Systems and Methods for Supporting a Concrete Slab

Abstract

Systems and methods for supporting a concrete slab are disclosed. The disclosed systems and methods may comprise an array of coupled hollow boxes to support a concrete slab monolithically poured on the array. The array of hollow boxes may be particularly suited for supporting a concrete slab to be emplaced at a construction site on expansive, collapsible, compressible, and/or rocky soils. The disclosed systems and methods may be more economically feasible and more reliable than other methods of preventing damage to a concrete slab in an expansive soil setting.

Description

TECHNICAL FIELD

The present disclosure relates generally to the field of construction systems. More particularly, the present disclosure relates to supporting a poured concrete slab, such as upon which a structure may be constructed.

BRIEF DESCRIPTION OF THE DRAWINGS

The present embodiments will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that the accompanying drawings depict only typical embodiments, and are, therefore, not to be considered limiting of the scope of the disclosure, the embodiments will be described and explained with specificity and detail in reference to the accompanying drawings.

FIG. 1 is a perspective view of a hollow box that may be used as part of a concrete slab support system for supporting a concrete slab while avoiding the effects of expansive soils.

FIG. 2A depicts a top plan view of an embodiment of a hollow box that may be used as part of a concrete slab support system.

FIG. 2B is a plan view of the bottom of the hollow box that may be used as part of a concrete slab support system of FIG. 2A.

FIG. 3 is a perspective view of a concrete slab support system comprising an array of clusters of hollow boxes arranged, including a cluster of four hollow boxes, a cluster of two hollow boxes, a cluster of one hollow box, and a plurality of clips.

FIG. 4 is a perspective view of an upper clip, which is an analog of the upper clips of FIG. 3.

FIG. 5 is a detail perspective view of a portion of a concrete slab support system according to an embodiment of the disclosure, having an upper clip analogous to upper the upper clip of FIG. 4.

FIG. 6 is a perspective view of a lower clip analogous to the lower clips of FIG. 3.

FIG. 7 is a perspective view of a portion of a concrete slab support system according to an embodiment of the disclosure, and having a lower clip analogous to the lower clip of FIG. 6.

FIG. 8 is a detail cross section of a portion of a hollow box concrete slab support system and, more particularly, of a clip hole analogous to the clip holes of FIG. 1.

FIG. 9 is a detail cross section of a portion of a hollow box of a concrete slab support system and, more particularly, of an anchor indentation, analogous to the anchor indentations of FIG. 1.

FIG. 10 illustrates a flow chart of a method of laying a concrete slab foundation.

FIG. 11 is a perspective view of a hollow box that may be used as part of a concrete slab support system for supporting a concrete slab, according to another embodiment of the disclosure.

DETAILED DESCRIPTION

A concrete slab is a common fixture, such as for a foundation for structures (e.g., buildings, decks, etc.) because it is relatively simple to engineer and install. While methods vary, some concrete slab foundations are a slab on grade, in which appropriate measures are taken to prepare the soil, forms are placed, and the concrete is poured directly on the ground, often with reinforcement materials such as reinforcing bar (“rebar”) or mesh. Various soils respond to the introduction or removal of moisture to differing degrees. Proper preparation of the ground to receive the pour requires a determination of the soil's characteristics for expansion and contraction, and mitigation thereof. The presence of clay, or clay-related minerals, can cause a soil to expand when water is present, and to contract when water is removed. Such soils are known generally as expansive soils.

Expansive soils, when not properly identified and remediated before pouring a concrete slab, such as a foundation for a structure, can lead to failure of the slab over time as the amount of water increases, decreases, or varies over time. Systems disclosed herein can limit or prevent concrete slab damage resulting from expansive soils. Additionally, the systems and methods may be used with collapsible, compressible, and/or rocky soils.

It will be readily understood that the components of the embodiments as generally described and illustrated in the figures herein could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the disclosure, as claimed, but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

FIG. 1 is a perspective view of a hollow box 110 that may be used as part of a concrete slab support system for supporting a concrete slab, and can avoid adverse effects of expansive soils on the concrete slab. The hollow box 110 consists of a top wall 120, four side walls 130-136, and an open bottom.

