Nestable structural hollow body and related methods

Abstract

A multi-piece interconnected body for use in at least structural support and/or in creating internal cavities for an improved strength-to-weight ratio in a variety of structures is nestable prior to its assembly and use. When assembled, the device preferably forms a generally spherical and hollow body, with (1) one or more ribs or similar structural support network associated with and/or integrally formed in the body; (2) at least one latch mechanism to help hold the pieces in a desired assembled relationship with each other; and (3) a hinge or other interconnecting element that facilitates nesting and/or stacking of a plurality of the bodies with each other prior to assembly, association of the multiple parts of each body with each other prior to assembly, and ready repositioning of those parts into a desired assembled position.

1 . A device for structural support or creating internal cavities in material, comprising: 
 a spherical hollow body having a top section and a bottom section;    a structural support network disposed within the hollow body, said support configured to increase the load bearing capacity of the hollow body against external forces;    at least one latch mechanism positioned along a periphery of each of the top section and the bottom section; and    a hinge corresponding to said latch mechanism and connecting the top section and the bottom section to each other, said hinge configured and positioned to permit selected repositioning of the top section of the hollow body and the bottom section of the hollow body with respect to each other, between a first position permitting nesting of a plurality of such hollow bodies with other similarly sized and shaped devices, and a second closed position in which the device defines a hollow body.    
     
     
         2 . The device of  claim 1 , wherein the structural support network includes; 
 a concentric ring located generally near a central portion of each of the top section and the bottom section of the hollow body; and    a plurality of support arms radiating outward from each of the concentric rings in a direction toward the periphery of each of the top section and the bottom section.    
     
     
         3 . The device of  claim 1 , wherein the latch mechanism includes: 
 a head portion formed on the periphery and protruding from a recessed portion formed on one of the top section and the bottom section of the hollow body, and    a correspondingly shaped cavity formed on the periphery of a recessed portion on the other one of the top section and the bottom section of the hollow body for mating with the head when the hollow body is in the closed state.    
     
     
         4 . The device of  claim 3 , further including a plurality of such latch mechanisms.  
     
     
         5 . The device of  claim 1 , wherein the top section and the bottom section are substantially the same size and shape.  
     
     
         6 . A structural concrete span formed with a plurality of the devices of  claim 1  in the interior of the span.  
     
     
         7 . A generally spherical body comprising: 
 a top section and a bottom section of substantially similar size and shape;    a structural support network associated with the spherical body to increase the load bearing capacity of the spherical body when subjected to external forces;    a hinge element connecting the top section and the bottom section and permitting selected positioning of the top section and the bottom section with respect to each other, including positioning in a generally open state permitting stacking and nesting of a plurality of such spherical bodies with each other, and a closed state generally defining a void within the sealed assembly; and    at least one latch mechanism operatively positioned to at least partially hold the top section and the bottom section in the closed state.    
     
     
         8 . The body of  claim 7 , in with said body is formed of injection molded plastic and said structural support network is integrally formed into that plastic.  
     
     
         9 . A system for fabricating concrete structural spans, comprising the steps of: 
 fabricating a plurality of devices of  claim 1  or  claim 7;     stacking said devices with each other in a nested relationship;    assembling said devices into a form defining an internal generally void space;    positioning said devices within a space into which concrete is to be poured, and pouring concrete around the devices.    
     
     
         10 . A method of creating internal cavities in concrete or other materials that set after pouring, comprising the steps of: 
 providing at least one device of  claim 1  or  claim 7  in its assembled form; and    pouring a setting material around the device.