NL2024526B1

NL2024526B1 - Forming device for forming a construction material

Info

Publication number: NL2024526B1
Application number: NL2024526A
Authority: NL
Inventors: Raymond Rouwenhorst Dennis; Jongstra Hendrik
Original assignee: Redeahold Apeldoorn B V
Priority date: 2019-12-20
Filing date: 2019-12-20
Publication date: 2021-09-02

Abstract

Forming device for forming a construction material, in particular ﬂashing material. The device comprises a beater body having a proximal end and a blunt distal end, the blunt distal end forming an impact surface for, in use of the device, impacting the construction material to form it. The beater body at its proximal end is mechanically connected to powered drive means, Which drive means is arranged for driving the beater body in a reciprocating motion.

Description

P125587NL00 Title: FORMING DEVICE FOR FORMING A CONSTRUCTION

MATERIAL

FIELD OF THE INVENTION The invention generally relates to a forming device, beater body, kit, modular forming device and use of a device for shaping a construction material. More specifically, the invention relates to a device for shaping flashings for water-proofing and/or weatherproofing a building structure.

BACKGROUND It 1s commonly known to install sheets of impervious material as a water barrier to prevent the passage of water into a building structure from joints and transitions of a building structure. Such joints and transitions for example exist at a connection of skylights, dormer windows or chimneys with a roof covering, such as tile roof.

For proper weatherproofing, the sheets of flashing material is required to be shaped closely around contours of a building structure to avoid that any water passages form between the sheets of flashing material and the building structure. Accordingly, sheets of flashing material are required to be relatively pliable to be formed, on a construction site, into a variety of shapes, while also being very durable to withstand the harsh and varying weather conditions the material is subjected to. A typically used flashing material is Lead which has unique properties that render it highly suitable for such application. More environmentally friendly and more lightweight alternatives also exist on the market, such as LeadaxTM which is described 1n patent publication WO-A-2016/108686.

Shaping a sheet of flashing material closely around a contour of a building structure, for example a contour of tile roof, is typically done by means of a so called lead dresser. Such lead dresser is formed by a beater body having a handle for manually holding the lead dresser. A sheet of flashing material is positioned at a desired location onto a building structure, and subsequently shaped around a contour of the structure by a beating of the sheet with the lead dresser. Forming flashings with such a conventional lead dresser involves a great deal of physical labour of a skilled craftsman, and is rather time consuming. Also the quality of the end result, i.e. the weather proofness of the installed flashing, greatly depends on the competence of the craftsman. In particular, with the conventional lead dresser, the sheet of flashing material can be easily damaged and/or unevenly deformed which may adversely affect the durability and weatherproofing properties of the flashing.

SUMMARY An object of the invention is to address at least some of the disadvantages of the conventional lead dresser. More specifically, it is an object to provide an improved device for shaping a construction material, such as a flashing material. Accordingly, an aspect of the invention provides a forming device for forming a construction material, in particular flashing material, such as flashing material available as Leadax™. The device comprises a beater body having a proximal end and a blunt distal end. The blunt distal end forms an impact surface for, in use of the device, impacting the construction material to form it. The beater body, at its proximal end, is mechanically connected to powered drive means, which drive means is arranged for driving the beater body in a reciprocating motion. With the forming device, a construction material, particularly a sheet of flashing material, can be conveniently deformed into a desired shape by impacting the material with the impact surface of the beater body, with little physical effort, at least in comparison to the conventional lead dresser. The drive means induces a percussive movement of the beater body for impacting the construction material as to cause a deformation in the construction material.

In use of the device, a sheet of flashing material can be deformed by impacting, e.g. repetitively, the material with the impact surface of the beater body.

Repetitive impacts can thus gradually shape the sheet of material closely around a building structure.

An operator of the device can control a transmission of impact energy to the construction material by modulating a pressure applied with the device onto the construction material.

This gives the operator great control over the deformation of the construction material.

Is appreciated that the blunt distal end is arranged to transmit and distribute, in use of the device, impact energy over a surface of the construction material, and to avoid penetrating, piercing, and/or puncturing the construction material.

