Abstract:
This invention relates to a method of manufacturing a framework having a honeycomb structure with a plurality of compartments running the length of the framework, the method comprising joining a first sheet of a flexible material to a second sheet along a plurality of join lines to form a first row of compartments, joining a third sheet to the second sheet along a plurality of intermediate join lines to form a second row of compartments, joining a fourth sheet to the third sheet, and so on. At least some of the compartments may be closed at a first end or a second end or at both ends of the framework. A further embodiment of the invention relates to a framework produced by the method. The invention may be used in the manufacture of various structures including mine supports, dam walls, storage packs, artificial reef units, road supports, contamination barriers, linings and the like.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to a method of manufacturing a framework having a honeycomb structure with a plurality of compartments running the length of the framework from a first end to a second end, for use, for example, in the construction of a structure such as a mine support, a dam wall or an artificial reef unit or the like, where at least some of the compartments are closed at at least one end.  
         [0002]     It is well known to form support structures such as roadways, canals or river or bank linings, mine supports and artificial reef units from a material having an open honeycomb structure, i.e having a plurality of compartments or cells divided by dividing walls, each compartment or cell being filled with a suitable filler material. Examples of such materials having an open honeycomb structure for use in these support structures are Hyson-Cells from M &amp; S Technical Consultants &amp; Services (Pty) Limited, Geoweb from Presto Products Company, Tenweb from Tenax Corp, Armater from Crow Company, Terracell from Webtech Inc, Envirogrid from Akzo Nobel Geosynthetics Co, and Geocells from Kaytech.  
         [0003]     It is also known how to manufacture such materials having an open honeycomb structure. An example is illustrated in U.S. Pat. No. 4,478,659 to A R M Hall.  
       SUMMARY OF THE INVENTION  
       [0004]     According to a first aspect of the invention there is provided a method of manufacturing a framework having a honeycomb structure with a plurality of compartments running the length of the framework from a first end to a second end thereof, with at least some of the compartments being closed at the first end or at the second end or at both ends of the framework, from a plurality of sheets of a flexible material, including the steps of: 
        joining a first sheet to a second sheet along a plurality of join lines to form a first row of compartments,     joining a third sheet to the second sheet along a plurality of join lines intermediate the join lines between the first and second sheets to form a second row of compartments,     joining a fourth sheet to the third sheet along a plurality of join lines to form a third row of compartments,     and so on to form the honeycomb structure, and     closing at least some of the compartments at the first end of the framework or at the second end of the framework or at both ends of the framework.        
 
         [0010]     When it is desired to close some or all of the compartments at the first end of the framework, the closure step preferably comprises: 
        providing a skirt depending from an edge of each sheet at the first end of the framework and either joining the skirt on the first sheet to the second sheet to close the first row of compartments, joining the skirt on the second sheet to the third sheet to close the second row of compartments and so on; or joining the skirt on the first sheet to the skirt on the second sheet to close the first row of compartments, joining the skirt on the third sheet to the skirt on the fourth sheet to close the third row of compartments, and so on.        
 
         [0012]     Alternatively, when it is desired to close all of the compartments at the first end of the framework, the closure step preferably comprises: 
        providing a skirt depending from an edge of the first sheet and a skirt depending from an edge of the last sheet at the first end of the framework, providing two skirts depending from an edge of every sheet intermediate the first and the last sheets at the first end of the framework, joining the skirt on the first sheet to an adjacent skirt on the second sheet to close the first row of compartments, joining adjacent skirts on the second and third sheets together to close the second row of compartments, joining adjacent skirts on the third and fourth sheets together to close the third row of compartments, and so on.        
 
         [0014]     If desired, certain of the skirts may be omitted so as to leave certain of the compartments open with others being closed.  
         [0015]     The same procedure may be repeated at the second end of the framework to close some or all of the compartments at the second end of the framework as well.  
         [0016]     The method of joining the sheets together along join lines, as well as the method of closing at least some of the compartments at the first end of the framework or at the second end of the framework or at both ends of the framework may be any suitable method such as for example heat or ultrasonic welding, sewing, gluing or the like.  
         [0017]     The sheets may be made from a variety of materials, including (but not limited to) plastics materials, non-woven materials, composites with laminates (such as aluminium), or any flexible material where one sheet can be joined to another. The material may permit the framework to be hot- or cold-filled with toxic chemicals in liquid, gas or powder form, heavy metals, mine tailings, mine sludge or the like.  
         [0018]     According to a second aspect of the invention there is provided a framework having a honeycomb structure with a plurality of compartments running the length of the framework from a first end to a second end with at least some of the compartments being closed at the first end or at the second end or both of the framework, the framework being manufactured from a plurality of sheets of a flexible material.  
