Method for producing a structural element, and a staircase and a structural element and a staircase which have been produced according to this method

Abstract

Disclosed is a method for producing a structural element by joining together at least two separately produced parts where at least one part is made of concrete by cutting it from a volume of concrete and where all parts extend over the entire length of the structural element; a method for producing a staircase by joining together at least two separately produced staircase parts, which are cut from a volume of material and extend over the entire length of the staircase, and a structural element and a staircase which have been produced in this way.

Claims

1. Method for producing a structural element which is assembled by joining together and connecting separately produced parts, wherein each of the separately produced parts, when assembled in the structural element, extends over an entire length of the structural element, and wherein at least one of the separately produced parts is made of concrete and at least one of the separately produced parts is made of a material other than concrete, comprising: cutting each of the at least one concrete part from a volume of concrete.

2. Method for producing a structural element according to claim 1, wherein each part in the separately produced parts has two flanks extending according to the longitudinal direction of the structural element and having a varying transverse dimension.

3. Method for producing a structural element according to claim 1, wherein at least one part in the separately produced parts comprises a surface which runs visibly on a surface of the structural element and which is a partial surface of an outer surface of the structural element.

4. Method for producing a structural element according to claim 1, wherein each part in the separately produced parts comprises two practically flat flanks and is a slice of the structural element, which slice extends according to the longitudinal direction.

5. Method for producing a structural element according to claim 1, wherein at least one of the at least one of the separately produced parts made of a material other than concrete is made of one of the following materials: a stone material, a wood or wood-based material, a glass, a plexiglass, a metal, or a plastic.

6. Method for producing a structural element according to claim 1, wherein at least one part in the separately produced parts is made of a transparent material.

7. Method for producing a structural element according to claim 1, wherein the separately produced parts are connected to one another using a mechanical connecting element and/or a chemical bonding agent, wherein the mechanical connecting element and/or the chemical bonding agent is a silicon-based copolymer, an epoxy glue, or a polyurethane glue.

8. Method for producing a structural element according to claim 1, wherein the cutting each of the at least one concrete part from a volume of concrete comprises using a water jet cutting method.

9. Method for producing a structural element according to claim 1, further comprising producing each of the at least one of the separately produced parts made of a material other than concrete using a cutting method, and wherein the cutting method is a laser cutting method, a plasma cutting method, or a water jet cutting method.

10. Method for producing a structural element according to claim 1, wherein the structural element is a staircase, wherein at least each concrete part comprises a cut surface which is located on an upwardly directed surface of the staircase when the staircase is installed.

11. Method for producing a structural element according to claim 1, wherein the weight of each part in the separately produced parts is no higher than 80 kg.

12. Method for producing a structural element according to claim 1, wherein the at least one of the separately produced parts made of concrete comprises at least two concrete parts and wherein the at least one of the separately produced parts made of a material other than concrete comprises a metal part, further comprising providing the metal part between the at least two concrete parts.

13. Structural element comprising separately produced and mutually connected parts, wherein the mutually connected parts, when assembled in the structural element, extend over an entire length of the structural element, wherein at least one of the mutually connected parts is made of concrete, wherein each concrete part is cut from a volume of concrete using a cutting method, wherein at least one part in the mutually connected parts is made of a material other than concrete.

14. Structural element according to claim 13, wherein the material other than concrete comprises: a stone, a wood or wood-based material, glass, plexiglass, metal, or a plastic.

15. Structural element according to claim 13, wherein each part in the mutually connected parts comprises two flanks extending according to the longitudinal direction of the structural element and having a varying transverse dimension.

16. Structural element according to claim 13, wherein at least one part in the mutually connected parts comprises a surface which runs visibly on a surface of the structural element and which is a partial surface of the outer surface of the structural element.

17. Structural element according to claim 13, wherein each part in the mutually connected parts has two practically flat flanks and is a slice of the structural element, which slice extends according to the longitudinal direction.

18. Structural element according to claim 13, wherein at least one part in the mutually connected parts is made of a light-transmitting material.

