DEVICE FOR SHAPING A NETTING AND A BUILDING ELEMENT COMPRISING SUCH SHAPED NETTING

Abstract

A device comprises at least two shaping cylinders each comprising a multitude of protrusions radially extending outward from the cylinder. 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 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 to at least one of the shaping cylinders. In this device, the biasing module, the first protrusions and the second protrusions are arranged such that when netting is provided between the shaping cylinders, the netting is force fitted between the shaping cylinders at substantially each rotational position of the shaping cylinders.

Claims

1. A device for shaping a netting, the device comprising: 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; 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; 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; a biasing module arranged to apply a biasing force 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; wherein 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.

2. The device according to claim 1, wherein the protrusions have an elongate shape.

3. The device according to claim 2, wherein the first protrusions are provided substantially parallel to a first centreline of the first shaping cylinder and the second protrusions are provided substantially parallel to a second centreline of the second shaping cylinder.

4. (canceled)

5. A device according to claim 1, wherein the protrusions 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.

6. A device according to claim 1, wherein the centreline of the first shaping cylinder is substantially horizontally placed and the second shaping cylinder is provided above the first shaping cylinder.

7. (canceled)

8. (canceled)

9. The device according to claim 1, wherein the biasing force provided by the biasing module is adjustable.

10. The device according to claim 9, wherein the biasing module comprises at least one of a hydraulic cylinder, a pneumatic cylinder and a resilient biasing element.

11. The device according to claim 1, wherein the first drive unit is arranged to drive the first shaping cylinder, the device further comprising a second drive unit arranged to drive the second shaping cylinder.

12. The device according to claim 11, wherein the first drive unit comprises a first electromotor and the second drive unit comprises a second electromotor, the device further comprising an electronic power supply unit 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 and a second waveform of the second electrical power supply signal.

13. (canceled)

14. The device according to claim 1, further comprising 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.

15. (canceled)

16. A building element 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, wherein: 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; 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 at the first side of the body; and at least part of the netting protrudes from the building element at the first side of the building element.

17. The building element according to claim 16, wherein 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, such that a space is provided between the first side of the body and the netting at locations of one of the first body level and the second body level.

18. The building element according to claim 17, wherein the first difference is less than the second difference, such that the space is provided between the first side of the body and the netting at locations of the second body level.

19. The building element according to claim 16, wherein the netting is affixed to the body by a part of the netting being embedded in the body at the first side of the body and part of the netting protruding from the body.

20. The building element according to claim 16, wherein the netting is affixed to the body by means of a binding agent.

21. (canceled)

22. The building element according to claim 16, wherein at least one of the body shapes and the netting are shaped in a single dimension.

23. (canceled)

24. The building element according to claim 16, wherein at least one of the body shapes and the netting have a trapezoid shape.

25. (canceled)

26. (canceled)

27. (canceled)

28. The building element according to claim 16, wherein the netting comprises a first set of parallel wires and a second set of parallel wires.

29. The building element according to claim 28, wherein the wires of the first set are perpendicular to the second set.

30. The building element according to claim 28, wherein the netting shapes are shaped in a single dimension and the shapes are provided by only shaping the first set of parallel wires.

31. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The technology discussed above and further details thereof will now be discussed in further detail below in conjunction with drawings. In the drawings:

[0032] FIG. 1 A shows a first view of a machine for shaping netting;

[0033] FIG. 1 B shows a second view of the machine for shaping netting;

[0034] FIG. 2 shows rollers as a detail of the machine for shaping netting;

[0035] FIG. 3 shows a shaped netting; and

[0036] FIG. 4 shows a building module as a building element.

DETAILED DESCRIPTION

[0037] FIG. 1 A and FIG. 1 B show a machine 100 for shaping a netting. The machine 100 comprises a frame 110 comprising a base frame part 112, a first roller pillar 114, a second roller pillar 116 and two real holders 118. The real holders 118 are arranged for holding a reel 172 arranged for holding a netting. Between the first roller pillar 114 and the second roller pillar 116, a first roller 122 as a first shaping cylinder and a second roller 124 as a second shaping cylinder are provided.

[0038] FIG. 2 shows the first roller 122 and the second roller 124 in further detail. The first roller 122 comprises a first cylindrical body 212 on which a first multitude of first protrusions 214 are provided. The second roller 124 comprises a second cylindrical body 222 on which a second multitude of second protrusions 224 are provided.

[0039] 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.

[0040] 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.

