BE1017521A5 - Liquid basin production method, comprises positioning modules with vacuumizable external walls on top of airtight surface and securing them into position by applying vacuum - Google Patents

Abstract

Modules with vacuumizable external walls are positioned on top of a sufficiently flat and quasi-airtight surface, then these modules are connected together and to the floor using vacuum technology. An independent claim is also included for a method for constructing a desired base contour inside liquid basins by mechanically cutting synthetic foam bodies in order to create this contour on the top side and at least one vacuumizable structure on the bottom side, and then securing the bodies to the floor using vacuum technology.

Description

System for the production of (liquid) basins built up by means of modular wall elements and custom-made floor elements, mutually and to the substrate connected by vacuum generated pressure forces.

The present invention relates to a method for the manufacture of liquid basins built up by means of modular wall elements, mutually connected to the substrate and connected via vacuum generated pressure forces.

It also relates to the floor elements that, via a modular construction, lead to a global system of such fluid basins. It finally relates to the globally constructed system.

State of the art known to date:

Currently, such liquid basins are manufactured in cement, stone and steel, ... which takes a long time and often produces very permanent structures. In certain cases, it may be desirable to manufacture fluid basins that can be adjusted more simply and quickly. The use of existing techniques also does not permit the reuse of building materials. Applying a specific soil relief in liquid basins is useful, for example, in building scale models. A large gain in flexibility and construction time can be made by using these new techniques.

The present invention has for its object to provide a solution to the aforementioned and other disadvantages in that it provides a composite modular system (Fig. 1).

The system consists of wall elements (l1) and / or bottom elements (l.2). These different types of elements have the property that they are fixed to the bottom with vacuum technology. The wall elements can also be attached to each other using vacuum technology. This requires a pipework to distribute compressed air among the various elements (fig. 1: solid and dashed lines). This also requires a system to check the vacuum in the vacuum chambers (1.4 and dotted line). A possible arrangement is shown schematically in FIG.

The pipework of the walls and that of the relief elements distributes compressed air from a central compressor system (1.3) parallel to the elements. This compressed air is converted into suction in the wall elements by venturi elements (hereinafter referred to as ejectors). For the bottom elements this already happens earlier in the circuit.

The control system (1.4) here consists of one long serial electric loop across all vacuum chambers in use.

It is recommended that the sides of the floor elements correspond to the length of the long side of the wall elements in order to be able to make a well-fitting composition.

A large increase in efficiency can be created in this way within the world of research on physical scale models. The much higher degree of finishing of the soil and the possibility of creating more complex shapes are also a plus.

The system according to the invention described here makes it possible in a simple manner to temporarily connect elements to each other and to a prepared floor surface.

The composite system therefore comprises two applications:

Application 1: Walls for the production of (liquid) basins In this case it is a question of manufacturing a wall by means of a sequence of identical elements, each element having the option of connecting to the floor and to other elements.

Application 2: Elements for installing specific soil relief

In this case, it concerns various elements (of, for example: 1x1m) that are placed next to each other in a grid pattern to form a desired bottom relief.

Ideally, both systems are used together.

Method:

Application 1: The elements are connected to the bottom by means of a chamber on the underside that is vacuum-drawn. This chamber is optimally dimensioned to achieve the required connection strength. This requires from the bottom that it is virtually impermeable to water and air, is very flat and also has a sufficiently high tensile strength.

The confirmation of wall elements can be done in the same way. A wall element is formally optimized for functionality and can be made by means of. rotational molding, a technique that makes it possible to turn large volume plastic elements into small numbers. Each element uses standard vacuum components. In this way a wall can be manufactured quickly which can be removed or moved just as quickly.

Application 2: The elements are connected to the bottom by means of a chamber on the underside that is vacuum-drawn. This chamber is optimally dimensioned to achieve the required connection strength. In this case, the vacuum for each element must be generated via suction lines in the soil or from the element itself. The elements can be CNC machined from plastic. In this way, a relief can be produced quickly that can be removed or changed just as quickly.

A variant of the above is as shown in Fig. 2. (however, without soil relief elements). It is clear herein that a wall is formed by placing various basic elements in sequence. The element provides a number of facilities. See further.