The four side walls include two vertical sidewalls and two angled sidewalls. More particularly, the hollow box 110 has a first angled sidewall 130, a second angled sidewall 132, a first vertical sidewall 134 and a second vertical sidewall 136. Opposite the top wall 120 is an open bottom, which, with the top wall 120 and the four side walls 130-136, defines an unenclosed void within the hollow box 110. The two angled sidewalls 130, 132 are angled in an outward direction relative to the top wall 120 of the hollow box. Adjacent the bottom along a lower edge of the first angled sidewall 130 and the second angled sidewall 132 is a flange 150. The flange 150 extends away from the hollow box 110 and is coupled to two of the side walls and adjacent the open bottom of the hollow box 110. The flange 150 has a first straight length and a second straight length, wherein the two straight lengths are coupled together at a corner of the hollow box 120. More particularly, the straight lengths of the flange 150 couple at a lower edge of a corner formed by intersecting the two angled sidewalls 130, 132.

The hollow box 110 has, arranged about a perimeter of the top wall 120, a series of clip holes, including clip holes 144, 146, 148. The series of clip holes in the top wall 120 may serve to secure the hollow box 110 to other hollow boxes via clips. The clip holes, including the clip holes 144, 146, 148, may be spaced along the entire perimeter of the top wall 120. The clip holes 144, 146, 148 may be used to couple the hollow box 120 to an adjacent hollow box, as further described below. Two center clip holes 144 are disposed with one clip hole located at a middle portion of each edge of the top wall 120 adjacent each angled sidewall 130, 132. Three corner clip holes 146 are disposed with one clip hole located in the top wall 120 near an intersection of the two angled sides 130, 132, another clip hole located near an intersection of the angled sidewall 130 and the vertical sidewall 136, and another clip hole located near an intersection of the angled sidewall 132 and the vertical sidewall 134. Two additional clip holes 148 are disposed with one clip hole located adjacent each of the vertical sides 134, 136 and near an intersection of the vertical sides 134, 136. The two additional clip holes 148 being nearer a corner of the top wall 120 than the two center clip holes 144.

The flange 150 of the hollow box 110 comprises one or more indentations for placing anchors to secure the hollow box 110 to the soil. In the present example, the flange 150 of the hollow box 110 has three anchor indentations 166, 168, 170. The anchor indentations 166, 168, 170 may facilitate anchoring the hollow box 120 to the soil upon which the hollow box rests, as further described below. A corner anchor indentation 166 is located in the flange 150 on the corner formed at the intersection of the two angled sides 130, 132. A second anchor indentation 168 is located on the first straight length of the flange 150 toward a distal end of the first straight length from the corner anchor indentation 166. A third anchor hole 170 is located on the second straight length of the flange 150 toward a distal end of the second straight length from the corner anchor indentation 166.

In some embodiments, a rib 152 couples between each angled sidewall 130, 132 and the flange 150 at a location distal of the anchor indentations 168. In some embodiments, another rib 152 couples between each angled sidewall 130, 132 and the flange 150 at a location near the anchor indentation 166. The ribs 152 may provide support and/or strength to the angled sidewalls 130, 132 and/or flange 150.

Approximately midway between each rib 152, on an exterior surface of each angled sidewall 130, 132 and adjacent the flange 150 may be a clip receiver 154. In some embodiments, each clip receiver 154 passes generally vertically from an exterior of the hollow box 110 to an interior of the hollow box 110. In some embodiments, each clip receiver 154 defines a chamber to receive a clip (see 256 in FIG. 3B).

FIG. 2A depicts a top plan view of an embodiment of a hollow box 210 that may be used as part of a concrete slab support system. The hollow box 210 includes many of the features described with reference to the hollow box 110 of FIG. 1. Accordingly, like features are designated with like reference numerals, with the leading digits incremented to “2.” For example, the embodiment depicted in FIG. 2A includes a hollow box 210 that may, in some respects, resemble the hollow box 110 of FIG. 1. Relevant disclosure set forth above regarding similarly identified features thus may not be repeated hereafter. Moreover, specific features of the concrete slab support system and related components shown in FIG. 1 may not be shown or identified by a reference numeral in the drawings or specifically discussed in the written description that follows. However, such features may clearly be the same, or substantially the same, as features depicted in other embodiments and/or described with respect to such embodiments. Accordingly, the relevant descriptions of such features in FIG. 1 apply equally to the features of the hollow box 210 and related components depicted in FIG. 2A. Any suitable combination of the features, and variations of the same, described with respect to the hollow box 110 and related components illustrated in FIG. 1 can be employed with the hollow box 210 and related components of FIG. 2A, and vice versa. This pattern of disclosure applies equally to further embodiments depicted in subsequent figures and described hereafter, wherein the leading digits may be further incremented.