It is appreciated that the distal end is blunted or dulled, such that the impact surface, formed by the blunt or dull impact surface, is free of any sharp features, such as sharp edges and/or pointed protrusions.

The powered drive means may be electrically powered drive means.

The drive means may comprise an actuator, such as an electric actuator, e.g. an electromotor, which is powered by a power source.

The drive means can for example be powered by an electric power source such as a battery or via a cable by electric power from the net.

The drive means may be conventional powered drive means, for instance drive means of reciprocating tooling, such as an electric jigsaw, or impact drill.

Is appreciated that the blunt distal end is arranged to, in use of the device, distribute impact energy over a surface of the construction material and to avoid penetrating, piercing, and/or puncturing the construction material.

The blunt distal end may for example form a convexly shaped impact surface.

The drive means is arranged to drive the beater body in a reciprocating motion in which the beater body is generally driven in a back-and-forth movement along a driving trajectory. The driving trajectory includes an outward stroke in which the beater body is driven generally away from the driving means, and a return stroke in which the beater body is driven generally towards the driving means. An outward stroke trajectory and the return stroke trajectory may differ. Alternatively, the outward stroke trajectory and the return stroke trajectory may, at least partly, overlap. In particular, the beater body may be driven in a back-and-forth motion, in which the outward stroke trajectory of the beater body and the return stroke trajectory of the beater body coincide. Optionally, the driving trajectory is linear, i.e. the beater body 1s driven by the drive means along a rectilinear driving axis. Optionally, the beater body extends between the proximal end and the distal end along the driving axis, wherein the dive means is arranged for driving the beater body along the driving axis in a reciprocating motion.

The construction material described herein can be a sheet of construction material, such as a sheet of flashing material. For example, the construction material may be a sheet of metal flashing material, such as lead, aluminium, copper, stainless steel, zinc alloy. Optionally, the construction material comprises a bituminous material. The construction material may be a sheet of flashing material available as Ubiflex™ and/or Perform™ and/or Leadax™. Particularly, the construction material may comprise a perforated sheet of metal and on at least one side of the perforated sheet of metal a thermoplastic layer, wherein the thermoplastic layer has 1) a modulus of elasticity as measured according to ISO 527 of 0.6-20 MPa, ij) a Shore A hardness as measured according to ISO 7619-1 in the range of 25-65, and ui) an elongation at break as measured according to ISO 527 of 250-400 %.

Preferably, the thermoplastic layer comprises a polymer comprising butyral groups, preferably 40 % or more by total weight of the thermoplastic layer, such as 60 % or more.

It 1s also possible that the construction material is a synthetic 5 flashing material that comprises 75 wt.% of polymer material and 10 wt.% or less of metals, based on total weight of the flashing material.

Preferably, the construction material is substantially free, i.e. 1 wt.% or less, such as 0.5 wt.% or less based on total weight of the construction material, of heavy metals, such as lead.

Optionally, the impact surface of the beater body is circular symmetric around the driving axis. This way, in use of the device, an impact force will be symmetrically and consistently distributed over the construction material irrespective of an angular orientation of the beater body about the driving axis.

Optionally, the blunt distal end forms a dome-shaped impact surface. The dome shape allows for an accurately impacting the construction material, while also evenly distributing impact forces over the impact surface and construction material. Moreover, with the dome shaped impact surface, the construction material can be driven into hollow structures. The curvature, e.g. the pointedness, of the impact surface may be adapted to a building structure. For example, in situations where a construction material, e.g. a sheet of flashing material, is to be shaped to follow a contour of a tight cavity, it may be desired that the blunt distal end forms a relatively pointed impact surface to drive the material into the tight cavity.

Similarly, a relatively flat impact surface may be desirable in situations where the construction material, e.g. a sheet of flashing material, is to be shaped to follow a contour of a relatively flat, or mildly curved, surface of a building structure.