We will now go into more detail on the properties of the wall elements which, when interconnected, give shape to the modular wall system according to the invention.

Properties of the wall element (application 1):

The wall element (Fig. 3) consists of a beam-shaped tub (3.3) in plastic, which makes it light and strong. This tub can be filled with a container for the weighting of the element. The element has been formally adjusted for easy installation and transport. It has three external half vacuum chambers, the other half of which is formed by another element or the bottom on which the element stands. One is on the bottom, the other on one of the narrow vertical sides. The element has a double-walled design, as a result of which it has one hollow space (3.1) in the wall and bottom that can also be filled with a container for weighting. The element is equipped with suction lines for the vacuum chambers, pressure sensors, connections to fill or empty the hollow wall and mechanical fixing points for any other materials.

The dimensions of the element can be dimensioned according to the requirements of the specific application. However, it is preferable to take half of the length of the width in order to be able to easily make different compositions. The useful height of the bins is limited to approximately twice the width. In this way the suction surface of the bottom is dimensioned sufficiently large with respect to the possible liquid height (read: liquid pressure).

The size of the bins is limited by the flatness of the floor. If the floor only has a maximum deviation of 2 mm / m, an element of lm height seems easily achievable. The largest sides of the wall element (3.5) are preferably smooth, unless it proves technically necessary to provide more strength on the side itself. The vacuum sides (3.4 and on the opposite side) can be ribbed in such a way that in vacuum (in this text near-vacuum is always meant, when there is vacuum) the sides of two elements bend into each other by bending towards each other and thus no longer allow transverse movements (furthermore: anchoring ribs). This can be done by applying a relief asymmetrically on the side in such a way that when the elements are placed exactly opposite each other, the relief structure fits together (not in the drawing). Other methods are also conceivable for this, such as: mechanical locking.

Furthermore, all vacuum chambers are dimensioned in such a way that maximum firmness is achieved, while maximum useful air surface is retained, therefore these chambers must keep the largest possible surface at a short distance from the floor or another element. Thus, the greatest suction power is generated when the chamber is pulled under vacuum. This can be done by providing a large number of studs (further as: distance studs) with a limited surface on a slightly recessed floor space (3.2, bottom). The dimensions, position and amount of these studs depend on the rigidity of the base material used. The stiffer the material, the fewer nubs will be needed to achieve acceptable deformation. Deformation is acceptable as long as the vacuum chamber does not close itself. The latter can be checked visually by vacuumizing the element on a glass plate. In the case of the side chambers, a good ratio between anchoring ribs and spacing studs must be sought. The element as a whole must be sufficiently rigid not to bend too much and sufficiently tough not to break under the fluid pressure. The vacuum walls must be sufficiently rigid so that external forces are distributed over the entire vacuum surface.

Each wall element contains a piping system to generate underpressure from compressed air and to use this underpressure to anchor itself to other elements and to the fluidity further). The wall (3.1) of the element is hollow, so that it can be filled with a liquid for weighting. To empty the frying wall, a system can be provided, consisting of: an internal suction pipe, with an opening in the wall bottom and with a garden hose coupling at the top, a compressed air coupling (also at the top) to completely empty the frying wall, or to blow just enough that: deflate the wall by communicating the fluid with the lower garden hose end (take a sufficiently thick hose).

The edges of the element are shaped (beveled) in such a way that a suitable seal (eg silicone paste) can be easily applied.

The tub (3.3) itself is hollow and can, if desired, be filled with a material to temporarily weigh the whole (eg: water, Rhine sand, ...). Each element provides connection points by means of (threaded) openings and metal (threaded) bushes cast in rotation molds, for mechanical attachment of air lines, reinforcement elements, handrails, etc .... Each element contains a system for generating its vacuum from compressed air supplied to each element.

Each element contains a reading instrument (eg: manometer) for each room and a vacuum sensor that interrupts an electrical switch when there is insufficient underpressure in that room. These sensor switches can be connected in series in a simple way, depending on the rooms used. If this electric loop is interrupted, a central alarm is generated. Upon indication of this alarm, all vacuum chambers can be checked for underpressure and the technical failure must be corrected. It goes without saying that a much more complex control installation can be set up with the vacuum sensors.