FIG. 2A is a plan view of the top of a hollow box 210 that may be used as part of a concrete slab support system similar to the hollow box 110 of FIG. 1. The hollow box 210 is depicted having a top wall 220, and the top wall 220 is shown having a plurality of clip holes 244, 246, 248 disposed similarly to the clip holes 144, 146, 148 of FIG. 1. Angled sidewalls 230, 232, and vertical sidewalls 234, 236 are shown, as is a flange 250, the clip receivers 254, and anchor indentations 266, 268, 270. The hollow box 210 also comprises a series of ribs 222 intersecting along an interior surface of the top wall 220. Each rib of the series of ribs 222 couples to the top wall 220 and two sidewalls 230-236. A detail area A identifies the area shown in FIG. 8. A detail area B identifies the area shown in FIG. 9.

FIG. 2B is a plan view of the bottom of the hollow box 210 that may be used as part of a concrete slab support system of FIG. 2A. The hollow box 210 is shown, along with the top wall 220, the two angled sides 230, 232, the two vertical sides 234, 236, the clip holes 244, 246, 248, the flange 250, the anchor indentations 266, 268, 270, and the supporting ribs 222.

With respect to FIGS. 2A and 2B, the vertical sidewall 236 couples to the vertical sidewall 234 at a first sidewall edge 290, the vertical sidewall 234 couples to the angled sidewall 232 at a second sidewall edge 292, the angled sidewall 232 couples to the angled sidewall 230 at a third sidewall edge 294, and the angled sidewall 230 couples to the vertical sidewall 236 at a fourth sidewall edge 296.

A series of clip holes are located around a perimeter of the top wall 220. The series of clip holes includes three clip holes 246 in the top wall 220 at each of the second sidewall edge 292, the third sidewall edge 294, and the fourth sidewall edge 296. The series of clip holes further include two clip holes 248 in the top wall 220 between the corner adjacent the first sidewall edge 290 and, respectively, the second sidewall edge 292 and the fourth sidewall edge 296. The clip holes 248 may be equidistant from the corner of the top wall 220 adjacent the first sidewall edge 290. The flange 250 extends along both of the angled sides 230, 232. The vertical sides 234, 236 of the hollow box 210 are thus configured to abut, or nearly abut, a vertical sidewall of another hollow box.

The ribs 222 each couple to the top wall 220 and span between opposing sides of the hollow box 210. One or more of the ribs are generally parallel the vertical wall 234 and span between the vertical wall 236 and the angled wall 232; and one or more additional ribs are generally parallel the vertical wall 236 and span between the vertical wall 234 and the angled wall 230. The ribs 222 may have a lateral thickness and a vertical length particularly configured to assist in supporting the top wall 220 of the hollow box 210.

FIG. 3 is a perspective view of a concrete slab support system 300 comprising an array 302 of clusters of hollow boxes arranged, including a cluster 310 of four hollow boxes 313, 314, 315, 316, a cluster 311 of two hollow boxes 317, 318, a cluster 312 of one hollow box 319, and a plurality of clips. The arrangement of clusters 310, 311, 312 and hollow boxes 313-319, and additional clusters of hollow boxes, is for convenience of the disclosure and not by way of limitation. For example, an array may comprise multiples rows of clusters each having four hollow boxes; or an array may comprise a first row of clusters having two hollow boxes disposed between and coupled to second rows of clusters that may have four hollow boxes and a third row of clusters having four hollow boxes. The space between the clusters is used to form concrete ribs of a slab when the concrete is poured monolithically over the slap support system 200.

The cluster 310 of four hollow boxes 313-316 may be created by placing a vertical sidewall (see 234, 236 in FIGS. 2A, 2B) of a first hollow box adjacent or abutting a vertical sidewall of another hollow box. Each of the hollow boxes 313-319 is configured to be placed directly on soil of a site oriented such that the open bottom abuts the soil. In the present example, a first vertical sidewall of the hollow box 313 abuts a first vertical sidewall of the hollow box 314, and a second vertical sidewall of the hollow box 313 abuts a first vertical sidewall of the hollow box 316. The second vertical sidewall of the hollow box 314, and the second vertical sidewall of the hollow box 316, each abuts one vertical sidewall of the hollow box 315. Each hollow box is disposed with the top wall (see 220 in FIGS. 2A, 2B) up, and the unenclosed bottom of each hollow box resting on the ground.