Optionally, the beater head is exchangeably connected to the drive means, which allows for exchanging different beater bodies. For instance, it allows for interchanging beater bodies having differently shaped impact surfaces and/or having different mechanical properties.

Optionally, the beater device comprises connection means for mechanically connecting, e.g. exchangeably, the beater device to the drive means. The connection means may for example be provided at the proximal end of the beater body.

Optionally, the device comprises a drive shaft, wherein the beater body is connected, e.g. directly coupled or couplable, to the drive shaft. The drive shaft, extending along the drive axis, can be driven by the drive means. The coupling means may be arranged to fixedly couple the beater body and the drive shaft in a direction of the drive axis, while in allowing a free rotation of the beater body about the drive axis. This way, unintentional damage, e.g. rupture, of the construction material can be prevented as the beater body is allowed roll on the construction material about the drive axis.

Optionally, the beating device comprises impact absorption means. The impact absorption means can be arranged for absorbing, at least a part of, the impact on the construction material to prevent damaging the construction material with the device. Further the absorption means may be arranged to absorb shocks transmitted to an operator of the device, induced by the impacts of the beater body on the construction material.

Optionally, the impact absorption means comprise a resilient material, which resilient material at least partly forms the impact surface. With a resilient material forming the impact surface may, the material can elastically deform on impact with the construction material, thereby absorbing some of the impact forces. This deformation of the resilient material ensures that impact forces are evenly distributed over the impact surface and are evenly transferred to the construction means to avoid unintentional damaging of the construction material.

Optionally, the beater body is formed as an integral piece.

Optionally, the beater body comprises a core of a core material, and a cladding, at least partly surrounding the core, of a cladding material different from the core material. The core material can be substantially rigid, at least relative to the cladding material, for precisely and effectively transmitting an impact force to the construction material. The cladding material may be formed by a resilient material for absorbing a part of the impact.

Optionally, the drive means is arranged for driving the beater body in a reciprocating motion along the driving axis with a stroke amplitude of 1-50 mm, preferably 10-20 mm. The stroke amplitude corresponds to position difference between an outermost and an innermost position of the beater body with respect to a remainder of the forming device. For example, For example, a length of the outward stroke and/or the inward stroke in Linear drive trajectory.

Optionally, the device is arranged to adjust, e.g. increase and/or decrease, the stroke amplitude.

Optionally, the drive means is arranged for driving the beater body in a reciprocating motion along the driving axis at a stoke rate up to approximately 5000 strokes per minute, such as 1-4000 strokes per minute, or 100-3000 strokes per minute, or 1000-2000 strokes per minute. A stroke may correspond to an inward stroke and/or outward stroke of the beater body.

Optionally, the drive means is arranged for driving the beater body in a rotating motion about the driving axis. The rotating motion of the beater body, in combination with the reciprocating motion, facilitates deformation of the construction material. Furthermore, the rotational motion of the beater body, and hence the rotating impact surface, ensures an even spread-out out the construction material, e.g. a sheet of flashing material, over a surface of a building structure.

Optionally, the device is arranged to adjust, e.g. increase and/or decrease, the stroke rate.

Optionally, the device is a hand-held device. The device may comprise a housing in which the powered drive means is provided. The housing may further hold a power source such as a battery. The housing can be provided with a handle, which handle is arranged for manually holding the device. At or near the handle, an operator means, such as a power button, may be provided for powering the driving means such as to induce a percussive motion with the beater body.

According to an aspect 1s provided a beater body, in particular for a forming device as described herein, the beater body having a proximal end and a blunt distal end, the blunt distal end forming an impact surface for, in use of the device, impacting the construction material to form it, wherein the beater body comprises connection means for connection to a powered drive means. The connection means can be provided at the proximal end of the beater body.