19. Structural element according to claim 13, wherein the mutually connected parts are connected to one another by means of a mechanical connecting element and/or a chemical bonding agent, wherein the mechanical connecting element and/or the chemical bonding agent is a silicon-based copolymer, an epoxy glue, or a polyurethane glue.

20. Structural element according to claim 13, wherein the structural element is a staircase, wherein at least each concrete part has a cut surface which is located on the upwardly directed surface of the staircase.

21. Structural element according to claim 13, wherein the weight of each part in the mutually connected parts is no higher than 80 kg.

22. Structural element according to claim 13, wherein the mutually connected parts comprise a metal part between at least two concrete parts.

23. Method for producing a staircase which is assembled by joining together and connecting separately produced staircase parts, wherein the separately produced staircase parts, when assembled in the staircase, extend over an entire length of the staircase, and wherein the separately produced staircase parts comprises parts made of different materials, the different materials comprising a concrete material and one or more of: a stone material, a wood or wood-based material, a glass, a plexiglass, a metal, or a plastic, the method comprising: cutting each staircase part made of concrete from a volume of material using a cutting method.

24. Method for producing a staircase according to claim 23, wherein each staircase part in the separately produced staircase parts has two flanks extending according to the longitudinal direction of the staircase.

25. Method for producing a staircase according to claim 24, wherein each staircase part in the separately produced staircase parts has two practically flat flanks and is a slice of the staircase, which slice extends according to the longitudinal direction.

26. Method for producing a staircase according to claim 23, wherein at least one staircase part in the separately produced staircase parts is made of a transparent material.

27. Method for producing a staircase according to claim 23, further comprising connecting the separately produced staircase parts to one another using a mechanical connecting element and/or a chemical bonding agent, wherein the mechanical connecting element and/or the chemical bonding agent is a silicon-based copolymer, an epoxy glue, or a polyurethane glue.

28. Method for the producing a staircase according to claim 23, wherein the cutting method is a laser cutting method, a plasma cutting method, or a water jet cutting method.

29. Method for producing a staircase, according to claim 23, wherein at least one staircase part in the separately produced staircase parts comprises a surface which, in the assembled staircase, runs visibly on a surface of the staircase and is a partial surface of the outer surface of the staircase.

30. Method for producing a staircase according to claim 23, wherein the weight of each staircase part in the separately produced staircase parts is no higher than 80 kg.

31. Method for producing a staircase according to claim 23, wherein the separately produced staircase parts comprise a metal staircase part between at least two concrete staircase parts.

32. Staircase comprising separately produced staircase parts, wherein the separately produced staircase parts, when assembled in the staircase, extend over an entire length of the staircase, wherein the separately produced staircase parts comprise parts made of different materials, and wherein the different materials comprise a concrete material and one or more of: a stone material, a wood or wood-based material, a glass, a plexiglass, a metal, or a plastic, wherein each staircase part made of concrete has been cut from a volume of material using a cutting method.

33. Staircase according to claim 32, wherein each staircase part in the separately produced staircase parts has two flanks extending according to the longitudinal direction of the staircase.

34. Staircase according to claim 33, wherein each staircase part in the separately produced staircase parts has two practically flat flanks and is a slice of the staircase, which slice extends according to the longitudinal direction.

35. Staircase according to claim 32, wherein at least one staircase part in the separately produced staircase parts is made of a light-transmitting material.

36. Staircase according to claim 32, wherein the separately produced staircase parts are connected to one another by a mechanical connecting element and/or a chemical bonding agent, wherein the mechanical connecting element and/or the chemical bonding agent is a silicon-based copolymer, an epoxy glue, or a polyurethane glue.

37. Staircase according to claim 32, wherein at least one staircase part in the separately produced staircase parts comprises a surface, which, in the assembled staircase, runs visibly on a surface of the staircase and is a partial surface of the outer surface of the staircase, wherein this partial surface traverses uninterruptedly at least the entire length of the structural element.

38. Staircase, according to claim 32, wherein each staircase part in the separately produced staircase parts comprises a cut surface which is visible on the top surface of the staircase placed in a usage position.