The cluster 311 of two hollow boxes 317, 318, may be formed by placing a vertical sidewall of the hollow box 317 adjacent or abutting a vertical sidewall of the hollow box 318. The cluster 312 of one hollow box 319 may be formed of the hollow box 319. A cluster comprising multiple hollow boxes, e.g., the cluster of four 310, the cluster of two 311, is formed with the vertical sides of the comprising hollow boxes disposed inward relative to the cluster and toward each other, and the angled sides outward relative to the cluster. For a cluster of four, e.g., the cluster 310, the outward facing angled sides of the comprising hollow boxes define an angled perimeter of the cluster. For a cluster of two, e.g., the cluster 311, the outward facing angled sides of the comprising hollow boxes define an angled perimeter along three sides of the cluster, and outward facing vertical sidewalls define a vertical perimeter along the fourth side. Clusters, e.g., the clusters 310, 311, 312, are typically arranged with angled cluster sides of a first cluster facing angled cluster sides of a second cluster, and vertical cluster sides, when present, typically define an exterior perimeter of an array 302 of clusters.

In the example of FIG. 3, the cluster 310 is shown laterally adjacent the cluster 311 and diagonally adjacent the cluster 312. The cluster 310 is also laterally adjacent at least one additional cluster of four hollow boxes, laterally adjacent a second cluster of two hollow boxes, and diagonally adjacent at least two clusters of two hollow boxes.

With regard to each cluster of at least two hollow boxes, e.g., cluster 310 with hollow boxes 313-316 and cluster 311 with hollow boxes 317, 318, the disposition of each hollow box with a vertical sidewall adjacent a vertical sidewall of a neighboring hollow box also disposes at least two clip holes of the respective portions of the tops of each hollow box immediately adjacent to corresponding clip holes of the neighboring hollow box. Furthermore, adjacent clusters, e.g., cluster of four 310, cluster of two 311, and cluster of one 312, may be disposed so that three clip holes along the angled side-perimeters of the top wall of each hollow box are disposed opposite and aligned to three clip holes along the angled side-perimeters of a hollow box of a neighboring cluster.

In one embodiment, a clip 340a may comprise a longitudinal member having a vertical member at each end, with the vertical member at each end configured to be inserted into, or to be received by a clip hole, e.g., clip holes 344, 346. The clip 340a is shown positioned above and aligned with a clip hole 346 of the hollow box 318, and with a corresponding clip hole 346 of the hollow box 313. Similarly, a clip 340b is shown installed to corresponding clip holes 346 of the hollow boxes 317 and 316, and another clip 340b is shown installed to corresponding clip holes 344 of the hollow boxes 317 and 316. A support member, e.g., the support member 382a, may be disposed on top of a series of clips 340a, 340b, etc.

Within a cluster of four, e.g., cluster 310 or a cluster of two, e.g., cluster 311, neighboring hollow boxes within the cluster may be coupled together by means of at least one clip 341. Each such clip 341 has at least two posts connected by a crosspiece. A first post of a clip 341 may be inserted into a clip hole 348 of a first hollow box and a second post of the clip 341 may be inserted into an immediately adjacent clip hole 348 of the neighboring hollow box. The clip 341 may contribute to maintaining the positioning of the hollow boxes within the cluster relative to one another.

Similarly, as between neighboring clusters, an upper clip 342a having a longer crosspiece connecting the at least two posts may be used. In the present example, the upper clip 342a comprises four posts, with two posts disposed at either end of the upper clip 342a. The post(s) at one end of the upper clip 342a may be inserted into a pair of clip holes 346a along an angled side-perimeter of a hollow box, and the post(s) at the opposite end of the upper clip 342a may be inserted into an opposite and adjacent pair of clip holes 346b along an angled side-perimeter of a hollow box of the neighboring cluster. An upper clip 342b is shown installed to the array 302.

With an array 302 of clusters of hollow boxes, e.g., clusters 310, 311, 312, disposed in this manner, a channel 380 is defined between the angled sides of neighboring clusters. The channel 380 provides a form for concrete beams. A reinforcing member 382a, e.g., a section of rebar, may be disposed on the crosspieces of a row of clips 342a spanning each channel 380 between the clusters.

A lower clip 356a may be coupled at a first clip receiver 354a of a hollow box of a first cluster, and at a second clip receiver 354b of a hollow box of a second cluster. A lower clip 356b is shown installed to the array 302 and disposed within a channel 380 between clusters of hollow boxes. The first clip receiver 354a and a second clip receiver 354b are shown for, respectively, the hollow box 313 and the hollow box 317, with the clip receivers 354a, 354b disposed directly opposite each other across the gap 380. A clip 356 is shown which may be at least partially inserted into and received by the clip receivers 354a, 354b whereby the hollow boxes 313, 317 may be coupled together. Each hollow box 313-317, et al, of the array 302 may have clip receivers analogous to 354a, 354b disposed opposite each other may be similarly coupled by a clip analogous to the clip 356. The clips may support supporting bars to be positioned within cement ribs defined by the space between the clusters.

