WO2016024112A1

WO2016024112A1 - Structure formation apparatus

Info

Publication number: WO2016024112A1
Application number: PCT/GB2015/052332
Authority: WO
Inventors: James Charles WESTBROOK; Patricia MACGILLIVRAY
Original assignee: VZEE PAPER PRODUCTS Ltd
Current assignee: VZEE PAPER PRODUCTS Ltd
Priority date: 2014-08-12
Filing date: 2015-08-12
Publication date: 2016-02-18
Anticipated expiration: 2017-02-12
Also published as: GB201414261D0; GB2529619A

Abstract

A structure formation apparatus comprising a profiler and former assembly (104), arranged to receive a first sheet (102) from a first sheet feeder (100), and to profile and form the first sheet to form the structure, the profiling and forming comprising: profiling the first sheet with a substantially quadrilateral wave profile; forming the profiled first sheet by manipulating the profiled first sheet to convert the substantially quadrilateral wave profile to a substantially triangle wave profile that forms a plurality of oppositely oriented substantially triangle-section ducts (130), the bases of which substantially triangle- section ducts together form a first substantially continuous surface with the first sheet; wherein the profiler and former assembly is arranged to profile and form the first sheet as the first sheet moves through the assembly in a first direction, the profile being arranged to extend in a second direction that is substantially perpendicular to the first direction.

Description

STRUCTURE FORMATION APPARATUS

The present invention relates generally to a structure formation apparatus, to a method of forming a structure, and a structure made using that apparatus or method.

It is known to form structures that are reinforced in some way. In once instance, for example, it is known to provide a composite structure that includes a profiled and/or formed structure (e.g. having a corrugation or undulation, such as a wave-like form), overlaid with a cover or capping sheet. Such a cover or capping sheet may be located on an upper and/or lower surface of the profiled section. The resulting structure is far stronger than if the cover or capping layer was used in isolation, yet the resulting structure is still relatively lightweight. Such a structure is sometimes referred to as a board. The board does not necessarily need to be planar in form, and could be curved or similar. Such structures are often formed from paper-product, which allows for relatively cheap construction and disposal, yet still offers a good degree of strength and robustness.

Although structures as described above are advantageous, methods and machines for forming such structures are typically inefficient and/or complex. In terms of inefficiency, for instance, a section of profiled sheet may be formed. A section of planar sheet may then be used to cover or cap one surface of the profiled sheet. A second section of planar sheet may be used to cover or cap an opposite side of the profiled sheet. The final, composite structure thus comprises a profiled sheet section sandwiched between two planar sheet sections. However, forming a sheet in this sectional or batch-like manner leads to production inefficiencies, and a likely increase in production time and costs, and a related affect on sale costs.

In terms of complexity, the formation of the profiled sheet is not at all straightforward. The profiling may lead to different parts of the sheet moving through a profiler or the like at different speeds, which may be difficult to achieve without a relatively high degree of machine or control complexity.

It is an example aim of example embodiments of the present invention to at least partially obviate or mitigate one or more disadvantages of the prior art, whether identified herein or elsewhere, or to at least provide an alternative to existing methods and apparatus for forming structures as described herein. According to the present invention there is provided at least an apparatus and method as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

According to a first aspect of the present invention, there is provided a structure formation apparatus, comprising: a profiler and former assembly, arranged to receive a first sheet from a first sheet feeder, and to profile and form the first sheet to form the structure, the profiling and forming comprising: profiling the first sheet with a substantially quadrilateral (e.g. rectangle) wave profile; forming the profiled first sheet by manipulating the profiled first sheet to convert the substantially quadrilateral wave profile to a substantially triangle wave profile that forms a plurality of oppositely oriented substantially triangle-section ducts, the bases of which substantially triangle-section ducts together form a first substantially continuous surface with the first sheet; wherein the profiler and former assembly is arranged to profile and form the first sheet as the first sheet moves through the assembly in a first direction, the sheet also extending in a second direction that is substantially perpendicular to the first direction, and wherein the profile is arranged to extend in the second direction, substantially transverse to the first direction in which the sheet moves.

The profiler and former assembly may comprise one or more guides and/or rollers for performing the profiling and/or forming. Optionally, a spacing between one or more guides or parts thereof, and/or a spacing between protrusions or recesses of the one or more rollers, decreases from an upstream end of the profiler and former assembly to a downstream end of the profiler and former assembly.