Each element can be formally equipped with transport, storage and installation facilities, such as handles and openings for forklift pressure, etc ....

Openings are provided for passing through pneumatic and electrical cabling (not in the drawing).

A lid can also be provided to close the element at the top. This lid can be walked on. For this, the element or cover provides a mounting option for a handrail, staircase, etc ...

We will now discuss the properties of the soil relief element in more detail.

The element for application 2:

The material in which this element is made is preferably watertight and airtight.

Apart from a variable relief structure at the top, the elements are identical. What is also needed here is a vacuum chamber on the underside, for fixing to the floor surface. This room must keep the largest possible surface at a short distance from the floor. Thus, the greatest suction power is generated when the chamber is made vacuum. This can be done by providing a large number of studs with limited surface on a slightly recessed room. The dimensions, position and amount of these studs depend on the rigidity of the base material used. The stiffer the material, the fewer nubs will be needed to achieve acceptable deformation. Deformation is acceptable as long as the upper relief is not affected and as long as the vacuum chamber does not close itself. The latter can be checked visually by vacuumizing the element on a glass plate. This room must be easy to seal. A circumferential chamfer can be provided for this. If the element itself is vacuumised, a groove must be provided at the bottom of the element to house the air line and any non-return valve.

Figure 4 shows the top and bottom of a possible element that can be mounted in the bottom via a suction pipe system. It has the same stud structure and beveled edges as with the first application.

In Fig. 5, a circumferential slot is provided in the same element for arranging suction lines if the vacuumization takes place from the element itself. An additional advantage of this slot is that any deformations due to the attraction to the bottom (for example, with an irregular layer thickness of the sealing paste used) cannot penetrate to the relief structure.

Cavities are provided in the underside on the 4 sides to possibly provide a suction pipe. The element can for example be milled from foamed polystyrene. In that case the cavity for the suction line can be made with a warm awl. This closes the polystyrene structure, after which the suction line can be easily applied by gluing. When using several of these elements in a grid form, numerous configurations are conceivable for the suction lines. Important here is that each element (or possibly series of elements) is immediately closed with a non-return valve. Since this is usually a one-time use, it is not necessary to provide a button to release the vacuum. To maintain the simplicity, there is also no check of the vacuum on site. This check can be done at the start of a pipe that connects various elements. The vacuum must then be maintained by periodically blowing the ejectors. Different elements can be made vacuum here with a single ejector.

If necessary, a tongue and groove system can be applied to ensure that the various elements fit together nicely.

With the insight to better demonstrate the features of the invention, a few preferred embodiments of the invention are described below with reference to the accompanying drawings, in which:

Figure 1 schematically represents a modularly constructed system according to the invention;

Figure 2 shows a perspective view of a modularly constructed system according to the invention, but without relief elements;

Figure 3 represents a basic element in perspective;

Figure 4 shows a perspective top and bottom view of a possible variant of a bottom relief element, without a slot;

Figure 5 shows a perspective top and bottom view of a possible variant of a bottom relief element, with slot;

Figure 6 shows a schematic representation of a possible vacuum configuration of one wall element;

Figure 7 shows views and cross section of a possible "water stop float";

Figure 8 represents a representation of a possible vacuum configuration of one wall element in perspective;

A further description of the vacuum generation for the various basic elements for the globally modular system according to the invention follows.

To generate a near vacuum (approximately -0.88 bar), each element uses a combination of commercially available components. Schematically this looks like in fig.6.

The ejectors (see 6.1 and 8.6) of the different elements are connected to each other by means of one or more main lines (if divided into several sections) that has a branch (s) for each element. The main line must be dimensioned in such a way that sufficient flow can be supplied to all ejectors of one section simultaneously. The branches must be dimensioned in such a way that the available flow rate is not much greater than what is needed for one ejector, so one element can be disconnected without compromising the operation of the others. A compressor system must then be automated in such a way that it periodically blows all the ejectors of a section with the necessary pressure and the required flow. If this happens once per hour in 1 minute, that is more than sufficient. Provided a good seal, the vacuum can remain good for weeks. It is advisable to install a second compressor redundantly, to compensate for any failure.