According to an aspect is provided a kit comprising a forming device as described herein, a sheet of construction material, in particular a sheet of flashing material, and adhesion means for adhering the construction material to a building structure. The adhesion means could adhere the sheet of construction material to a surface of a building structure, e.g. a roof surface. The adhesion means may for example be provided on the sheet and/or on the surface of the building structure to secure the sheet to the building structure. This is particularly beneficial for light weight flashing materials such as Leadax™, that are prone to being blown over by wind catching under the flashing material. The adhesion means thus prevents blow-over of the flashing material and provides. Furthermore, while installing the construction material, particularly on hazardous sites such as on a roof of a building, an operator of the forming device can locally fixate the construction material to a surface of the building structure with the adhesion means, such that the operator can use his hands to secure himself to the building structure and operate the forming device.

The adhesion means may for example comprise a double-sided adhesive tape that is locally provided on the construction material and/or a surface the building structure.

The adhesion means are preferably separable from the construction material to facilitate recycling of the construction material.

According to an aspect is provided a modular forming device for forming a construction material, in particular a sheet of flashing material, the device comprising powered drive means, and a set of beater bodies, each beater body of the set of beater bodies having a proximal end and a blunt distal end, the blunt distal end forming an impact surface for, in use of the device, impacting the construction material to form it, wherein the beater body at its proximal end is mechanically connected to the powered drive means, which drive means is arranged for driving the beater body in a reciprocating motion, wherein the impact surface of each beater body differs in geometry.

According to an aspect is provided a use of a forming device as described herein, a beater body as described herein, or a modular forming device as described herein, for shaping a flashing material.

A construction material is provided, particularly a sheet of construction material, more particular a sheet of flashing material.

The construction material is positioned onto a building structure, shaped, at least partly, around a contour of the building structure by means of a device as described herein.

Optionally, the construction material is adhered to the building structure.

This ensures a close fit between the sheet of flashing material and the building structure.

Optionally, the construction material is adhered to the building structure by means of an adhesion means, wherein the adhesion means comprise a double-sided adhesive tape. This facilitates efficient recycling of the construction material. It will be appreciated that any one or more of the above aspects, features and options can be combined. It will be appreciated that any one of the options described in view of one of the aspects can be applied equally to any of the other aspects. It will also be clear that all aspects, features and options described in view of the transmission system apply equally to the vehicle and the method.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will further be elucidated on the basis of exemplary embodiments which are represented in a drawing. The exemplary embodiments are given by way of non-limitative illustration. It is noted that the figures are only schematic representations of embodiments of the invention that are given by way of non-limiting example. In the drawing: Fig. 1A shows a schematic side view of a forming device in a state in which a beater body is at first end of a stroke; Fig. 1B shows a schematic side view of the forming device of Fig. 1A in a state in which the beater body is at a second end of the stroke; Fig. 2A shows a schematic side view of a first exemplary beater body; Fig. 2B shows a schematic side view of a second exemplary beater body; Fig. 2C shows a schematic side view of a third exemplary beater body; Fig. 2D shows a schematic side view of a fourth exemplary beater body.

DETAILED DESCRIPTION Fig. 1A and 1B show a schematic side view of a forming device 1. The forming device comprises a beater body 3 which is connected to a drive shaft 7 of the drive means 5. The drive means 5 may comprise an electromotor and a transmission, wherein the electromotor is powered by a power source 9, such as a (re)chargeable battery. The beater body 3 extends between a proximal end 11 and a blunt distal end 13. The distal end 3 forms an impact surface 15 for, in use of the device, impacting a construction material, such as a sheet of flashing material. The beater body comprises coupling means (not shown) for exchangeably coupling the beater body to the drive shaft 7.

The drive means 5 and the power source 9 are provided in a housing 17 which is provided with a handle 19 for manually holding the device 1. A power button 18 may be provided at or near the handle 19, to activate the drive means 5 to percussively drive the beater body 3.

The drive means 5 is arranged for reciprocatingly driving the beater body 3. The transmission of the drive means 5 may for instance convert a rotational motion of a rotor of the electromotor into a translational motion of the drive shaft 7. Here the driving means 5 is arranged to drive the beater body back and forth along a drive axis 21. Here, the drive axis 21 coincides with an axial direction of the beater body 3. In use of the device 1, the beater body 3 is moved back and forth along the drive axis.

