Patent Application
20240246138
An aspect and embodiments thereof relate to a machine for shaping a netting for a building element. Another aspect and embodiments thereof relate to the building element.
Shaped netting for building panels having the shaped netting attached thereto are known from EP1759071B1. This patent discloses a flat panel with shaped netting embedded in the foam material. Such netting may be manufacturing using folding machines, though this has proven to be a cumbersome process that does not provide an accurate and reproducible shaping of the netting.
To address issues with existing machines, a device for shaping a netting is provided. The device comprises a first shaping cylinder comprising a multitude of first protrusions radially extending from an outer wall of the cylinder and annularly equidistantly distributed over the outer wall and a second shaping cylinder comprising a multitude second of protrusions radially extending from an outer wall of the cylinder and annularly equidistantly distributed over the outer wall. The device further comprises a first drive unit for driving unit for driving at least one of the first shaping cylinder and the second shaping cylinder, a device frame arranged to support the first shaping cylinder and the second shaping cylinder in a rotating fashion such that first centreline of the first shaping cylinder is substantially parallel to the second shaping cylinder and such that the multitude of first protrusions is arranged to engage with the multitude second of protrusions and a biasing module arranged to apply a biasing force, preferably in a resilient way, to at least one of the first shaping cylinder and the second shaping cylinder such that the first shaping cylinder and the second shaping cylinder are biased towards one another. In this device, the biasing module, the first protrusions and the second protrusions are arranged such that when netting is provided between the first shaping cylinder and the second shaping cylinder, the netting is force fitted between the first shaping cylinder and the second shaping cylinder at substantially each rotational position of the first shaping cylinder and the second shaping cylinder.
By providing the substantially continuous force fit—for example for at least 90%, at least 95% or at least 99% of the circumference of the shaping cylinders—the netting is kept at a stable position between the shaping cylinders and is unable to slip or otherwise move relative to the shaping cylinders during the shaping process. This, in turn, allows for a controlled continuous feed of the netting by action of the shaping cylinders alone, without the need of further driving means for feeding the netting through the process.
The protrusions may have an elongate shape. This allows for forming of elongate deformations in the netting, for example wave-shaped.
The first protrusions may be provided substantially parallel to a first centreline of the first shaping cylinder and the second protrusions may be provided substantially parallel to a second centreline of the second shaping cylinder. This allows for waves perpendicular to the length of the netting.
The first protrusions may be provided under a first angle relative to a first centreline of the first shaping cylinder and the second protrusions may be provided under a second angle relative to a second centreline of the second shaping cylinder, wherein the first angle is preferably substantially the same as the second angle. With the first angle substantially the same as the second angle, the first protrusions and the second protrusions are allowed to mesh like gears, as with other implementations and the general concept. For certain use of the netting, providing waves under an angle may have advantages.
The protrusions may have a trapezoid shape, wherein the longer parallel sides are provided at the outer wall of the first shaping cylinder and the outer wall of the second shaping cylinder and the shorter parallel side is provided at a distance from at the outer wall of the first shaping cylinder and the outer wall of the second shaping cylinder. With such shapes, trapezoid shaped waves may be provided in the netting. The angles in the waves are obtuse, which means less stress in the netting compared to square angles, which may lead to fatigue and breaking of the netting. Curved waves may provide even more benefits at such points and the protrusions may be shaped to provide curved waves. However, trapezoid shaped protrusions are preferred as that shape provides improved meshing as indicated.
The centreline of the first shaping cylinder may be substantially horizontally placed and the second shaping cylinder may be provided above the first shaping cylinder. This allows for stable feed of the netting to be shaped, in a horizontal orientation.
The distance between the first centreline and the second centreline may be varied. With the first shaping cylinder and the second shaping cylinder being arranged in the frame such that at least one of the shaping cylinder is movable relative to the frame and relative to the other shaping cylinder, netting with different thickness may be processed, while ensuring the force fitting of the netting between the shaping cylinders. For example, the biasing module may be further arranged to move the first centreline relative to the second centreline.
The biasing force provided by the biasing module may be adjustable. This allows for optimising setting for different types of netting for example with different materials, different shapes, different weaves and different thicknesses to ensure optimal force fitting.