To save costs, it would be possible to implement most elements with only two vacuum sets instead of three. The third half chamber (one of the two vertical ones) can then simply be sealed at its connection point. The element must always be placed in the right direction, so that the pressure gauges will not always be in the most visible place (It is a solution to mount the pressure gauges in a rotating lid).

In the following table and in Figure 8, components of the SMC brand have been used ('www.smceu.coml

The components are connected to each other by means of flexible tubes. A system with rigid tubes is also possible, but more expensive. The system uses quick couplings in which the tubes can be easily assembled and disassembled.

Components 8.4 and 8.7 are no more than coupling elements that make the connection between components resp. 8.3 and 8.1 with the tubes.

Component 8.6 (also 6.1) is a vacuum ejector. This is a box in which there is a venturi element. About 5 bar of air pressure is applied to this, distributed from a central compressor, using tubes and quick couplings of the same type. This results in a consumption of 101 / min. The ejector thus sucks approximately 5 1 / min from the vacuum chambers of one wall element. The smaller the chambers, the faster each chamber can be made vacuum. There is, however, a downside: the smaller the chambers, the faster the underpressure will be achieved with a small fit in the seal. A volume between 1 and 2 liters is optimally chosen per total room.

The suction side of the ejector is connected to a filter (8.5, also 6.2). Ideally, the filter should be placed immediately after the suction chamber, but that would mean that three filters are needed per element, which increases the cost. It may be considered to omit the filter.

Component 8.4 splits the pipes into three times components 8.2 and 8.1 (once for each room). Component 8.2 (also 6.3) is a non-return valve that ensures that the vacuum in the chambers is maintained when there is no suction. Component 8.1 (also 6.4) is a normally closed 3/2 valve that is connected in such a way that the chamber is vented normally and the pipe is closed after the non-return valve. Only if the button is pushed mechanically, the connection to the chamber is open and the vacuum can be set. This arrangement is necessary in order to not have to vacuum-seal all rooms, if required, and to be able to vent the rooms. The button is locked by screwing a plate over it.

Further explanation of the figures: 4.1 Fill the wall with water.

4.2 Sealing edges and vacuuming the floor on the floor.

4.3 Fill the tub with water or Rhine sand.

4.4 Vacuum elements together.

4.5 Constant monitoring of the vacuum by means of a simple control installation.

6.6 Pressure gauge 6.7 Vacuum chamber 6.8 Vacuum sensor

The waterstop float (fig71:

In the diagram of Figure 6 there is also a water stop float (6.5). This part is possibly commercially available and, if not easy to construct, according to Figure 7. The float housing must be screwed vertically (as on section A-A) into the connection point of a vacuum chamber (with sealing paste). If liquid is sucked up due to an incomplete seal of the chamber, the (rubber) ball will float due to a rising liquid level and thus close off the suction line. This will cause the alarm to sound and the error to be corrected. It is therefore essential that the reading and checking instruments directly measure the vacuum of the chamber and therefore not be placed on the suction line.

Preparation of the floor:

It is important to use a floor that is as flat as possible for this application. A maximum deviation of 2 mm / m is preferably achieved. A lot of attention goes to the preparation of the floor. The finishing layer of the floor is preferably sufficiently water and airtight and should preferably not show any absorption. A standard epoxy floor covering can be used. This type of floor has an adhesion to a cement-based floor with a tensile strength of approximately 7 N / mm 2 which is sufficient for this application. However, the tensile strength of a cement-based floor (screed, concrete, ...) is rarely specified because this type of material can actually only be loaded on pressure. That is why consolidation must be sought. Three methods can be used for this: - adding additives to the cement floor.

- adding reinforcement elements in the finishing layer.

- Mechanically attach an intermediate layer to the cement floor with the finishing layer there.

Manufacture of the relief structure of the floor elements.

This embossed shape can optionally be produced for each element separately by means of a CNC router. A three-axis machine can remove material by moving a rotating milling head in a Χ, Υ, Ζ axis system. The maximum deviation in these directions naturally determines the size of the piece.