Fig. 1A shows a first state of the device 1, in which the beater body 3 is at a first end of a stroke. The first end of the stroke corresponds to the beater body 3 being proximate to a remainder of the device e.g. the housing 17 of the forming device 1.

Fig. 1B shows the device 1 of Fig. 1A in which the beater body 3 is at a second end of the stroke. The second end of the stroke corresponds to the beater body 3 being extended away from a remainder of the device 1, e.g.

the housing 17. A stroke of the beater body 3 can thus be defined as a movement of the beater body from the first end of the stroke to the second end of the stroke or vice versa. Here the stroke corresponds to a linear translation of the beater body 3 along the drive axis 21, from the first stroke end as shown in Fig. 1A, to the seconds stroke end as shown in Fig. 1B. The drive means 5 is arranged to drive the beater body 3 outward from the first end to the second end of the stroke, and to retract the beater body 3 from the second end to the first end of the stroke.

Furthermore, the drive means 5 may be arranged to drive the beater body 3 in a rotational motion about the drive axis 21. It is preferred that the beater body 3, particularly the impact surface 15 thereof, is circular symmetric around the drive axis 21, when the beater body 3 is rotatingly driven around the drive axis.

A stroke rate, at which the drive means 5 drive the beater body 5 in a reciprocating motion, is for example up to 5000 strokes per minute, preferably about 1000-2000 strokes per minute.

A stroke amplitude of the stroke can be for 1-50 mm, preferably 10-20 mm.

The stroke amplitude corresponds to a distance, e.g. measured in a direction of the drive axis, between the of the beater body 3 at the first end and the beater body 3 at the second end of the stroke.

The impact surface 15 of the beater body 3 is arranged to transfer impact energy to a construction material such as to deform the construction material.

The distal end 13 of the beater body is blunted so as to prevent perforation of the construction material.

The impact surface 15 may be formed by a resilient material to at least partly absorb impact energy.

Figs. 2A, 2B, 2C and 2D show respective embodiments of a beater body 3. In Figs. 2A, 2B, 2C and 2D, the beater body 3 is coupled to a drive shaft 7. The beater body 3 has a proximal end 11 and a blunt distal end 13, wherein the blunt distal end 13 forms an impact surface 15. A geometry of the impact surface 15 of each of the beater bodies 3 of respective figures Figs. 2A, 2B, 2C, 2D differ.

In situations where a construction material, e.g. a sheet of flashing material, is to be shaped to follow a contour of a tight cavity, it may be desired that the blunt distal end 13 forms a relatively pointed impact surface 15 to drive the construction material into the tight cavity.

Similarly, a relatively flat impact surface may be desirable in situations where the construction material, e.g. a sheet of flashing material,

is to be shaped to follow a contour of a relatively flat, or mildly curved, surface of a building structure.

Fig. 2A shows an exemplary embodiment of a beater body 3 as shown in Fig. 1A, 1B, having a circular symmetric and dome shaped impact surface 15.

Fig. 2B shows an exemplary embodiment of a beater body 3 also having a circular symmetric and dome shaped impact surface 15. Compared to the beater body 3 shown in Fig. 2A, the beater body 3 in Fig. 2B is a more slender, and has a more pronounced impact surface 15. In other words, the blunt distal end 13 of the beater body 3 of Fig. 2B is more pointed compared to the beater body of Fig. 2A.

Fig 2C shows an exemplary embodiment of a beater body 3 having an asymmetric blunt distal end 13. This may be advantageous for in situations where a construction material is to be driven into asymmetrical cavities.

Fig. 2D shows an exemplary embodiment of a beater body 3 having a blunt distal end 13 wherein a central portion 23 of the impact surface 15 is relatively flat compared to a peripheral portion 25 of the impact surface 15. The peripheral portion 25 comprises blunted edge portion. Accordingly, the relatively flat central portion 23 of the impact surface 15 may be used for forming a construction material on a relatively flat, or mildly curved, surface of building structure, whereas the peripheral portion 25 of the impact surface 15 may be used for tighter corner spaces.