The apparatus may further comprise a sheet modifier located upstream of the profiler and former assembly, and arranged to modify the first sheet to introduce fold lines in the first sheet that extend in the first direction, the fold lines being arranged to facilitate subsequent profiling and/or forming.

The sheet modifier may be arranged to introduce fold lines in the form of one or more of: perforation lines, score lines, and/or crease lines. The sheet modifier may conveniently take the form of one or more rollers.

The apparatus may further comprise a sub-sheet joiner, arranged to receive a first sub- sheet travelling in the first direction, and a second sub-sheet travelling in the first direction, an edge of the second sub-sheet being arranged to partially overlap an edge of the first-sub sheet in the first direction, the sub-sheet joiner being further arranged to join the first and second sub-sheets together along the overlap, thereby forming the first sheet. Depending on how the apparatus is arranged, each sub-sheet may pass through its own dedicated sheet modifier, prior to joining, profiling and/or forming.

The sub-sheet joiner may be located: upstream of the profiler and former assembly; or within the profiler and former assembly; or within the profiler and former assembly, after the profiling takes place and before the forming takes place.

The structure formation apparatus may further comprise a first treatment arrangement, arranged to treat the first sheet to maintain continuity of the first substantially continuous surface formed with the bases of the substantially triangle-section ducts.

The first treatment arrangement may comprise a first cover arrangement, arranged to receive a second sheet from a second sheet feeder, and further arranged to at least partially cover the first substantially continuous surface of the first sheet with the second sheet, and to attach the second sheet to the first substantially continuous surface of the first sheet.

The manipulation of the first sheet may be arranged to result in opposing bases of the substantially triangle-section ducts together forming a second substantially continuous surface with the first sheet, substantially on an opposite side of the substantially triangle-section ducts to the first substantially continuous surface.

The structure formation apparatus may further comprise a second treatment arrangement, arranged to treat the first sheet to maintain continuity of the second substantially continuous surface formed with the bases of the substantially triangle-section ducts.

The second treatment arrangement may comprise a second cover arrangement, arranged to receive a third sheet from a third sheet feeder, and further arranged to at least partially cover the second substantially continuous surface of the first sheet with the third sheet, and to attach the third sheet to the second substantially continuous surface of the first sheet.

The quadrilateral wave profile may be a square wave profile, such that the substantially triangle-section ducts, once formed, are equilateral substantially triangle-section ducts. The apparatus may be arranged to form the structure in a continuous manner. For example, the one or more sheets may be fed in a continuous manner to any one or more of, or a combination of the sheet modifier, the sheet joiner, the profiler and former assembly, or the treatment arrangement. According to a second aspect of the present invention, there is provided a method of forming a structure, comprising: profiling and forming a first sheet to form the structure, the profiling and forming comprising: profiling the first sheet with a substantially quadrilateral wave profile; forming the profiled first sheet by manipulating the profiled first sheet to convert the substantially quadrilateral wave profile to a substantially triangle wave profile that forms a plurality of oppositely oriented substantially triangle-section ducts, the bases of which substantially triangle-section ducts together form a first substantially continuous surface with the first sheet; wherein the profiling and forming is undertaken as the first sheet moves in a first direction, the sheet also extending in a second direction that is substantially perpendicular to the first direction, and wherein the profile is arranged to extend in the second direction, substantially transverse to the first direction in which the sheet moves.

According to a second aspect of the present invention, there is provided a structure formed using the apparatus or method according to an aspect of the present invention.

One or more of the first, second and/or third sheet feeders may comprise one or more reels of respective sheet material, or a source of discrete sheets (which may be joined or separate) that can be fed in a repeated and/or continuous manner. One or more features of any aspect or embodiment described herein may, where appropriate to the skilled person from a reading of this disclosure, be used in conjunction with and/or replace one or more features of another aspect of embodiment described herein.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic Figures in which:

Figure 1 schematically depicts a structure formation apparatus that is different to that in accordance with the present invention;

Figures 2 and 3 schematically depict a structure formation apparatus according to an example embodiment, in side and plan views respectively;

Figure 4 schematically depicts profiling and forming of a sheet in a second direction, transverse to a first movement direction of the sheet, in accordance with an example embodiment;

Figure 5 schematically depicts a composite structure formed using the apparatus of Figures 2 and 3, according to an example embodiment; and Figure 6 schematically depicts principles of joining adjacent sub-sheets to form a larger, first sheet, according to an example embodiment. Figure 1 schematically depicts a structure formation apparatus that is different to that of the present invention. The structure formation apparatus comprises a first continuous sheet feeder 2 in the form of a reel of sheet material. The first continuous sheet feeder 2 is thus arranged to provide a continuous source of first sheet 4 in a first (sheet movement or flow) direction. In another embodiment (not shown), the apparatus may not comprise the first continuous sheet feeder (or any other sheet feeders, for that matter) and may instead simply be arranged to receive and use sheet from such one or more sheet feeders.