During a concrete pour, a quantity of concrete may enter each channel 380 (and envelope the reinforcing member 382), as well as covering the array 302 of clusters. Concrete within each channel between clusters may form a concrete beam which rests atop the respective flanges of the hollow boxes comprising the clusters and atop any soil exposed between the flanges. These concrete beams may serve to principally support the load of the concrete and any structure or load atop the concrete. The array 302 of clusters of hollow boxes, as well as that concrete overlying the clusters of hollow boxes, may serve to distribute the weight of the concrete and any structure or load atop the concrete slab.

With the arrangement of clusters 310, 311, 312, et al, thus disposed and coupled, the concrete slab support system 300 may resist an effect of expansion and/or contraction of the soil underlying the concrete slab. For example, expansion of soil resulting from an influx of water may be distributed primarily into the areas of the unenclosed bottoms of the hollow boxes whereby upward pressure is dissipated without applying destructive degrees of force to the underside of the concrete slab itself. Similarly, contraction of soil may be distributed across or throughout the hollow boxes without transferring destructive compression forces to the concrete slab. Mitigation of destructive forces in expansive soils may be achieved more economically through the use of the concrete slab support system 300 than by other means, such as removal and replacement of the expansive soil, including transport away from the site, costs of disposal, acquisition and transport of non-expansive fill material, installation of fill on the site (and the accompanying issues arising from improper or incomplete compaction of the replacement material).

An anchor 343 is shown aligned to an anchor indentation (see 166 in FIG. 1). A number of anchors 343 may be installed to various anchor indentations, e.g., the anchor indentations 166, 168, 170 of FIG. 1, to assist in disposing each hollow box and hollow box cluster of the array 302 prior to a monolothic concrete pour.

FIG. 4 is a perspective view of an upper clip 442, which is an analog of the upper clips 342a, 342b of FIG. 3. The upper clip 442 has a plate 444 at either end. At each plate 444, the upper clip 442 has posts 443 which extend upward 443a and downward 443b from the upper clip 442. The upper clip 442 further comprises a support member receiver 447 to receive a horizontally disposed support member, and a support member receiver 449 to receive a vertically disposed support member. The upper clip 442 further comprises four ribs 445, with two ribs 445 radiating from a portion of the support member receiver 447, 449 toward the plates 444 at either end of the upper clip 442. The posts 443a, 443b may permit installation of the upper clip 442 as illustrated in FIGS. 3-5, or inverted.

FIG. 5 is a detail perspective view of a portion of a concrete slab support system according to an embodiment of the disclosure, having an upper clip 542 analogous to upper the upper clip 442 of FIG. 4. A hollow box 510a and hollow box 510b have adjacently disposed clip holes (see 146 in FIG. 1) defining a clip hole pair 546a. Two hollow boxes 510c, 510d may be similarly disposed with a clip hole pair 546b opposite the clip hole pair 546a across a channel 580. An upper clip 542 is shown above the channel 580 between the hollow boxes 510a-510b, 510c-510d. A first pair of posts 543a is shown aligned to the clip holes pair 546a, and a second pair of posts 543b is aligned to the clip holes pair 546b. When the upper clip 542 is installed disposing the posts 543a in the clip holes pair 546a and the posts 543b in the clip holes pair 546b, the upper clip 542 may couple together the hollow boxes 510a-510d in a preferred configuration to receive a monolithic concrete pour. A horizontal support member 582 is shown above the upper clip 542. With the upper clip 542 installed to the hollow boxes 510a-510b, the horizontal support member 547 may be disposed to receive the horizontal support member 580.

FIG. 6 is a perspective view of a lower clip 656 analogous to the lower clips 356a, 356b of FIG. 3. At either end of the lower clip 656 is a first tab 657a and a second tab 657b, each configured to be inserted into a clip receiver (see 154 in FIG. 1). A rib 659 extends along either side of the lower clip 656 approximately from the first tab 657a to the second tab 657b and disposed along a lower portion of the lower clip 656. At a medial portion of an upper side of the clip 656 is a support member receiver 658 configured to receive a support member, e.g., the support member 382b in FIG. 3.

FIG. 7 is a perspective view of a portion of a concrete slab support system according to an embodiment of the disclosure, and having a lower clip 756 analogous to the lower clip 656 of FIG. 6. A first hollow box 710a and a second hollow box 710b are shown for reference, with flanges 750a, 750b, a rib 752, and an anchor indentation 768. The first hollow box 710a has a clip receiver 754a, and the second hollow box 710b has a clip receiver 754b. The lower clip 756 is shown ready to be coupled to the first and second hollow boxes 710a, 710b by lowering the lower clip 756 to insert a first tab 757a into the clip receiver 754a of the first hollow box 710a, and a second tab 757b into the clip receiver 754 of the second hollow box 710b. With the lower clip 756 installed to the first and second hollow boxes 710, 710b, a support member 782 may be installed to a support member receiver 758 if the lower clip 756.

