In the first or stowed configuration, the second portion <NUM>' of the locking element <NUM>' is provided substantially parallel to the first layer <NUM>'.

In the second or deployed configuration, the second portion <NUM>' of the locking elements <NUM>' is provided substantially perpendicular to the first layer <NUM>' and to the second layer <NUM>'. Thus, in the second or deployed configuration, the second portions <NUM>' of the locking elements <NUM>' extend substantially parallel to each other along a length of the first layer <NUM>' and second layer <NUM>'.

Advantageously, as in the first embodiment <NUM> of <FIG>, a width of the locking elements <NUM>' is substantially equal to or marginally less than the width of a respective channel <NUM>. This can be seen in <FIG>. By such provision, in the second of deployed configuration, the provision of a locking element <NUM>' on one or both sides of each connecting element <NUM>' helps prevent the connecting elements <NUM> from reverting to their first or stowed configuration, thus "locking" the connecting elements <NUM>' in their second of deployed configuration. Advantageously, as depicted in <FIG>, there is provided a pair of locking elements <NUM>' in each channel <NUM>' between adjacent connecting elements <NUM>'. By such provision, maximum stability and/or strength may be provided by ensuring that at least one locking element <NUM>' engages at least one side of each connecting element <NUM>', in the deployed configuration.

In this embodiment. the height of the locking elements <NUM>', e.g. second portion <NUM>' thereof, is approximately equal to or marginally less than the height of the gap between the first layer <NUM>' and the second layer <NUM>' in the second or deployed configuration. This permits the locking elements <NUM>' to provide additional strength and structural integrity in the deployed configuration by acting as a further support element between the first layer <NUM>' and the second layer <NUM>', in addition to the connecting elements <NUM>'. In order to allow a user to "pull" the second portion <NUM>' of the locking elements <NUM>' into their deployed configuration, the locking elements <NUM>' of <FIG> have an aperture <NUM>' (in their second portion <NUM>') sized to allow a digit or a tool to be inserted therein in order to move, e.g. pull, the locking elements <NUM>' and deploy them between two adjacent connecting elements <NUM>'.

In this embodiment, the locking elements <NUM>' each have a third portion <NUM>' hingedly connected to the second portion <NUM>' via a second cut or score <NUM>'. Thus, the second portion <NUM>' is provided between the first portion <NUM>' and the third portion <NUM>'. Advantageously, the third portion <NUM>' is configured to engage the second layer <NUM>' in the second or deployed configuration. This may provide additional strength and structural integrity in the deployed configuration.

The purpose of the third hinged connection <NUM> (in this embodiment in the form of a third longitudinal score or cut <NUM> provided on the second face <NUM>) will now be explained by reference to a method of manufacturing the void former <NUM>.

The connecting elements <NUM> are prepared. A sheet of <NUM>-thick fluted polypropylene is cut strips of about <NUM> x <NUM>. A first longitudinal score or cut <NUM> is made on the first face <NUM> of the connecting element sheet <NUM>, about <NUM> from a first longitudinal edge 31a thereof. The portion of the connecting element between the first score or cut <NUM> and the first longitudinal edge 31a defines a first portion <NUM>.

A second longitudinal score or cut <NUM> is made on the second face <NUM> of the connecting element sheet <NUM>, about <NUM> from the second longitudinal edge 32a thereof. Thus, the first <NUM> and second <NUM> longitudinal scores or cuts are provided about <NUM> from respective opposite longitudinal edges 31a,32a of the connecting element sheet <NUM>. The portion of the connecting element sheet <NUM> between the second score or cut <NUM> and the second longitudinal edge 32a may define the second portion <NUM>.

A third longitudinal score or cut <NUM> is made on the second face <NUM> of the connecting element sheet <NUM>, about <NUM> from the first longitudinal edge 31a thereof. Thus, the third longitudinal score or cut <NUM> is provided about <NUM> from the first longitudinal score or cut <NUM>, on an opposite face <NUM> of the connecting element sheet <NUM>. The portion of the connecting element sheet between the first longitudinal score or cut <NUM> and the third longitudinal edge <NUM> defines a fourth portion <NUM>. Thus, the proximal first <NUM> and third <NUM> longitudinal scores or cuts define a "double hinge" <NUM>, depicted in <FIG>. The connecting elements <NUM> are thus prepared, as shown in <FIG>, before use.

The locking element <NUM> are also prepared.

A sheet of <NUM>-thick fluted polypropylene is cut strips of about <NUM> x <NUM>.

A first longitudinal score or cut <NUM> on a first face <NUM> of the locking element sheet <NUM>, about <NUM> from a first longitudinal edge 41a thereof.

A first notch <NUM> is cut at or near a first corner of the locking element sheet <NUM> including the first longitudinal edge 41a, as best shown in <FIG>. The first notch <NUM> has a size of about <NUM> x <NUM>. The locking elements <NUM> are thus prepared, as shown in <FIG>, before use.

A first sheet <NUM> of <NUM>-thick fluted polypropylene is provided, having a size of about <NUM> x <NUM>.

A first connecting element <NUM> is provided, and the first face <NUM> of the first portion <NUM> of the first connecting element <NUM> is connected to the first layer <NUM>, using ultrasonic welding. There are typically provided a plurality of welds along the first portion, e.g. about <NUM> long and/or disposed at about <NUM> intervals.