Referring back to Figure 1 , the apparatus further comprises a profiler 6. The profiler 6 is arranged to receive the continuous source of first sheet 4 from the first continuous sheet feeder 2, in the first direction. The profiler 6 is arranged to profile the first sheet with a rectangle wave profile 8. As shown in the Figure, the profile 8 extends along the sheet, in the first movement direction of the sheet. Folds, creases, scores, or perforations that may be used to form the profile extend in a linear manner in a second direction, across the sheet Therefore, a series of such folds, creases, scores, or perforations will be located adjacent to one another to form the substantially rectangular wave profile that, overall, extends along the sheet in the first direction. The direction in which the profile extends is important, as will be discussed in more detail below.

Downstream of the profiler 6 is located a former arrangement 10. The former arrangement 10 is arranged to receive the profiled first sheet 8 from the profiler 6, again in the first movement direction of the sheet. The former arrangement is further arranged to manipulate in some way the profiled first sheet 8. The manipulation is such that the substantially rectangle wave profile of the profiled first sheet is converted to, or at least urged towards, a triangular wave profile.

Conversion or urging from a rectangle wave profile to or toward a triangle wave profile may be achieved in one of a number of ways. In a first approach, an at least partial linear acceleration or deceleration of the sheet as it passes through the former arrangement 10 may be undertaken in order to cause upstanding walls of the rectangle wave profile to angle in toward one another to form, or at least begin to form, the triangle wave profile. Ultimately, the walls of the rectangle wave profile are urged toward one another to an extent that the walls touch one another and the sheet forms a plurality of oppositely oriented triangle-section ducts 12, thus at least partly forming the structure. The bases (i.e. sides facing out from the sheet 12) of the triangle section ducts 12 will together form at least one first substantially continuous surface with the first sheet. That is, the bases align with one another to form such a continuous surface. It is likely that, in practice, two such surfaces will be formed, on opposite sides of the triangular wave profile formed in the sheet 12. A second continuous sheet feeder 14 in the form of a reel is provided. The second continuous sheet feeder 14 is arranged to provide a continuous source of second sheet 16. Again, in other embodiments (not shown) such a second continuous sheet feeder may not be provided, and the apparatus as a whole may be configured to receive sheet from such a continuous sheet feeder.

The apparatus further comprises a first cover arrangement 18. In this embodiment, the cover arrangement 18 is arranged to receive the sheet having the triangle wave profile 12, and to cover the first substantially continuous surface of the profiled first sheet 12 with the second sheet 16. The cover arrangement also attaches the second sheet 16 to the substantially continuous surface of the first sheet 12 to form a composite structure that comprises the profiled first sheet 12 and the covering second sheet 16. The attachment may be achieved using, for instance, adhesive applied to one or both of the continuous surface of the first sheet 12 or the second sheet 16. The covering second sheet 16 not only covers the substantially continuous surface of the profiled first sheet 12, which may afford some protection or similar. The covering second sheet 16 also maintains the continuity of the profiled structural form of the first sheet 12, which maintains the functionality of such profiling. Although not shown in Figure 1 , a cover or capping sheet may also be applied to another substantially continuous surface of the triangle section ducts, that surface being opposite to the surface provided with the layer as shown in Figure 1 . This second layer may be provided in much the same way as already described above in relation to the provision of the first cover or capping layer. Sheet used to form the second cover layer on the opposite side of the sheet having the triangle ducts may be provided by a third continuous sheet feeder, which may take the form of a reel of sheet material.

As shown in Figure 1 , a continuous composite structure is formed using the depicted apparatus. Should sections of the continuously provided structure be required, one or more cutting, slicing or otherwise dividing arrangements may be located downstream of the former arrangement 18 to in some way section the continuously formed structure into discrete sections. Perhaps at first glance, the apparatus of Figure 1 might be understood as allowing the composite structure to be constructed in a simple and efficient manner. However, this might not necessarily be the case, as will now be discussed.