The biasing module may comprise at least one of a hydraulic cylinder, a pneumatic cylinder and a resilient biasing element, in particular a hydraulic cylinder and a pneumatic cylinder allow for adjustment of the distance between the centrelines of the shaping cylinders. And the pneumatic cylinders and (passive) resilient biasing elements allow for variations of the distance between the centrelines of the shaping cylinders, under a biasing force. The latter may improve the force fitting principle, without damage or in any case by reducing damage to the netting.
The first drive unit may be arranged to drive the first shaping cylinder and the device may further comprise a second drive unit arranged to drive the second shaping cylinder. This allows for independent driving of each cylinder—although the drive units may be synchronised to rotate at generally the same rotational speed to allow the protrusions to mesh or to engage in a meshing action.
More in particular, the first drive unit may comprises a first electromotor and the second drive unit comprises a second electromotor and the device further comprising an electronic power supply unit. The electronic power supply unit may be arranged to, provide a first electrical power supply signal to the first electromotor, provide a second electrical power supply signal to the second electromotor; and synchronise a first waveform of the first electrical power supply signal to a second waveform of the second electrical power supply signal.
The electromotor may be a stepper motor, but it may also be a brushless electromotor or another AC electromotor of which the rotational speed may be controlled by means of controlling a frequency of a power signal provided to the electromotor.
The device according may further comprise a mechanical coupling means for coupling the first drive unit, the first shaping cylinder and the second shaping cylinder such that the first driving unit drives the first shaping cylinder and the second shaping cylinder at substantially the same annular speed, in opposite directions. Whereas a mechanical coupling may, in certain scenarios be more reliable, it may introduce slack between the shaping cylinders.
It is preferred to provide a building element having improved rigidity.
A building element is provided comprising a polymer foam material body and a reinforcement netting affixed to a first side of the body, the reinforcement netting being shaped in a first multitude of netting shapes having a first netting level and a second multitude of netting shapes having a second netting level. In this building element, the first side of the body is shaped in a first multitude of body shapes having a first body level and a second multitude of body shapes having a second body level; and the netting is affixed to the body by at least part of the first multitude of netting shapes being affixed to at least part of the first multitude of body shapes. The first multitude of body shapes may be at locations where the polymer foam material body is thinner than at locations of the second multitude of body shapes. This provides a rigid building element, providing insulation and anchoring for further layers to be attached to the building element, like concrete or plaster material.
A first difference between the first body level and the second body level is different from a second difference between the first netting level and the second netting level. This allows for connecting one of the first plurality of shapes of the netting to the foam body and the other not. This means that space may be provided between the second plurality of shapes of the netting and the foam body. In this space, at least one of plaster material may be provided for strength or conduits for power or fluid material may be provided—or other elements that may be required or desirable in a building.
The netting may be affixed to the body by at least part of the netting being embedded in the body. This provides improved attachment of the netting to the body.
The netting is affixed to the body by means of a binding agent. This may be established by embedding the netting—in which case the foam base material is the binding material—or by applying a glue or other type of cement to the surface of the foam body to attach the netting to the foam body. These options may also be combined.
The binding agent comprises a binding agent material similar to the polymer foam material of the body. For example, the foam may comprise polyurethane foam and the binding agent may be polyurethane glue.
The body shapes may be shaped in a single dimension. Basically, this means that the body shapes are provided as longitudinal element.
The body shapes may have a periodic structure. This enhances the ease of manufacturing and the ease of using the building element in design and construction of buildings.
The netting shapes may be shaped in a single dimension. Basically, this means that the netting shapes are provided as longitudinal element.
The netting shapes may have a periodic structure. This enhances the ease of manufacturing and the ease of using the building element in design and construction of buildings.
The netting may comprise a first set of parallel wires and a second set of parallel wires. Such netting is generally well available and may be processed without complications or significant complications.
The wires of the first set may be perpendicular to the second set. Such netting provides structural rigidity in two directions.
The shapes may be provided by only shaping the first set of parallel wires. This may allow for convenient processing of the netting, as well as rigidity, as only one set of wires is to be shaped.