A template is then provided to allow accurate and consistent positioning of the connecting elements <NUM> on the first layer <NUM> parallel to each other ad at about <NUM> intervals. Each of the connecting elements <NUM> are then welded to the first layer <NUM>.

Each of the remaining seven connecting elements <NUM> are then welded via the first face <NUM> of their first portion <NUM>, similarly to the first connecting element.

The following step involves attaching the locking elements <NUM> to the first sheet <NUM>.

Starting at one end of the apparatus <NUM>, a first connecting element <NUM> is folded over the first hinge <NUM> and second hinge <NUM> thereof, thus placing it into the conformation shown in <FIG>.

A first pair of locking element <NUM> is then placed next to it. The method comprises connecting the first portion <NUM> of the first pair of locking element <NUM> to the first layer <NUM>, using ultrasonic welding. The first pair of locking element <NUM> is provided between two adjacent connecting elements <NUM> and each locking element <NUM> of the pair is provided near a respective opposing edge of the first layer <NUM> at about the edge.

The second connecting element <NUM> is then folded over its first hinge <NUM> and second hinge <NUM>, and at least partially over the first pair of locking elements <NUM>.

Another pair of locking elements <NUM> is then positioned in the adjacent channel between the second and third connecting elements <NUM>, and welded in the same manner.

This process is repeated until the last connecting element <NUM> is reached at the far end of the apparatus <NUM> and until each channel between adjacent connecting elements <NUM> has been provided with a pair of locking elements <NUM>. The structure is then as shown in <FIG> and <FIG> (without the second layer <NUM>).

Each of the connecting elements <NUM> is then moved such that their respective first faces <NUM> face towards the first layer <NUM>, i.e., such that at least a portion of the first face <NUM> of the intermediate portions <NUM> and of the second portions <NUM> overlaps or extends over an adjacent pair of locking elements <NUM>, as shown in <FIG>.

Advantageously, the provision of the third longitudinal score of cut <NUM> on the second face <NUM> near the first longitudinal score of cut <NUM>, provides a double hinge region <NUM> which allows the connecting element <NUM> to remain flat and parallel to and adjacent a pair of locking elements <NUM> when overlapping or extending over such. This is advantageous as it may allow the second layer <NUM> to be placed flat and/or flush against the second face <NUM> of the second portion <NUM> for subsequent welding, as shown in <FIG>.

The second layer <NUM> is then placed against and welded to the second face <NUM> of the second portion <NUM> of each connecting element <NUM>, using ultrasonic welding. There are typically provided a plurality of welds along the second portion <NUM>, e.g. about <NUM> long and/or disposed at about <NUM> intervals.

In order to place the void former in its stowed configuration, the first layer <NUM> and the second layer <NUM> are then brought into proximity with each other.

In one embodiment, as shown in <FIG>, the first layer <NUM> and the second layer <NUM> are brought into proximity with each other such that the first face <NUM> of each connecting element <NUM>, faces towards the first layer <NUM> and such that at least a portion of the first face <NUM> of its intermediate portion <NUM> and second portion <NUM> overlaps or extends over a pair of locking elements <NUM>. Advantageously, this configuration may provide a thinner and/or more compact size or thickness in the first or stowed configuration.

In another embodiment, as shown in <FIG>, the first layer <NUM> and second layer <NUM> are brought in proximity with each other such that the first hinged connection <NUM> and the second hinged connection <NUM> of each connecting element <NUM> are folded over. Thus, at least a portion of the second face <NUM> of the intermediate portion <NUM> faces and overlaps at least a portion of the second face <NUM> of the first portion <NUM>, and at least a portion of the first face <NUM> of the intermediate portion <NUM> faces and overlaps at least a portion of the first face <NUM> of the second portion <NUM>. Advantageously, this configuration may provide a degree of "spring" in the void former <NUM> when provided in its stowed configuration, which may cause the void former <NUM>, upon deployment, to partially unfold upon deployment into or towards its deployed configuration.

The method may comprise securing, e.g. temporarily securing such as using adhesive tape, Velcro®, or the like, the void former <NUM> in its first or stowed configuration. This may conveniently allow a user to store the void former <NUM> and/or transport the void former <NUM> to a deployment site whilst in its first or stowed configuration.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as described herein without departing from the scope of the present invention. The present embodiments are therefore to be considered for illustrative purposes and are not restrictive, and are not limited to the extent of that described in the embodiment.

For example, and for the avoidance of doubt, it will be understood that, although <FIG> include certain dimensions, these dimensions are included as exemplary dimensions only to provide a level of context, and a person of skill in the art will understand that the invention is not in any way limited to any specific dimensions.

For example, the overall thickness of the void former <NUM> in the deployed configuration, i.e. the height of the connecting elements <NUM>, may be selected depending on the expected degree of ground heave at the deployment site.

Claim 1:
A building apparatus (<NUM>) comprising:
a first layer (<NUM>);
a second layer (<NUM>);
at least one connecting element (<NUM>) configured to connect the first layer and the second layer; and
at least one locking element (<NUM>) configured to maintain the apparatus in the second or deployed configuration, wherein the at least one locking element has a first portion (<NUM>) attached to the first layer (<NUM>), and a second portion (<NUM>) hingedly connected to the first portion (<NUM>),
wherein the building apparatus has a first or stowed configuration in which the at least one connecting element (<NUM>) is in a stowed state and a second or deployed configuration in which the at least one connecting element (<NUM>) is in a deployed state and is configured to maintain the first layer (<NUM>) and the second layer (<NUM>) in a distal relationship from each other.