As highlighted above, the profile of the sheet extends along the sheet in the first direction. That is, the profile is formed in the same direction in which the sheet moves. It has been realised that this is potentially a problem with the apparatus. For example, as the sheet is profiled and formed, its linear speed through the apparatus changes in compliance with the accordion effect (sometimes known as the concertina effect). This is because the profiling and forming results in the sheet material bunching up in accordance with the introduced profiled and formation. This means that the sheet introduced to the profiler may be moving many multiple times faster than the sheet moving through and leaving the former. In practise, this may be very difficult to achieve without complex driving, indexing, timing and control systems and the like. Such complexity comes with a cost, both in in terms of initial outlay and long term maintenance.

According to example embodiments of the present invention, one or more disadvantages of the prior art may be overcome by introduction of the profile across the sheet, as opposed to along the sheet. That is, the profile extends in a second direction across the sheet, substantially transverse to the first direction in which the sheet moves through the apparatus. An advantage of this subtle but important change is that that linear speed of the sheet through the apparatus is not affected by the profiling and forming, thereby completely avoiding the accordion effect. By completely avoiding the accordion affect, the need for complex driving, indexing, timing and control systems and the like is also avoided, or at least reduced. Therefore, apparatus according to an example embodiment is far simpler, and likely far easier and cheaper to produce, purchase and maintain than that shown in Figure 1.

Figures 2-6 will be used to explain features of example embodiments. The Figures are not drawn to scale, and are only given as an explanatory aid. The same features appearing in different Figures are given the same reference numerals for consistency and clarity.

Figures 2 and 3 show a structure formation apparatus according to an example embodiment, in side and plan views respectively. Figures 2 and 3 will be referred to in combination. The apparatus comprises sheet feeders 100 in the form of reels of sheet material. The sheet feeders 100 each supply sheet 102 in a continuous manner to a profiler and former assembly 104 via one or more optional roller/driving arrangements 106. The roller/driving arrangements 106 may be used to control the flow path and speed of the sheet 102 through the apparatus. The use of multiple sheet feeders 100 ensures that a dimension (e.g. a width) of any resultant structure formed by the apparatus is not limited by, for example, an axial length of a single sheet feeder 100. That is, multiple sheets 102 from multiple sheet feeders 100 can be joined together to form a larger sheet. To that extent, the apparatus may comprise a sheet joiner, arranged to receive multiple sheets and to join those sheets together to form a larger sheet. The sheet that is ultimately formed may be referred to a first sheet, whereas the sheets used to form that larger sheet may be referred to as sub-sheets. The joining can take place at any particular location, but may be more conveniently undertaken before any profiling and/or forming of the sheet takes place within the profiler and former 104. This is because the forming, at least, might make it difficult to join adjacent sheets. An example of sheet joining is discussed in more detail below, in relation to Figure 6.

Referring back to Figures 2 and 3, located upstream of the profiler and former assembly 104 are sheet modifiers 108. Each sheet 102 passes through a sheet modifier 108 before encountering the profiler and former assembly 104. The sheet modifier 108 is arranged to modify each sheet 102 to introduce fold lines in the sheet 102 that extend in the first direction in which the sheet moves or flows. The fold lines are arranged to facilitate subsequent profiling and/or forming of the sheet 102, and may take the form of one or more of perforation lines, score lines and/or crease lines. Each sheet modifier 108 may conveniently take the form of one or more rollers or the like.

In another example, a single sheet modifier may modify one, more or all sheets.

The sheets 102, which may already be joined together at this stage, are then fed into the profiler and former assembly 104. The profiler and former assembly 104 is operates in a similar manner to the apparatus described above in relation to Figure 1 . Referring to Figures 2 and 3, in general the profiler and former assembly 104 is arranged to receive the or each sheet 102, profile the sheet, and form the profiled sheet such that the sheet leaves the assembly 104 having a form comprising a plurality of oppositely oriented triangle-section ducts. The bases of the triangle-section ducts together form a substantially continuous surface with the sheet. However, and in contrast with the apparatus shown in Figure 1 , the apparatus shown in Figures 2 and 3 is arranged to introduce the profile in a second direction, across the sheet 102, substantially transverse (i.e. perpendicular) to the first direction in which the sheet 102 moves through the apparatus.