39. Staircase according to claim 32, wherein the weight of each staircase part in the separately produced staircase parts is no higher than 80 kg.

40. Staircase according to claim 32, wherein the separately produced staircase parts comprise a metal staircase part between at least two concrete staircase parts.

41. Method for producing a structural element according to claim 3, wherein each part in the separately produced parts comprises the surface.

42. Method for producing a structural element according to claim 8, wherein the water jet cutting method uses an abrasive.

43. Method for producing a structural element according to claim 11, wherein the weight of each part in the separately produced parts is no higher than 60 kg.

44. Method for producing a structural element according to claim 11, wherein the weight of each part in the separately produced parts is no higher than 50 kg.

45. Structural element according to claim 16, wherein each part in the mutually connected parts comprises the surface.

46. Structural element according to claim 21, wherein the weight of each part in the mutually produced parts is no higher than 60 kg.

47. Structural element according to claim 21, wherein the weight of each part in the mutually produced parts is no higher than 50 kg.

48. Method for producing a staircase, according to claim 29, wherein each staircase part in the separately produced staircase parts comprises the surface.

49. Method for producing a staircase according to claim 30, wherein the weight of each staircase part in the separately produced staircase parts is no higher than 60 kg.

50. Method for producing a staircase according to claim 30, wherein the weight of each staircase part in the separately produced staircase parts is no higher than 50 kg.

51. Staircase according to claim 37, wherein each staircase part in the separately produced staircase parts comprises the surface.

52. Staircase according to claim 39, wherein the weight of each staircase part in the separately produced staircase parts is no higher than 60 kg.

53. Staircase according to claim 39, wherein the weight of each staircase part in the separately produced staircase parts is no higher than 50 kg.

54. Method for producing a structural element according to claim 5, wherein the material other than concrete comprises a marble or a blue stone or a multiplex.

55. Structural element according to claim 14, wherein the material other than concrete comprises a marble or a blue stone or a multiplex.

56. Method for producing a staircase according to claim 23, wherein the different materials comprise a marble or a blue stone or a multiplex.

57. Staircase according to claim 32, wherein the different materials comprise a marble or a blue stone or a multiplex.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In this description, reference is made by means of reference numerals to the accompanying figures, whereof

(2) FIG. 1 shows a closed staircase having five steps assembled from three concrete staircase parts and two marble staircase parts, in perspective view,

(3) FIG. 2 shows a closed staircase having five steps assembled from two concrete staircase parts and one wooden staircase part, in perspective view,

(4) FIG. 3 shows the concrete staircase part of the three-part staircase of FIG. 2, in perspective view, and

(5) FIG. 4 shows a closed staircase assembled from eight marble staircase parts, in perspective view.

DETAILED DESCRIPTION

(6) The staircase represented in FIG. 1 is a closed staircase having five steps and assembled from three identical staircase parts (A1), (A2), (A3) made of concrete and two identical staircase parts (B1), (B2) made of marble. All staircase parts are those cut out of a volume of material by means of a water jet cutting method using quartz sand. The concrete staircase parts (A1), (A2), (A3) are cut from a beam-shaped concrete block having two parallel surfaces which are distanced apart with a spacing (d1). The material is here cut through over the full thickness (d1) in a direction perpendicular to the parallel surfaces.

(7) The marble staircase parts (B1), (B2) have been cut from a beam-shaped block of marble having two parallel surfaces which are distanced apart with a spacing (d2). The material is here cut through over the full thickness (d2) in a direction perpendicular to the parallel surfaces.

(8) Each staircase part consequently has two identical flat flanks (1), which extend parallel to one another, and a transverse surface (2), which is directed perpendicular to these flanks (1) and is obtained by cutting the staircase part from the volume of material and in this patent application is referred to as a cut surface. The transverse surface (2) encloses each staircase slice and defines the shape thereof. On the one side, the transverse surface (2) forms five steps consisting of surfaces which adjoin one another at a right angle and, on the other side, a flat wall. All staircase parts have a practically identical cross section according to the longitudinal direction (L). The flanks (1) of each staircase part (A1), (A2), (A3), (B1), (B2) have a transverse dimension (w1), (w2) perpendicular to the longitudinal direction (L1) which varies according to the longitudinal direction (L1) of the flank (1).