         [0019]     The framework of the invention may be used in the manufacture of various structures including mine supports, dam walls, storage packs, artificial reef units, roof supports, vertical and horizontal pressure supports, contamination barriers and the like. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]      FIG. 1  is a perspective view of a plurality of sheets of a flexible material prior to being joined to one another to form a framework of the invention;  
         [0021]      FIG. 2  is a perspective view of a framework formed from the sheets of  FIG. 1 , prior to closure of some or all of the compartments at a first end or a second end of the framework;  
         [0022]      FIGS. 2   a  are plan views of alternative embodiments of compartments formed and  2   b  by the framework of  FIG. 1 ;  
         [0023]      FIG. 3  is a view along the arrow A of the framework of  FIG. 2 ;  
         [0024]      FIG. 4  is a view along the arrow B of the framework of  FIG. 2 ;  
         [0025]      FIG. 5  is a schematic view of a first method of closure of some or all of the compartments of the framework of  FIG. 2 ;  
         [0026]      FIG. 6  is a schematic view of a second method of closure of some or all of the compartments of the framework of  FIG. 2 ;  
         [0027]      FIG. 7  is a schematic view of a third method of closure of some of the compartments of the framework of  FIG. 2 ;  
         [0028]      FIG. 8  is a schematic view of the closure of some or all of the compartments at both ends of the framework of  FIG. 2 ;  
         [0029]      FIG. 9  is a view along the arrow B of the framework of  FIG. 2 ;  
         [0030]      FIG. 10  is a schematic view of the closure of some or all of the compartments of the framework of  FIG. 2 ; and  
         [0031]      FIG. 11  is a schematic view of an alternative embodiment of the framework of the invention. 
     
    
     DESCRIPTION OF EMBODIMENTS  
       [0032]     The crux of the invention is that a framework having a honeycomb structure with a plurality of compartments running the length of the framework from a first end to a second end, which is manufactured from a plurality of sheets of a flexible material, has some or all of the compartments closed at the first end or at the second end or at both ends of the framework.  
         [0033]     The closure of some or all of the compartments allows material filled into the compartments to be contained therein, for various purposes.  
         [0034]     The method of manufacture of the framework of the invention will now be described with reference to the accompanying drawings.  
         [0035]     Referring to  FIG. 1 , there is provided a plurality of sheets  10  of a plastics or other suitable flexible material.  
         [0036]     Referring to FIGS.  2  to  4 , a framework  12  having a first end  14  and a second end  16  is formed from the plurality of sheets  10  as follows.  
         [0037]     A first sheet  10 A is joined to a second sheet  10 B along a plurality of join lines  18  to form a first row of compartments  20 . It can be seen that the join lines  18  stop short of one of the ends of the sheets  10 A,  10 B so as to leave a skirt  22 A depending from the sheet  10 A and similarly a skirt  22 B depending from the sheet  10 B.  
         [0038]     Thereafter, a third sheet  10 C is joined to the second sheet  10 B along a plurality of join lines  24  which again are generally substantially parallel, and which are intermediate the join lines  18 , to form a second row of compartments  26 . Again the join lines  24  stop short of one of the ends of the sheet  10 B,  10 C so as to leave a skirt  22 C depending from the third sheet  10 C.  
         [0039]     Thereafter, a fourth sheet  10 D is joined to the third sheet  10 C along a plurality of join lines  28  which again are generally substantially parallel, and which in this particular embodiment are in register with the join lines  18  (although the join lines  28  need not necessarily be in register with the join lines  18 ), to form a third row of compartments  30 . Again the join lines  28  stop short of one of the ends of the sheets  10 C,  10 D so as to leave a skirt  22 D depending from the fourth sheet  10 D.  
         [0040]     This process is continued to form the framework  12 .  
         [0041]     The join lines  18 ,  24 ,  28 , etc., may be formed in any suitable manner, for example by heat or ultrasonic welding, by sewing or by gluing. Depending on the thickness of the join lines  18 ,  24 ,  28 , etc, the shape of the compartments may be either hexagonal compartments  20 A,  26 A,  30 A, etc. or quadrangular compartments  20 B,  26 B,  30 B, etc., as illustrated in  FIGS. 2   a  and  2   b , respectively.  
         [0042]     The next step is to close some or all of the rows of compartments  20 ,  26 ,  30 , etc., at the second end  16  of the framework  12 .  
         [0043]     A first method of closing some or all of the compartments is illustrated in  FIG. 5 . The skirt  22 A depending from the sheet  10 A is folded over and joined to the sheet  10 B at the end of the join lines  18  between the sheets  10 A and  10 B so as to close the row of compartments  20  at the second end  16  of the framework  12 . Likewise the skirt  22 B depending from the sheet  10 B is folded over and joined to the sheet  10 C at the end of the join lines  24  between the sheets  10 B and  10 C so as to close the row of the compartments  26 . In a similar manner the skirt  22 C is joined to the sheet  10 D and the skirt  22 D is joined to the sheet  10 E to close the row of compartments in the various rows in the framework  12 . In this way, all of the rows of compartments  20 ,  26 ,  30 , etc., in the framework  12  are closed at the second end  16  of the framework  12 .  
         [0044]     It is to be noted that the compartments in a row are in communication with each other, e.g. all the compartments  20  are in communication with each other, but not in communication with the compartments  26 ,  30  etc in other rows. In an alternative embodiment shown in  FIG. 9 , one or more of the internal sheets  10 B,  10 C, etc has openings  42  which permit communication between adjacent compartments in different rows, e.g. between compartments  20  and  26 .  