FIG. 8 is a detailed cross section of a portion of a hollow box 810 of a concrete slab support system 800 and, more particularly, of a clip hole analogous to the clip holes 144, 146, 148 of FIG. 1. The area illustrated in FIG. 8 is an analogous area to the area identified in FIG. 2A at A. A top wall 820 of the hollow box 810 is shown, as is a clip hole 844 of the hollow box 810. The clip hole 844 may be representative of more than one clip hole of the hollow box. The clip hole 844 is disposed within the top wall 820. The portion of the clip hole 844 at the top wall 820 of the hollow box 810 has a first diameter 841. The clip hole 844 comprises a tapered cylinder or tapered walls. In other words, the clip hole 844 has a tapered portion 843 which tapers downward to a second diameter 842 narrower than the first diameter 841. The tapered walls may provide a friction fit for the clips.

In one embodiment, the tapered portion 843 may terminate at location within the clip hole 844 whereby the clip hole 844 may further comprise an untapered portion 845. The tapered portion 843 may facilitate insertion of a post of a clip while the untapered portion 845 may provide a tight fit whereby resistance is introduced so the post of the clip is more securely retained in the clip hole 844.

FIG. 9 is a detail cross section of a portion of a hollow box 910 of a concrete slab support system 900 and, more particularly, of an anchor indentation 960 analogous to the anchor indentations 166, 168, 170 of FIG. 1. The area of FIG. 9 is an analogous area to the area identified in FIG. 2A at B. An angled wall 930 of the hollow box 910 is shown, as well as the flange 950 and the rib 952. An anchor indentation 960 is disposed in an upper side of the flange 950. The anchor indentation 960 may have a generally circular shape (see 266, 268 in FIG. 2A) and may include a portion 962 which extends partially into the upper side of the flange 950. The anchor indentation 960 may further comprise a tapered portion 963 extending from the lower extent of the vertical portion 962 further into the flange 960.

In some embodiments, the vertical portion 962 may extend through the flange 950 to nearly penetrate the flange 950 or may fully penetrate the flange 950. In some embodiments, the tapered portion 963 may extend through flange 950 so as to penetrate the flange 950. The shape and form of the anchor indentation 960 may facilitate installation of an anchor pin (see 343 in FIG. 3) to anchor the hollow box 910 to a selected location on the ground prior to pouring concrete. In some implementations, the anchor indentation may include either the vertical portion 962 or the tapered portion 963, but not both. The construction of the anchor indentation 960 can be used for the anchor indentations 166, 168, 170 of FIG. 1.

FIG. 10 illustrates a flow chart of a method 1000 of laying a concrete slab foundation. The method 1000 includes placing 1010 a plurality of hollow boxes in an array on the ground of a site. The array comprising clusters of one or more of the plurality of hollow boxes, each of the clusters spaced apart from other clusters. The method 1000 further incudes coupling 1020 together the hollow boxes in each cluster with clips or pins, and coupling 1030 together the clusters with clips or pins. For example a cluster may be configured to be coupled with one or more clips to immediately surrounding clusters that are laterally adjacent via one or more of clip holes on top of each hollow box.

Additionally, in some embodiments, each of the hollow boxes includes a flange extending away from the hollow box and adjacent to a bottom of the box bottom. The flange may include one or more indentations for placing anchors to secure the hollow box to the soil. The method 1000 further includes securing 1040 the hollow boxes in place by driving one or more anchors through the one or more indentations of the flange and into the soil by driving. Additionally, the illustrated method includes placing 1050 support members across one or more clips between the clusters of hollow boxes, and pouring 1060 concrete over the hollow boxes and support members. In some embodiments, the concrete is poured monolithically. The hollow boxes may be left under the concrete after the concrete is poured.

FIG. 11 is a perspective view of a hollow box 1110 that may be used a part of a concrete slab support system for supporting a concrete slab, according to another embodiment of the disclosure. The hollow box 1110 is, in many respects, similar to the hollow box 110 of FIG. 1. A top wall 1120, a first and second angled sidewall 1130, 1132, a first and second vertical sidewall 1134, 1136, and a first sidewall edge 1190 are shown for reference.