(9) The concrete staircase parts (A1), (A2), (A3) have a weight of 80 kg and the marble staircase parts (B1), (B2) have a weight of 40 kg, so that these are easily movable by two persons.

(10) The staircase parts (A1), (A2), (A3), (B1), (B2) are placed side by side at the construction site by two persons, wherein, alternately, a concrete staircase slice and a marble staircase slice is provided. The width (d1) which is occupied by the concrete staircase parts (A1), (A2), (A3) is wider than the width (d2) which is occupied by the marble staircase parts (B1), (B2). After a polyurethane glue has been applied to the flanks (1), the staircase parts (A1), (A2), (A3), (B1), (B2) are installed with the flanks (1) one against another, wherein they are firmly connected to one another by the glue to form a rigid and stable entity. In the thus assembled staircase, all staircase parts (A1), (A2), (A3), (B1), (B2) extend according to the longitudinal direction (L) of the staircase over the entire length (m) thereof. Finally, the staircase is also at the top and bottom anchored and integrated into the surrounding structure of the building.

(11) The transverse surfaces (2) of the different staircase slices (A1), (A2), (A3), (B1), (B2) here form uninterrupted strips which extend, side by side and butting one against another, on the top side and underside of the staircase over the entire length (m) of the staircase. Through the combination of visible transverse surfaces (2) of the concrete staircase parts, alternated with visible marble transverse surfaces (2), wherein concrete and marble, with their respective typical surface structure and colour, form an attractive contrast, a staircase having a particularly original and varied look is obtained. The transverse surfaces (2) of the staircase parts are cut surfaces and consequently have a look different from the concrete surface of the flanks (1), which surfaces are not a cut surface, thereby ensuring an additional variation in the look of the staircase.

(12) The staircase represented in FIG. 2 is a closed staircase having five steps, assembled from two identical staircase parts (C1), (C2) made of concrete and one staircase part (D) made of oak wood. The concrete staircase parts (C1), (C2) have been cut out of a beam-shaped volume of concrete, having a uniform thickness (d3), by means of a water jet cutting method using quartz sand.

(13) The wooden staircase part (D) has been cut from a beam-shaped volume of oak wood, having a uniform thickness (d4), by means of a water jet cutting method using quartz sand. The thickness (d3) of the volume of concrete and the thickness (d4) of the volume of oak wood are practically equal. The material is here cut through over the full thickness (d3), (d4) in a direction perpendicular to the parallel surfaces which delimit the volume of material.

(14) Each staircase part (C1), (C2), (D) has an identical cross section in the longitudinal direction (L) and has two identical flat flanks (11), which extend parallel to one another, and a transverse surface (12)a cut surfacedirected perpendicular to these flanks (11), which, on the one side, forms five steps consisting of surfaces which adjoin one another at a right angle and, on the other side, a flat wall.

(15) The flanks (11) of each staircase part (C1), (C2), (D) have a transverse dimension (w1), (w2), perpendicular to the longitudinal direction (L1), which varies according to the longitudinal direction (L1) of the flank (11).

(16) The staircase parts (C1), (C2) made of concrete have a weight of 50 kg and the staircase part (D) made of oak wood has a weight of 20 kg, so that these are easily movable by two persons.

(17) The staircase parts (C1), (C2), (D) are placed side by side at the construction site by two persons, with the flanks (11) butting one against another. The wooden staircase slice (D) is here located centrally between the two concrete staircase parts (C1), (C2). The concrete staircase parts (C1), (C2) and the wooden staircase part (D) have practically the same width (d3), (d4). The staircase parts (C1), (C2), (D) are firmly connected to one another at the installation site by means of an epoxy glue, to form a rigid and stable entity. Alternatively or additionally, the staircase parts are connected to one another by mechanical connecting elements (13) extending through openings (14) in the flanks of the staircase parts (C1), (C2), and (D), as shown schematically in FIGS. 2-3. In the thus assembled staircase, all staircase parts extend according to the longitudinal direction (L) of the staircase over the entire length (m) thereof. Finally, the staircase is also at the top and bottom anchored and integrated into the surrounding structure of the building.