         [0045]     If desired, the join lines  18 ,  24 ,  28  may then be extended so as to close each compartment  20 ,  26 ,  30  from adjacent compartments  20 ,  26 ,  30  in the same row.  
         [0046]     Thus, any material filled into the compartments  20 ,  26 ,  30 , etc., is contained in the compartments  20 ,  26 ,  30 , etc., by virtue of the closure of these compartments  20 ,  26 ,  30 , etc., of the framework  12 .  
         [0047]     The joining of the skirts  22 A,  22 B, etc., to the adjacent sheets  10 B,  10 C, etc., may be achieved in the same manner as the formation of the join lines  18 ,  24 ,  28 , for example by heat or ultrasonic welding, by sewing or by gluing.  
         [0048]     Referring to  FIG. 6 , a second method of closure of some or all of the compartments  20 ,  26 ,  30  in the framework  12 , is illustrated. Firstly, additional skirts  32  are joined to the sheets  10 B,  10 C and in fact all sheets intermediate the first sheet  10 A and the last sheet of the framework  12  so that each intermediate sheet  10 B,  10 C, etc., has two skirts  22 ,  32  depending therefrom.  
         [0049]     Thereafter, the skirt  22 A on the sheet  10 A is joined to the skirt  22 B on the sheet  10 B at  34  to close the row of compartments  20 . The skirt  32 B attached to the sheet  10 B is joined to the skirt  32 C attached to the sheet  10 C at  34  to close the row of compartments  26 . Thereafter the skirt  22 C on the sheet  10 C is joined to the skirt  22 D on the sheet  10 D at  34  to close the row of compartments  30 . This process is continued until some or all of the rows of compartments  20 ,  26 ,  30 , etc., in the framework  12  are closed at the second end  16  of the framework  12 . Again, in a similar way to that described above, each compartment in a row may be closed off from adjacent compartments in the same row. Again, the skirts  22 ,  32  may be joined to one another by means of heat or ultrasonic welding, by sewing or by gluing.  
         [0050]     Referring to  FIG. 7 , a third method of closure of some or all of the compartments  20 ,  26 ,  30  in the framework  12 , is illustrated. The skirt  22 A on the sheet  10 A is joined to the skirt  22 B on the sheet  10 B at  36  to close the row of compartments  20 . The skirt  22 C on the sheet  10 C and the skirt  22 D on the sheet  10 D are joined at  36  to close the row of compartments  30 . The second row of compartments  26  and every second row thereafter are left open.  
         [0051]     As indicated above, it is possible to close some or all of the rows of compartments at both ends  14 ,  16  of the framework  12 . This is specifically illustrated in  FIG. 8  where all of the rows of compartments are closed, in the same manner as illustrated in  FIG. 6 .  
         [0052]     The method of closing some or all of the compartments at one end  14  may be different to the method of closing some or all of the compartments at the other end  16 , as illustrated in  FIG. 10 . The compartments  20 ,  26 ,  30  are closed at one end  16  according to the method illustrated in  FIG. 6 , but a unit  55  comprising a number of rows of compartments in communication with each other is formed by joining a skirt  23 A at the end  14  of sheet  10 A to a skirt  23 D(i) at the end  14  of sheet  10 D. A similar unit  56  is formed by joining a skirt  23 D(ii) to skirt  23 F to sheet  10 F.  
         [0053]     When some or all of the rows of compartments at one end of the framework are closed, particularly the end of the framework intended to rest on a base in use, the compartments may be filled with a material which is then retained in the closed compartments. This may assist in the formation of structures such as dam walls or artificial reef units.  
         [0054]     When all of the rows of compartments are closed at both ends of the framework so that the framework is in essence sealed, a material may be filled into or drained from the compartments through suitable openings  72  ( FIGS. 10 and 11 ). Some of the openings may be non-return valves, although in some circumstances the openings may permit the material to also flow out of the compartments, and the openings may be closed when it is no longer desired that the material be permitted to flow out of the compartments. Such a situation would arise when a first material in the compartments is replaced with a second material.  
         [0055]     In addition the framework may then be pressurized by introducing a fluid or fluidized solid under pressure into the framework, which may be useful where the framework is being used in the manufacture of a mine support. A hose or pipe  60  may be inserted through the openings to introduce the fluid or fluidized solid. The framework may include engaging means for a vibrator  64  or the like to facilitate compaction or pre-stressing of the material within the compartment, as illustrated in  FIG. 11 .  
         [0056]     The closure of compartments may also assist where it is intended to stack frameworks one on top of another.  
         [0057]     A first framework may be attached to a second similar framework to build a larger structure. For example a first end of a first framework  12  as illustrated in  FIG. 8  may be attached to a second end of a second framework  12  as illustrated in  FIG. 8 , e.g. by heat or ultrasonic welding, by sewing or by gluing.  
         [0058]     It is also possible to form a plurality of holes in the framework, or in an extension or extensions  52  and  54  to the framework, so that flexible stays  56  or rigid rods  58  or the like may be inserted through the holes to anchor the framework in position in use, as illustrated in  FIG. 11 .