Figure 4 shows the sheet 102 in various stages of profiling and forming as it passes through the profiler and former assembly 104. The profile and/or forming is shown as being transverse to the general (that is first) movement direction 1 10 of the sheet 102. The Figure therefore shows cross sections through the sheet 102, when viewed along the direction in which the sheet 102 passes through the apparatus (i.e. the first direction). The profiler and former assembly 104 may comprise one or more guides and/or rollers 1 12, 1 14, 1 16 for performing the profile and/or forming. It can be seen that the substantially planar sheet 102 is initially given a substantially undulating or wave-like profile, for example using one or more guides 1 12 located on opposite sides of the sheet 102. The guides 1 12 are provided with one or more appropriately shaped protrusions and/or recesses for implementing the profiling. The fold lines in sheet 102 facilitate and/or assist in maintaining the profiling.

In order to form the required and final triangle-section duct structure, the sheet must, in this embodiment, at least temporarily (which includes transiently) be provided with a rectangle- wave profile (in general, though, a quadrilateral-wave profile will suffice). A rectangle-wave profile might be conveniently achieved by the use of one or more rollers 1 14. The rollers 1 14 are provided with appropriately configured surfaces to achieve the profiling, which surfaces might comprise one or more planar surfaces, protrusions and/or recesses. The surfaces are used to urge or otherwise guide an undulating profile towards and/or into a substantially rectangle-wave profile. Again, the fold lines in sheet 102 facilitate and/or assist in maintaining the profiling.

A rectangle wave profile includes a square wave profile, in which square profile the height of the profile is equal to the width of a square of the profile (or, in other words, the amplitude is equal to half of the wavelength). A square wave profile may be advantageous, since it allows for the formation of triangular section ducts that have an equilateral triangle profile. Equilateral triangles are particularly strong and stable structures, meaning that the resulting structure formed from such triangles is also strong and stable.

Referring back to Figure 4, the rectangle-wave profile may be urged toward and into a triangle-like profile, and into and toward the required and final triangle-duct profile by forming guides 1 16. The forming guides 1 16 may comprise one or more protrusions and/or recesses which either protrude into or receive different parts of the now profiled sheet 102. The spacing between (or, more generally, dimensions of - e.g. a width of) one or more guides, and/or protrusions and/or recesses of the one or more guides, may decrease from an upstream region of the profiler and former assembly 104 toward a downstream region of the profiler and former assembly 104. The decrease (or tapering), may facilitate the urging of the sidewalls of the rectangle wave profile toward one another, towards and finally into the triangle-duct section formation. That is, the decrease/tapering provides a driving force to compress the profiled sheet in the second direction, transverse to the first movement direction, to form the ducts. Again, fold lines in sheet 102 facilitate and/or assist in maintaining the formation. "Urging", or the like, as used herein means that the profile is at least more triangular in form than rectangular in form. For instance, "urged towards" a triangular wave profile includes a situation when the profile is substantially trapezium-like in form, both profiles having a base, and sides extending from the base that are angled inwardly toward one another. Subsequent or continued profiling/forming of the sheet may urge the trapezium-like profile into the more defined triangle-duct form as described above, and, in more detail, below.

It will be understood that the exact nature of the guides/rollers that undertake the profiling and/or forming may depend on a number of different factors, ranging from the material that constitutes the sheet, to the required degree of accuracy of the resultant profile formulation. For instance, after the rectangle-wave profile is formed, a simple guide that bounds the sheet at its width, and which tapers in the downstream direction may be sufficient to urge the rectangle wave profile toward the triangle-section duct formation. One or more plates located above and/or below the sheet, thus preventing the sheet from buckling, may assist in this formation. However, this simple guide may result in non-uniform urging of the profiled sheet, and/or non-uniform formation of duct sections, for example with some sections collapsing or being of different spacing or the like. To limit or avoid these problems, more protrusions or recesses may be provided by the guides/rollers to assist in the more uniform formation of the profile and, ultimately, triangle-section ducts. A greater number of protrusions and/or recesses may lead to a correspondingly greater number of wavelengths of the sheet being adequately supported/urged toward a desired form. This leads to more reliable and consistent formation of the triangle-section ducts, and a reduction in snagging or unintentional folding or the like of the sheet within the profiler and former assembly.

As perhaps shown best in Figures 3 and 4, the result of the profiling and forming of the sheet 102 is that the width of the sheet 102 (i.e. in the second direction) decreases as the profiling and forming takes place. This is because the sheet 102 bunches up in this second direction. However, since the bunching or accordion effect is not in the movement direction, the movement speed of the sheet through the apparatus is generally unaffected. As a result, all the problems that would otherwise be associated with different movement speeds are avoided. The invention therefore significantly improves upon the apparatus and method shown in Figure 1 , or, for that matter, improves upon any profiling/forming method in which the profiling/forming is in the movement direction.