The hollow box 1110 includes additional clip holes 1145. The clip holes 1144, 1145, 1146, 1148 may be used to couple the hollow box 1110 to other boxes. and the hollow box also includes anchor indentations 1166, 1168, 1170, as well as clip receivers 1154, and ribs 1152. The additional clip holes 1145 are disposed in the top wall 1120 adjacent each vertical sidewall 1134, 1136 and approximately midway between each clip hole 1146 and the first sidewall edge 1190. Each additional clip hole 1145 may be configured similarly to the clip holes 1146, 1148, and may likewise receive a clip to couple the hollow box 1110 to an adjacent hollow box. The hollow box 1110 can include any of the features described above in connection with the hollow box 110 or otherwise. For example, the hollow box 1110 can include the anchor indentations 960 (as shown in FIG. 9 and described in connection with that figure) and/or the tapered clip holes 844 (as shown in FIG. 8 and described in connection with that figure).

In some embodiments, the array comprises a first row of clusters where each cluster comprises two hollow boxes, a second row of clusters where each cluster comprises four hollow boxes, and a third row of clusters where each cluster comprises four hollow boxes, wherein a plurality of clips couple clusters from the first row to clusters from both of the second row and the third row. In some implementations, an array can include different clusters that include one, two, three, and four hollow boxes.

In some embodiments, the one or more clip holes comprise a clip hole at three corners of a top wall of each hollow box, a clip hole at a middle portion of each edge of the top wall of each hollow box, and two clip holes near a fourth corner of the top wall of each hollow box. This configuration of clip holes can facilitate more flexible positioning and orientation of the hollow boxes, such as when a cluster of three boxes is used or a single box cluster is connected to another single box cluster or to a cluster having a larger number of boxes. The single box can be oriented in multiple different directions (e.g., to face the flange in a particular direction) and the clip holes shown in FIG. 11 can be used to facilitate connections with clips in the different directions.

In some embodiments, the one or more indentations in the flange comprise three indentations. Additional anchor indentations may also be included.

Throughout this specification, the phrase “coupled to” refers to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be coupled to each other even though they are not in direct contact with each other.

The terms “a” and “an” can be described as one, but not limited to one. For example, although the disclosure may recite an element having “a clip hole,” the disclosure also contemplates that the element can have two or more clip holes.

Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints.

Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.

Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment. Thus, the claims following this Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims.

Recitation in the claims of the term “first” with respect to a feature or element does not necessarily imply the existence of a second or additional such feature or element. Elements recited in means-plus-function format are intended to be construed in accordance with 35 U.S.C. § 112 ¶ 6. It will be apparent to those having reasonable skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. Embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.

Claims

1. An apparatus to support a concrete slab, the apparatus comprising: a hollow box comprising four side walls, a top wall, and an open bottom, wherein the hollow box is configured to be placed directly on soil of a site oriented such that the open bottom abuts the soil;a flange extending away from the hollow box, the flange coupled to two of the side walls and adjacent to the open bottom, wherein the flange comprises one or more indentations for placing anchors to secure the hollow box to the soil; anda plurality of clip holes in the top wall to secure the hollow box to other hollow boxes via clips.

2. The apparatus of claim 1, further comprising a plurality of ribs intersecting along an interior surface of the top wall, each rib of the plurality of ribs coupled to the top wall and two side walls.

3. The apparatus of claim 1, wherein the one or more indentations in the flange comprises three indentations.

4. The apparatus of claim 1, wherein the flange comprises a first straight length and a second straight length coupled by a corner, and wherein the first indentation of the three indentations is located on the corner, a second indentation of the three indentations is located on a first straight length, and a third indentation of the three indentations is located on a second straight length.

5. The apparatus of claim 1, wherein the plurality of clip holes comprise: a first clip hole adjacent to a middle portion of a first edge of the top wall; anda second clip hole adjacent to a middle portion of a second edge of the top wall, wherein the first clip hole and the second clip hole comprise tapered walls.

6. The apparatus of claim 5, wherein the four side walls comprise two vertical sidewalls and two angled sidewalls, wherein the two angled sidewalls are angled in an outward direction relative to the top wall, andwherein a first vertical sidewall is coupled to a second vertical sidewall at a first sidewall edge, the second vertical sidewall is coupled to a first angled sidewall at a second sidewall edge, the first angled sidewall is coupled to a second angled sidewall at a third sidewall edge, and the second angled sidewall is coupled to the first vertical sidewall at a fourth sidewall edge.