The building element may further comprise a granulate mineral material like sand provided on the first side of the body in a blanket fashion. This may provide additional anchoring of layer of cement, plaster or other material.
The technology discussed above and further details thereof will now be discussed in further detail below in conjunction with drawings. In the drawings:
The first protrusions 214 are provided on the first cylindrical body 212 substantially equidistantly on the circumferential outer wall of the first cylindrical body. Preferably, the first protrusions 214 are elongate protrusions, provided over at least 50%, preferably at least 75% and more preferably at least 90% of the length of the first cylindrical body 212. Preferably, the first protrusions 214 are provided on the first cylindrical body 212 such that the longitudinal orientation of the first protrusions 214 is parallel to the centreline of the first cylindrical body 212. Alternatively, the first protrusions 214 are provided under an angle relative to the centreline.
The second protrusions 224 are provided on the second cylindrical body 222 substantially equidistantly on the circumferential outer wall of the second cylindrical body. Preferably, the second protrusions 224 are elongate protrusions, provided over at least 50%, preferably at least 75% and more preferably at least 90% of the length of the second cylindrical body 222. Preferably, the second protrusions 224 are provided on the second cylindrical body 222 such that the longitudinal orientation of the second protrusions 224 is parallel to the centreline of the second cylindrical body 222. Alternatively, the second protrusions 224 are provided under an angle relative to the centreline, preferably substantially the same angle as the first protrusion relative to the centreline of the first cylindrical body 212.
The first protrusions 214 and the second protrusions 224 are in
As shown in
The first protrusions 214 and the second protrusions 224 preferably all have substantially the same shape. The angels of the trapezoid shapes as shown by
To enable the force fitting of multiple types of netting or other sheet-like material, the first roller 122 is suspended on the first roller pillar 114 by means of a first hydraulic cylinder 152 as a first biasing element and on the second roller pillar 116 by means of a second hydraulic cylinder 154 as a second biasing element. The first roller 122 is, by means of the hydraulic cylinders, movable relative to the second roller 124 such that the distance between the centrelines of the rollers may be varied.
Preferably, at least one of the hydraulic pressure provided and the position of the first roller 122 relative to the second roller 124 depends on the thickness of the netting to be shaped. Preferably, the distance between the first roller 122 and the second roller 124, the protrusions taken into account, is substantially the same or slightly less than the thickness of the netting to be shaped. In that way, no clearance or slack is present and the netting is drawn from the reel 172 with generally constantly a force being applied to the netting on the reel 172. Preferably, the netting is drawn from the reel at a substantially constant speed and a substantially constant force. The machine 100 may be provided with an input module like buttons or a touch screen to provide a thickness of the netting and a control circuit to retrieve data from a memory in response to the input thickness and to adjust at least one of hydraulic pressure and position of pistons in the hydraulic cylinders in accordance with the retrieved data.
Additionally or alternatively to the hydraulic cylinders, pneumatic cylinders may be used, using compressed gases rather than a dense compressed fluid like oil or water. An advantage is that pneumatic cylinders provide a certain resilience as the gas in the cylinders is compressible, in any case far more compressible than liquid in hydraulic cylinders. To enhance resilience of the system, i.e. resilience of a connection the cylinders and at least one of the rollers, resilient biasing elements like helical springs, other springs, rubber or other elastomer elements, other or a combination thereof, may be provided between the cylinders and the rollers, between the cylinders and the frame 110. Hence, a biasing module may be provided with at least one of a hydraulic cylinder, a pneumatic cylinder and a resilient biasing element.
The first roller 122 is connected to a first driving module 130 as a drive unit comprising a first electromotor 132 and a first drive train 134. The first electromotor 132 is arranged to rotate the first roller 122 via the first drive train 134. The first electromotor 132 may be a stepper motor, a bushed or brushless motor, a synchronous or asynchronous machine or any other type of electromotor. Preferably, the rotational speed of the first electromotor 132 may be controlled by controlling a frequency of a waveform of an electrical power signal provided to the first electromotor 132 for powering first electromotor 132.