To create even more complex shapes, a 5-axis device is available. With this the milling head can also be placed at an angle and also turn.

There are many types of milling cutters for these devices. The speed of processing depends on the type of machine and the material. If a relatively soft material is chosen, it is possible to mill very quickly. For this application it is recommended to choose a very fast machine because the surface to be worked is large. The accuracy of such devices is often much higher than desired for our application.

It is also possible with a similar type of machine to provide the relief surfaces with a possible coating or decorative elements (contour lines, color surfaces, ...).

The seal of the vacuum chambers.

For this purpose, a paste must be found that remains sufficiently flexible after curing to ensure that no cracks will appear over time. The purpose of the paste is only to make the rooms airtight and liquid-tight. It must be possible to simply remove the paste without damaging the elements or the floor. Optionally, element and / or floor can be sprayed in advance with non-stick Teflon spray. Sufficient cohesion and flexibility in the dried paste must make it possible to remove the seals in one go.

For this a silicone is thought of, often available in sprayable tubes.

Other elements.

It is possible to manufacture elements in a simple manner (e.g. with a lathe) in which mechanical anchoring points are provided which can be fixed to the floor or wall with the same principle. In this way many mechanical structures and machines can be anchored on site.

Optionally, the covers of the wall elements can be equipped with a vacuum chamber and anchoring points for this application.

Claims (19)

1. Method for the production of liquid basins by applying the following steps: • placing modular base elements with vacuum-resistant outer walls, on a sufficiently flat and almost airtight floor surface. • Interconnecting these basic elements and connecting them to the floor, via vacuum technology. Method according to claim 1, characterized in that the floor surface has a maximum deviation of 2 mm / m. Method according to claim 1, characterized in that the floor surface consists of a cemented floor with high tensile strength, provided with a quasi air and watertight cover layer in, for example, epoxy resin. Method according to claim 1, characterized in that the basic element has the following features: three vacuum walls, wherein each vacuum wall has a vacuum volume of between 1 and 2 liters. Method according to one of the preceding claims, further characterized in that the vacuum technology used makes use of at least one central compressor connected to different ejectors, at least one ejector per basic element. The method of claim 4, further characterized in that the vacuum used is between -0.5 bar and -1 bar. Method according to claims 1 and 5, characterized in that the ejectors of the different basic elements are connected to each other by means of one or more main pipes Method according to one of the aforementioned claims, further characterized in that the vacuum control system uses one or more electrical loops in which all active vacuum chambers are serially connected. Method according to one of the aforementioned claims, further characterized in that the vacuum system is protected against accidental suction of liquid by means of a "water stop float". Method according to claim 1, characterized in that the vertical vacuum walls of the basic elements have the following characteristics: antisymmetrically placed ridges that fit into one another when the elements are positioned exactly opposite each other and prevent mutual transverse displacement under vacuum in the vacuum chamber. Method according to claim 1, characterized in that the basic element is a tub that can be filled with a container for weighting the element. Method according to claim 1, characterized in that the base element has a double wall that can be filled with a container for weighting the element. 13. Method for incorporating a desired soil relief into liquid basins, by applying the following steps: • Machine leveling of foam plastic starting volumes to the desired relief shape on the top and at least one vacuum-removable structure on the bottom. • Fix the volumes obtained to the floor with vacuum technology. Method according to claim 13, characterized in that the elements obtained have a vacuum chamber for fixing to the floor. Method according to claims 1 and 4 and 13 and 14, characterized in that the vacuum chambers obtained are dimensioned in such a way that the greatest possible suction power is strived for while allowing for as little material deformation as possible by using spacer studs. Method according to claim 13, characterized in that the obtained elements have a circumferential slot that provides space for pipes. Method according to claim 13, characterized in that the elements obtained have a circumferential slot which ensures that material stresses obtained by vacuum generation do not result in deformation of the desired relief shape. Method according to claim 13, characterized in that the elements obtained have at least one cavity in the vacuum structure of the bottom, into which the suction line ends. 19. System consisting of modular basic elements constructed according to claim 1.