ELEMENT AND A GABION

BACKGROUND

The invention relates to landscaping and building fixed constructions, more specifically to manufacturing surface elements, the surface elements and use of the surface elements.

One example of fixed construction is a gabion, a cage filled with rocks, that may be used for landscaping roadsides or building embankments. Typically the cages are installed first and later filled with rocks or other heavy material. Visual appearance of the gabions is often homogenous, consisting of mere rocks and metal wire cage. Constructing the gabion may require careful placement of heavy rocks inside the cage, in order to reduce unnecessary impacts to the structure that could bend the cage. The construction may require a lot of manual labour.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that will be further described below in the detailed description. This summary is not intended to identify key features, nor to identify essential features of the claimed subject matter, nor to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not limited to implementations that solve any or all of the disadvantages noted in any part of this disclosure. A method of manufacturing a surface element is disclosed hereinafter. The surface element is constructed in a mould that is positioned onto a horizontal surface. Bottom portion of the mould is filled with sand or similar granular material. Multiple objects, such as rocks, are placed onto the sand. The objects are partially buried inside the sand. At this stage some sand may be added to the mould, to ensure that the objects are partially visible and partially under the sand. The objects and the sand are covered with polyurethane foam and waited until the foam has cured. The surface element may be removed from the mould.

At this stage the visible side of the surface element is the one that was facing the sand in the mould. The visible side has clean side of the objects attached to the surface element and sand attached to the polyurethane foam, between the objects. Most of the sand falls back into the mould. Only the portion being in contact with the polyurethane foam, now coating the foam on the visible side, is removed from the process.

The surface element may be substantially flat, according to the size of the mould and objects. When the objects are rocks, the visual impression of the surface element looks like combination of rocks and sand. The sand may be coloured dark to enhance the visual effect. In one exemplary embodiment the sand is previously used sandblasting sand, that has readily darker hue. Using sand in the mould provides initial support for the objects when they are placed into the mould. Polyurethane foam provides rigid structure to the surface element. Usually the polyurethane colour is not visually pleasing. Without the sand coating the greenish tint would glow between the objects.

In the use example of gabions, the surface element may be placed on each side of the gabion’s cage. Between the surface elements, inside the gabion, is a space that may be filled with plants or other landscaping objects. Therefore, the visual appearance or cages filled with rocks may be combined with plants growing on top of the gabion.

Each surface element may be quickly installed into the gabion. Multiple surface elements may be transported on site in a transport. As the method for manufacturing is simple, surface elements may be manufactured on site from components. The method for manufacturing the surface element may be applied to other objects than rocks. In one embodiment, the objects are lighter, decorative objects and the surface elements may be quickly manufactured on site. The mould may be a rectangular form made of wood planks that are covered in plastic wrap. The surface elements may comprise cones, branches or other natural objects, that appear to be attached to the sand. The method for manufacturing may be applied for trade fair decorations or similar temporary applications.

Many of the attendant features will be more readily appreciated as they become better understood by reference to the following detailed description considered in connection with the accompanying drawings. The embodiments described below are not limited to implementations which solve any or all the disadvantages of known surface element manufacturing methods or gabion applications.

BRIEF DESCRIPTION OF THE DRAWINGS

The present description will be better understood from the following detailed description read in light of the accompanying drawings, wherein

FIG. 1 a-1 f illustrate schematically, as an isometric view, one exemplary embodiment of method steps for manufacturing a surface element;

FIG. 2 illustrates schematically a sectional view of one exemplary embodiment of the surface element in the mould;

FIG. 3 illustrates schematically a sectional view of one exemplary embodiment of the surface element in the mould;

FIG. 4 illustrates schematically an isometric view of one exemplary embodiment of the surface element being lifted into a gabion cage; and

FIG. 5 illustrates schematically an isometric view of one exemplary embodiment of the gabion with surface elements in place. Like reference numerals are used to designate like parts in the accompanying drawings.

DETAILED DESCRIPTION

The detailed description provided below in connection with the appended drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present example may be constructed or utilized. However, the same or any equivalent functions and sequences may be accomplished by different examples.

As used herein, terms of relative elevation, such as “top,” “bottom,” “upper,” lower,” “above,” “below,” “up,” and “down,” when used in the context of the manufacturing method, the surface element 20 or the gabion 50, are used in their ordinary sense, that is, with respect to a direction of a gravitational force, such that gravity pulls objects down. Terms referring to “visible” when used in the context of the surface element 20, are used with respect to a viewer located outside the gabion 50, from which the viewer is expected to typically view the surface element 20. Terms referring to “non-visible” when used in the context of the surface element 20, are used with respect to the backside or inside of the gabion 50, where the viewer is no expected to typically view the surface element 20, or the connecting side of the surface element 20.