7. The apparatus of claim 6, wherein the plurality of clip holes further comprise: a third clip hole adjacent to a first corner of the top wall, where the first corner of the top wall is adjacent the second sidewall edge;a fourth clip hole adjacent to a second corner of the top wall, where the second corner of the top wall is adjacent the third sidewall edge; anda fifth clip hole adjacent to a third corner of the top wall, where the third corner of the top wall is adjacent the fourth sidewall edge wherein the third, fourth, and fifth clip holes comprise tapered walls.

8. The apparatus of claim 7, wherein the plurality of clip holes further comprise: a sixth clip hole generally between a middle portion of a third edge of the top wall and a fourth corner of the top wall, where the fourth corner of the top wall is adjacent the first sidewall edge, wherein the third edge is coupled to the first vertical sidewall; anda seventh clip hole generally between a middle portion of a fourth edge of the top wall and the fourth corner of the top wall, wherein the fourth edge is coupled to the second vertical sidewall.

9. The apparatus of claim 8, wherein the sixth clip hole and the seventh clip hole are an equal distance away from fourth corner of the top wall.

10. The apparatus of claim 7, wherein the first edge is adjacent to the first angled sidewall and the second edge is adjacent to the second angled sidewall, with the plurality of clip holes further comprising: an eighth clip hole adjacent to a middle portion of the third edge of the top wall; anda ninth clip hole adjacent to a a middle portion of the fourth edge of the top wall.

11. A system of supports for a concrete slab, the system comprising a plurality of hollow boxes, each hollow box comprising: four side walls, a top wall, and an open bottom, wherein the hollow box is configured to be placed directly on soil of a site oriented such that the open bottom abuts the soil; anda plurality of clip holes in the top wall, the clip holes spaced along and adjacent an exterior perimeter of the top wall, wherein the clip holes comprise tapered walls; anda plurality of clips comprising two or more posts and a crosspiece coupling the two or more posts together, wherein the two or more posts are configured to be selectively inserted into the clip holes to secure two or more hollow boxes together, wherein the tapered walls of the clip holes are configured to facilitate an interference fit between the clip holes and the posts,wherein the plurality of hollow boxes are configured to be placed in an array, the array comprising clusters of one or more of the plurality of hollow boxes with each of the clusters spaced apart from other clusters and configured to be coupled with one or more of the plurality of clips to every immediately surrounding cluster via one or more of the plurality of clip holes.

12. The system of claim 11, wherein one or more crosspieces of the plurality of clips configured to be used between the clusters are further configured to receive at least one support member configured to span a plurality of crosspieces.

13. The system of claim 11, wherein the plurality of clip holes are arranged on each hollow box to facilitate coupling between a first cluster comprising two hollow boxes and a cluster comprising four hollow boxes on any side of the first cluster via one or more of the plurality of clips.

14. The system of claim 11, wherein the plurality of clip holes are arranged on each hollow box to facilitate coupling between a first cluster comprising a single hollow boxes and a cluster comprising multiple hollow boxes on any side of the first cluster via one or more of the plurality of clips.

15. The system of claim 11, wherein the plurality of clip holes comprise a clip hole at three corners of the top wall, a clip hole at a middle portion of each of four edges of the top wall, and two clip holes near a fourth corner of the top wall.

16. The system of claim 11, wherein each of the plurality of hollow boxes further comprise a flange extending away from two of the side walls and adjacent to the open bottom, wherein the flange comprises one or more indentations for placing anchors to secure the hollow box to soil.

17. A method of laying a concrete slab, the method comprising: placing a plurality of hollow boxes in an array on the ground of a site, the array comprising clusters of one or more of the plurality of hollow boxes, each of the clusters spaced apart from other clusters and configured to be coupled with one or more clips to immediately surrounding clusters via one or more clip holes on top of each hollow box, wherein each of the hollow boxes comprises a flange extending away from the hollow box and adjacent to a bottom of the box bottom, wherein the flange comprises one or more indentations for placing anchors to secure the hollow box to the soil;securing the hollow boxes in place by driving one or more anchors through at least one of the one or more indentations of the flange and into the soil; andplacing support member across one or more clips between the clusters of hollow boxes; andpouring concrete monolithically over the hollow boxes and support members.

18. The method of claim 17, wherein the array comprises a first row of clusters with each cluster comprising two hollow boxes, a second row of clusters where each cluster comprising four hollow boxes, and a third row of clusters where each cluster comprising four hollow boxes, wherein a plurality of clips couple clusters from the second row to clusters from both of the first row and the third row.

19. The method of claim 17, wherein the one or more indentations in the flange comprise three indentations.

20. The method of claim 17, wherein the hollow boxes are left under the concrete after pouring the concrete.