[0041] The first protrusions 214 and the second protrusions 224 are in FIG. 2 shown as being separate monolithic elements. Alternatively, they may be manufactured as being part of a larger monolithic element including the first cylindrical body 212 and the second cylindrical body 222, respectively. The first protrusions 214 and the second protrusions 224 may also be provided as each comprising multiple monolithic elements.

[0042] As shown in FIG. 2, the first protrusions 214 and the second protrusions 224 have a trapezoid shape, with the larger parallel side, the base, being connected to the outer surfaces of the first cylindrical body 212 and the second cylindrical body 222, respectively. The smaller parallel side, the top, is provided away from the surfaces of the cylindrical bodies, further away from the centreline of the cylindrical bodies than the base. Preferably, the distance between the bases of the first protrusions 214 and the second protrusions 224 is substantially the same as the length of the tops of the trapezoid shapes. Alternatively, the distance between the bases of the first protrusions 214 and the second protrusions 224 is larger or smaller than the length of the tops of the trapezoid shapes.

[0043] 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 FIG. 2 are selected such that with a netting, for example a wire gauze or other sheet-like material with an open or a closed structure provided between the first roller 122 and the second roller 124, the netting is force-fitter between the first roller 122 and the second roller 124 at substantially every position of the first roller 122 and the second roller 124, preferably at every position of the first roller 122 and the second roller 124.

[0044] 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. FIG. 1 A and FIG. 1 B show the first roller 122 as the upper roller that is movable, but additionally or alternatively, the lower, second roller 124 is movable. Furthermore, by varying hydraulic pressurepressure of hydraulic fluidin the hydraulic cylinders, a biasing force exerted by the first roller 122 on a netting and the second roller 124 may be varied.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] With the machine 100 as shown by FIG. 1 A and FIG. 1 B, the driving modules are provided on one side of the machine 100 and on one and the same side in particular. With the first roller 122 being movable, for example in vertical slots in the first pillar 114 and the second pillar 116, this may result in imbalances in the first roller 122. To compensate for the weight of the first driving unit 130, a counterweight module 162 may be provided at the other side of the first roller, preferably coupled to the first roller 122.

[0052] 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.

[0053] FIG. 3 shows a shaped netting 300. The shaped netting 300 may shaped by the machine 100 or another machine. The shaped netting 300 comprises a first set of longitudinal wires 312 and a second set of transversal wires 314. The longitudinal wires 312 are provided substantially perpendicularly to the transversal wires 314. Alternatively, wires of two sets may be provided under an obtuse or acute angle relative to one another. Additionally, a further set of parallel wires may be provided, under any angle relative to the wires of the first set and the second set. In this way, hexagonal shapes, triangular shapes, other shapes or a combination thereof may be provided.

[0054] With the shaped netting 300 of FIG. 3, only the longitudinal wires 312 are shaped in trapezoid shapes. The transversal wires 314 are straight. As a starting material, preferably a flat sheet of netting provided, which means that in the case depicted by FIG. 3, means that the transversal wires are not shaped by the machine 100 or any other suitable machine. Additionally or additionally to the trapezoid shapes, also square, triangular, sinusoidal, sawtooth, other shapes or a combination thereof may be provided.

[0055] The longitudinal wires 312 and with that, the shaped netting 300 is shaped in shapestrapezoidshaving a first levelthe lower level of valleys 324and a second levelthe 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.

[0056] 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 levelsor 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.

[0057] FIG. 4 shows the shaped netting 300 affixed to a building panel 410, providing a building module 400 as a building element. The building panel 410 preferably predominantly comprises a rigid foam substance, like polyurethane or an equivalent substance like a polymer foam material, having a closed or open cell foam structure. Within the context of this description, a substance may comprise a single material or multiple materials. Like the shaped netting 300, also the building panel 410 is shaped over the longitudinal direction, indicated by the arrow L; the surface of the building panel 410 is substantially straight over the transversal direction indicated by the arrow T. The shape of the building panel 410 on the top side as a first side is substantially the same or at least similar or congruent to the shapes of the shaped netting 300.

[0058] With the building panel 410 as shown by FIG. 4, the building panel 410 is shaped in trapezoid shapes, having a first levelthe lower level of the upper surfaceand a second levelthe upper level of the top surface. In this embodiment, the difference between the first level of the top surface of the building panel 410 and the second level of the upper surface of the building panel 410 is smaller than the difference between the first level of the shaped netting 300 and the second level of the shaped netting 300. With the shaped netting 300 being at the valleys of the shaped netting 300 affixed to the building panel 410 at the valleys in the top surface of the building panel 410, this means that space is provided between the hills in the shaped netting 300 and the hills of the top surface of the building panel 410.

[0059] 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.

[0060] 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.

[0061] 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.