Figures 1 a-1 f illustrate schematically, as an isometric view, one exemplary embodiment of steps of a method for manufacturing the surface element 20. Figure 1a illustrates a mould 10, that is in this embodiment a simple rectangular frame constructed from plank wood. The mould 10 may be sized to any suitable size. In one non-limiting example the plank wood used may be 50 mm x 100 mm in size and length of one side of the mould 10 may be 1 m. The size of the mould 10 may be selected to have the surface element 20 liftable or suitable for transportation. The mould 10 is positioned on a horizontal plane, such as a floor. Small variations in the horizontal plane tilt are allowable without any effect to the manufacturing process. In Figure 1 b the mould 10 is covered in a plastic wrap 11 to protect the mould 10 and to ease removing the final product from the mould 10. The horizontal plane may not require any additional protection. When the surface elements 20 are manufactured on a construction site, only the outer frame of the mould 10 may be used. Alternatively, or in addition, the mould 10 may be applied with a mould release agent. In one embodiment, the mould 10 comprises material that is configured to release the final product.

In Figure 1 c the bottom layer of the mould 10 is filled with sand 12. The sand 12 provides the base of the manufacturing process and separates the mould 10 from the floor or from the horizontal plane. The sand 12 forms a sand surface 15 inside the mould 10. The sand 12 may comprise any solid granular objects that correspond the sand in size and shape. The sand may be coloured. In one embodiment the sand 12 is previously used and has been collected from sand blasting.

In Figure 1d a plurality of objects 13 are positioned into the sand 12. The objects 13 are positioned partially inside the sand 12, wherein a first portion of the objects 13 is partially under the sand surface 15 and a second portion of the objects 13 is partially above the sand surface 15. During this step more sand 12 may be added into the mould 10 to better accommodate the objects 13. All objects 13 should be partially visible at this step. In this exemplary embodiment the objects 13 are rocks. In one example the objects 13 are decorative objects, such as cones, pieces of logs, tree branches or some synthetic objects. In one embodiment, the objects 13 are placed onto the horizontal plane and the sand

12 is poured to the gaps between the objects. The steps disclosed in Figure 1 c and Figure 1d may be reversed

In Figure 1 e the surface of the sand 12 and the second portions of the objects

13 are covered by polyurethane foam 14. The polyurethane foam 14 is spread along the mould 10. In this embodiment, the polyurethane foam 14 is not covered from the top, and it may extend upwards. In one embodiment, the mould 10 comprises a top cover to provide even top surface for the polyurethane foam 14. In one embodiment, the polyurethane foam 14 cures into solid foam. In one embodiment, the polyurethane foam 14 is two-component foam. The two-component foam may be mixed during the foam application process. During this step, the polyurethane foam 14 is allowed to cure completely. In one embodiment, the polyurethane foam 14 is cured in 2 to 10 minutes.

Figure 1f illustrates the separation of the surface element 20 from the mould 10, after the polyurethane foam 14 has cured. Remainder of the sand 12 stays in the mould 10. One side of the surface element 20 comprises visible first portions of the objects 13 and sand 12 covering the polyurethane foam 14. In this example the visible side is below the surface element 20.

Figure 2 illustrates a sectional view of one exemplary embodiment of the mould 10 and the surface element 20. The objects 13 extend into the sand 12 and into the polyurethane foam 14. Suitable objects 13 have sufficient size to reach into the sand 12 and the polyurethane foam 14. The objects 13 may be placed freely, as the sand 12 fills the gaps between objects 13. By adjusting the amount of sand 12 in the mould 10, the fabricator may select how much the objects 13 should protrude from the finished surface element 20. The polyurethane foam 14 is very adhesive, configured to hold heavy objects 13 such as rocks in place when the surface element 20 is lifted from the mould 10. Another aspect of the adhesiveness of the polyurethane foam 14 is that sand 12 adheres into any point where the sand 12 surface contacts the polyurethane foam 14. The polyurethane foam 14 may extend heavily and reach into small gaps and find contact with the sand 12 surface. In one embodiment, the contact between the sand 12 surface and the polyurethane foam 14 is improved by shaking the horizontal plane below the mould 10.

Figure 3 illustrates a sectional view of one exemplary embodiment of the mould 10 and the surface element 20. During the manufacturing method, in one embodiment, a lifting point 31 is provided to the surface element 20 by positioning a lifting device 30 over the sand 12 or over the second portion of the objects 13, before covering the sand surface 15 and the second portions of the objects 13 by the polyurethane foam 14. A portion of the lifting device 30 is allowed to extend outside the mould 10 and the polyurethane foam 14. The lifting point 31 is arranged to be connected to the lifting device 30 embedded inside the cured polyurethane foam 14.

In one embodiment, the lifting device 30 comprises a tube; and the method for manufacturing comprises positioning the tube over the sand 12 or over the second portion of the objects 13, before covering the sand surface 15 and the second portions of the objects 13 by a polyurethane foam 14. Open ends of the tube are allowed to extend outside the mould 10 and the polyurethane foam 14. A rope is inserted into the tube, wherein the rope is the lifting point 31 outside the mould 10. In one embodiment, the tube is an electrical conduit.