The exemplary embodiments shown in Figs. 2A-2D exchangeably coupleable to the drive means 5 of the forming device 1, and are by no means exhaustive.

Herein, the invention is described with reference to specific examples of embodiments of the invention. It will, however, be evident that various modifications, variations, alternatives and changes may be made therein, without departing from the essence of the invention. For the purpose of clarity and a concise description features are described herein as part of the same or separate embodiments, however, alternative embodiments having combinations of all or some of the features described in these separate embodiments are also envisaged and understood to fall within the framework of the invention as outlined by the claims. The specifications, figures and examples are, accordingly, to be regarded in an illustrative sense rather than in a restrictive sense. The invention is intended to embrace all alternatives, modifications and variations which fall within the spirit and scope of the appended claims. Further, many of the elements that are described are functional entities that may be implemented as discrete or distributed components or in conjunction with other components, in any suitable combination and location.

In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word ‘comprising’ does not exclude the presence of other features or steps than those listed in a claim. Furthermore, the words ‘a’ and ‘an’ shall not be construed as limited to ‘only one’, but instead are used to mean ‘at least one’, and do not exclude a plurality. The mere fact that certain measures are recited in mutually different claims does not indicate that a combination of these measures cannot be used to an advantage.

Claims

Conclusions

A deformation device for deforming a construction material, in particular coating material, the device comprising a beater body having a proximal end and a blunt distal end, the blunt distal end forming an impact surface for impacting, in use of the device, the material of construction for deforming it, the beater body being mechanically connected at its proximal end to a powered propellant, the driving means being adapted to drive the beater body in a reciprocating motion.

The apparatus of claim 1, wherein the beater body extends between the proximal end and the distal end along a drive shaft, and wherein the drive means is adapted to drive the beater body along the drive shaft in a reciprocating motion.

Device according to claim 1 or 2, wherein the impact surface is circularly symmetrical about the drive shaft.

A device according to any one of the preceding claims, wherein the blunt distal end forms a domed abutment surface.

Apparatus as claimed in any of the foregoing claims, wherein the beater body comprises coupling means adapted for interchangeably coupling the beater body to the driven propellant.

An apparatus according to any one of the preceding claims, wherein the beater body comprises impact absorbing means.

7. Device as claimed in claim 6, wherein the impact absorbing means comprise a resilient material, which resilient material at least partly forms the impact surface.

An apparatus according to any one of the preceding claims, wherein the driving means is adapted to drive the beater body in a reciprocating movement along the drive shaft with a stroke amplitude of 1-50 mm, preferably 10-20 mm.

An apparatus according to any one of the preceding claims, wherein the propellant is adapted to drive the beater body in a reciprocating movement along the shaft at a stroke frequency of up to 5000 cycles per minute.

10. Device as claimed in any of the foregoing claims, wherein the driving means is adapted to drive the beater body in a rotating movement about the driving shaft.

Apparatus according to any one of the preceding claims, wherein the scrambling device is a mobile portable device.

A beater body, in particular for a device according to any one of the preceding claims, the beater body comprising a proximal end and a blunt distal end, the blunt distal end forming an impact surface for impacting the construction material in use of the device. deforming it, the beater body comprising connecting means for connecting to a powered propellant.

The beater body of claim 12, wherein the connecting means are provided at the proximal end of the knocker body.

A kit comprising a device according to any one of claims 1-11, a sheet construction material, in particular a sheet covering material, and adhesives for adhering the sheet to a building structure.

A modular deformation device for deforming a construction material, in particular coating material, the device comprising a powered propellant, and a set of beater bodies, each beater body of the set of beater bodies comprising a proximal end and a blunt distal end, the blunt distal end forms an impact face for impacting, in use of the apparatus, the construction material to deform it, the beater body being mechanically connected at its proximal end to the driven propellant, the propellant being adapted to drive the beater body in a reciprocating motion, wherein the impact face of each beater body differs in geometry.

Use of a device according to any one of claims 1-11, a beater body according to any one of claims 12-13, or a device according to claim 15, for deforming a coating material.