(18) The transverse surfaces (12) of the different staircase parts (C1), (C2), (D) here form uninterrupted strips, which extend, side by side and butting one against another, on the top side and underside of the staircase over the entire length (m) of the staircase. Through the combination of visible transverse surfaces (12) made of concrete and the visible transverse surface (12) made of oak wood, wherein concrete and oak wood form with their respective typical surface structure and colour a surprisingly fine combination, a staircase having a particularly original and varied look is obtained. The transverse surfaces (12) of the staircase parts (C1), (C2), (D) are cut surfaces and consequently have a look different from the concrete surface of the flanks (11), which surfaces are not a cut surface, thereby ensuring an additional variation in the look of the staircase.

(19) In FIG. 3 is represented only one of the concrete staircase parts (C1) of FIG. 2.

(20) In FIG. 4 is represented a staircase which is assembled from eight identical staircase parts (E1)-(E8) made of beech wood. For the production of these staircase parts, a water jet cutting method without use of abrasive particles is adopted. The staircase parts are cut from a beam-shaped volume of beech wood having a uniform thickness (d5). As a result of their small width, the separate staircase parts are very light and easy to handle, whereby this staircase is easily transported and positioned by two persons.

(21) The beech wood is here cut through over the full thickness (d5) in a direction perpendicular to the parallel surfaces which delimit the volume of oak wood.

(22) Each staircase part (E1)-(E8) has an identical cross section in the longitudinal direction (L) and has two identical flat flanks (21), which extend parallel to one another, and a transverse surface (22) directed perpendicular to these flanks (21)a cut surfacewhich, on the one side, forms five steps consisting of surfaces which adjoin one another at a right angle and, on the other side, a flat wall. The flanks (21) of each staircase part (E1)-(E8) have a transverse dimension (w1), (w2) perpendicular to the longitudinal direction (L1), which varies according to the longitudinal direction (L1) of the flank (1).

(23) The staircase parts (C1), (C2) have a weight of 15 kg, so that these are easily movable by one or two persons.

(24) The staircase parts are placed side by side at the construction site by two persons, with the flanks (21) butting one against another. All staircase parts (E1)-(E8) have practically the same width (d5). The staircase parts (E1)-(E8) are firmly connected to one another at the installation site by means of an epoxy glue to form a rigid and stable entity. In the thus assembled staircase, all staircase parts (E1)-(E8) extend according to the longitudinal direction (L) of the staircase over the entire length (m) thereof.

(25) Finally, the staircase is also, at the top and bottom, anchored and integrated into the surrounding structure of the building.

(26) The transverse surfaces (22) of the different staircase parts (E1)-(E8) here form uninterrupted strips, which side by side and butting one against another, extend on the top side and underside of the staircase over the entire length (m) of the staircase. As a result of the look of uninterrupted transverse surfaces (22)cut surfacesof beech wood staircase parts, which extend side by side over the entire length (m) of the staircase, a staircase having a particularly original look is obtained. Because the transverse surfaces (22) are cut surfaces and consequently have a look different from the surface of the flanks (1), which surfaces are not a cut surface, variation in the look of the staircase is obtained.

(27) Moreover, all staircases represented in the figures are produced according to a fully automatable process at a relatively low production cost, wherein, for the concrete staircase parts, no formwork has to be provided.

(28) The use of a water jet cutting method is here particularly advantageous and, moreover, allows the look of the cut surface to be altered by adapting the speed. Of course, the speed must also be determined as a function of the desired production speed and the desired quality of the cut surface. In addition, other parameters of the water cutting device must also be determined, such as, for example, the pressure of the water jet and the dimensions of the spray head, which are determinant for the flow velocity of the water jet and any abrasive particles. These parameters are determined empirically during one or more test productions.