Figure 4 illustrates schematically an isometric view of one exemplary embodiment of the surface element 20 being lifted into a gabion cage 40. The gabion 50 comprises the cage, cylinder or box, typically filled with rocks, concrete, or sometimes sand and soil for use in civil engineering, road building, military applications and landscaping. In this context, the gabion 50 is used for landscaping. In one aspect of the method for manufacturing, a gabion 50 is constructed from four surface elements 20, where each of the surface elements 20 is facing different direction inside the gabion cage 40. The surface elements 20 may be lifted into the gabion cage 40 in a vertical position. In the example of Figure 4, four surface elements 20 cover all sides of the gabion cage 40.

In one aspect the gabion 50 comprises multiple surface elements 20, wherein each surface element 20 comprises rocks protruding to a visible direction from a cured polyurethane foam 14; and the polyurethane foam 14 is coated by sand 12 towards the visible direction. The visual appearance of the gabion 50 hides the polyurethane foam 14 colour. Often the polyurethane foam 14 has very unnatural colour, yellowish green, that is not appealing in landscaping. The sand 12 on the surface of polyurethane foam 14 provides better visual appearance and therefore renders the surface element 20 as usable for gabions in landscaping applications.

Figure 5 illustrates schematically an isometric view of one exemplary embodiment of the gabion 50 with surface elements 20 placed on the sides of the gabion cage 40. The surface elements 20 facing different directions leave a space inside the gabion 50. In one embodiment, the space inside the gabion 50, between the surface element, is filled with substance 51 , such as sand, gravel, rocks or planter soil. The planter soil may be used for planting plants inside the gabion 50. In one embodiment, the space inside the gabion 50, between the surface elements 20, is used as a planting box for plants.

A method for manufacturing a surface element is disclosed herein. The method comprises providing a mould onto a horizontal plane; providing sand into the mould, the sand forming a sand surface inside the mould; positioning a plurality of objects into the sand, wherein a first portion of the objects is partially under the sand surface and a second portion of the objects is partially above the sand surface; covering the sand surface and the second portions of the objects by curing polyurethane foam; and after the polyurethane foam has cured, removing the surface element form the mould; wherein one side of the surface element comprises visible first portions of the objects and sand covering the polyurethane foam. In one embodiment, the method comprises providing a lifting point to the surface element by positioning a lifting device over the sand or over the second portion of the objects, before covering the sand surface and the second portions of the objects by a polyurethane foam, and allowing a portion of the lifting device to extend outside the mould and the polyurethane foam. In one embodiment, the lifting device comprises a tube and the method comprises positioning the tube over the sand or over the second portion of the objects, before covering the sand surface and the second portions of the objects by a polyurethane foam; allowing open ends of the tube to extend outside the mould and the polyurethane foam; and inserting a rope into the tube, wherein the rope is the lifting point outside the mould. In one embodiment, the objects are rocks. In one embodiment, the method comprises constructing a gabion from four surface elements, where each of the surface elements is facing to different direction.

Alternatively, or in addition, a gabion is disclosed herein. The gabion comprises multiple surface elements, wherein each surface element comprises rocks protruding to a visible direction from a cured polyurethane foam; and the polyurethane foam is coated by sand towards the visible direction. In one embodiment, the surface elements are positioned in vertical position with the visible direction outside the gabion and the non-visible side facing inside the gabion. In one embodiment, the space inside the gabion, between the surface element, is filled with sand, gravel, rocks or planter soil. In one embodiment, the space inside the gabion, between the surface elements, is used as a planting box for plants.

Alternatively, or in addition, a surface element is disclosed herein. The surface element comprises a visible side comprising first portions of objects having visible first portions and the area between the objects covered with sand; and a non-visible side comprising non-visible second portions of the objects embedded into a cured polyurethane foam. In one embodiment, the surface element comprises a lifting point partially embedded into the cured polyurethane foam and partially extending outside the polyurethane foam. In one embodiment, the lifting device comprises a tube embedded into the cured polyurethane foam, having open ends of the tube extending outside the cured polyurethane foam; and a rope travelling through the tube, wherein the rope is the lifting point outside the cured polyurethane foam. In one embodiment, the objects are rocks.

Any range or device value given herein may be extended or altered without losing the effect sought.

Although at least a portion of the subject matter has been described in language specific to structural features and/or acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as examples of implementing the claims and other equivalent features and acts are intended to be within the scope of the claims.

It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages. It will further be understood that any reference to ‘an’ item refers to one or more of those items. The steps of the methods described herein may be carried out in any suitable order, or simultaneously where appropriate. Additionally, individual blocks may be deleted from any of the methods without departing from the spirit and scope of the subject matter described herein. Aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples without losing the effect sought.

The term ‘comprising’ is used herein to mean including the method blocks or elements identified, but that such blocks or elements do not comprise an exclusive list and a method or apparatus may contain additional blocks or elements.

It will be understood that the above description is given by way of example only and that various modifications may be made by those skilled in the art. The above specification, examples and data provide a complete description of the structure and use of exemplary embodiments. Although various embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this specification.