The second roller 124 is connected to a second driving module 140 as a drive unit comprising a second electromotor 142 and a second drive train 144. The second electromotor 142 is arranged to rotate the second roller 124 via the second drive train 144. The second electromotor 142 may be a stepper motor, a bushed or brushless motor, a synchronous or asynchronous machine or any other type of electromotor. Preferably, the rotational speed of the second electromotor 142 may be controlled by controlling a frequency of a waveform of an electrical power signal provided to the second electromotor 142 for powering second electromotor 142.
The first electromotor 132 and the second electromotor 142 are preferably provided with a first electrical power signal and a second electrical power signal, respectively, which have substantially and preferably exactly the same frequency. Preferably, the first electrical power signal and the second electrical power signal are provided by an electrical control module 180 that is arranged to control frequency and, optionally, at least one of current, voltage and phase of the electrical power signals provided. In this way, the first roller 122 and the second roller 124 may be rotated at substantially and preferably exactly the same speed to shape a netting.
Alternatively, the machine 100 is provided with only one electromotor and the first roller 122 and the second roller are driven by one and the same electromotor and connected via a mechanical coupling module like a belt, a chain or a set of one or more gears.
With the machine 100 as shown by
Netting to be shaped may be provided on the reel 172 and be provided to the first roller 122 and the second roller 124 via a feeder plate 162. The feeder plate 162 may also be used to align the netting with the first roller 122 and the second roller 124. To that purpose, the feeder plate 162 may be provided with raised edges on either side of the feeder plate 162.
With the shaped netting 300 of
The longitudinal wires 312 and with that, the shaped netting 300 is shaped in shapes—trapezoids—having a first level—the lower level of valleys 324—and a second level—the higher level of hills 322. The first level and the second level are defined as perpendicular relative to a plane defined by the length and the width of the shaped netting 300, so perpendicular to the transversal direction and transversal to the longitudinal direction.
By shaping the longitudinal wires 312 only, the shaped netting is shaped in a single dimension only, with, as indicated above, only the longitudinal shapes being shaped. Alternatively, also the transversal wires 314 may be shaped in the same levels—or different levels—, resulting in local peaks, rather than in longitudinal raised regions and longitudinal depressed regions parallel thereto in the shaped netting 300. Preferably, the hills 322 and the valleys 324 or other shapes are provided in a periodic fashion.
With the building panel 410 as shown by
The shaped netting 300 may be connected to the building panel 410 in various ways. The shaped netting 300 may be embedded in the substance of which at least most of the building panel 410 is made. This may be established while manufacturing the building panel 410, for example before or during curing of a foam forming substance. Alternatively or additionally, a binding agent may be provided on top a cured or almost cured building panel 410 and the shaped netting 300 may be affixed to the building panel 410 by means of the binding agent. The binding agent may comprise a substance that is the same as a substance comprised by the building panel 410; additionally or alternatively, the binding agent may comprise a different substance.
At the top side of the building panel 410, a granulate mineral material, like sand (silicon dioxide), other, or a combination thereof may be provided. The granulate material may be affixed to the building panel 410 by means of a binding agent, which may be the same or a different binding agent as with which the shaped netter 300 is attached to the building panel 410. The granulate material may be provided on a part of the building panel 410 or in a blanket fashion, all over the top surface of the building panel 410. Optionally, the granulate material may be provided on other surfaces of the building panel 410. If the same binding agent is used as for affixing the shaped netting 300 to the building panel 410, the binding agent may be applied in a blanket fashion on the top surface of the building panel 410 prior to application of the shaped netting 300. After the binding agent has been applied in a blanket fashion, the shaped netting 300 is applied, followed by the granulate material.
After the building module 400 has been manufactured, it may be used as a building element for a wall, floor, ceiling or roof of a building like a house, warehouse, apartment building, factory, other, or a combination thereof. Between the shaped netting 300 and the building panel 410, with the building module 400 as depicted between the hills of the shaped netting 300 and the hills of the building panel 410, wires, tubes and conduits for utility like electricity, combustible fluids like gas, water and other material or energy may be provided. On the top side of the building module 400, concrete or another curable material may be provided, preferably after the conduits have been applied. The granulate material may enhance the bonding between the curable material and the building module 400.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2028389 | Jun 2021 | NL | national |
| 2028395 | Jun 2021 | NL | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/NL2022/050308 | 6/3/2022 | WO |