Referring back to Figure 2, it can be seen that in this embodiment the sheet 102 takes a curved or angled path through the profile and former assembly. The purpose of the curved or profile path is to reduce tension in the sheet 102, which might make it easier to profile and form the sheet 102. The sheet 102, now having the triangle-section duct formations, may leave the profiler and former assembly 104 via rollers 1 18. The rollers may drive movement of the sheet 102, and/or be used to assist in maintaining the first continuous surface formed by the bases of the triangle-section duct as the sheet 102 is passed to treatment arrangements 120.

Each of the treatment arrangements 120 are arranged to treat the sheet 102 to maintain continuity of the first (and optionally second) substantially continuous surface formed at the (oppositely oriented) bases of the triangle-section ducts formed by the first sheet. Each treatment arrangement 120 may perform any function that may be used to maintain continuity (e.g. over time) of the or each continuous surface formed by the bases of the triangle-section ducts.

Figures 2 and 3 depict a convenient and practical form of treatment arrangement 120 in the form of cover arrangements 122. Each cover arrangement 122 is configured to receive additional sheet 124 from additional sheet feeders, and to at least partially cover the substantially continuous surfaces of the first sheet (formed by the triangle-section duct bases) with that additional sheet. The additional sheets are then attached to those continuous surfaces to maintain the continuity of the triangle-duct structure. The sheet feeding and covering may be undertaken continuously, as the sheet 102 passes the cover arrangements 122. The cover arrangement 122 might conveniently take the form of a roller than can apply the cover/capping sheet 124 to the profiled sheet 102. The cover arrangement may attached the cover/capping sheet 124 to the profiled sheet 102 by way of adhesive, which may already be present on the cover/capping sheet 124. The cover arrangement 124 may be heated, to activate the adhesive. The cover arrangement might provide adhesive on one or both of the cover/capping sheet 124 and/or the profiled sheet 102. The capping/covering might be considered as a form of lamination.

In one example, a sheet that is applied to the continuous surface may match the dimensions of the continuous surface, so that the continuous surface is entirely covered. This may maintain continuity of the continuous surface formed by the triangle-section duct in the most robust manner. However, in another example, the cover arrangements may only at least partially cover that continuous surface with additional sheet material. For example the covering or capping sheet or sheets may be in the form of sheet strips that extend across the sheet 102 in the direction of the profile (i.e. in the second direction). The strips may be located at intermittent points, to maintain the general triangle-duct section formation along the length of the sheet. In another example, the treatment arrangements may provide, by spraying or spreading, a layer of adhesive or other coating onto the continuous surface of the sheet, which bonds the triangle-section ducts together in some way. For example, the layer itself may achieve this, or the adhesive may seep in-between abutting parts of the sheet to bond together the triangle- section ducts. In a perhaps more complex embodiment, the treatment arrangement may be located within the profiler and former assembly, or even upstream of the assembly, and provide adhesive or other material to parts of the sheet that will ultimately abut against one another in the formation of the triangle-section ducts, to achieve the required continuity.

Figure 5 shows a structure ultimately formed by the apparatus of Figures 2-4. The final triangle-section duct formation 130 is shown, together with capping or cover sheets 132 on oppositely oriented continuous surfaces that are formed by the triangle-section duct formation 130. The structure might be viewed as a composite structure, since it contains multiple parts.

The structure is formed in a continuous manner, in this embodiment, which allows for more efficient construction and higher throughout in comparison with batch formation of the structures. Should sections of the continuously provided structure be required, one or more cutting, slicing or otherwise dividing arrangements may be located downstream of the treatment arrangements 120 to in some way section the continuously formed structure into discrete sections. Together with the up-scaling in width that is facilitated by the multiple sheet feeders, a structure can be easily formed with any required length and width.

In some examples, it may not be necessary to join different sheets (sometimes referred to as sub-sheets) together to increase the width of the overall shape/structure that is formed. However, if joining is required, Figure 6 shows how this might be achieved. Figure 6 shows how initially profiled sub-sheets 102 may be joined at overlapping edges 140, for example using adhesive or the like may be suitably applied using the aforementioned sheet joiner.

The joining of the sheets 102 may be undertaken at any appropriate location within the apparatus, for example before, during or after any profiling and/or forming. It may be very difficult to join the sheets once the sheet has been formed into the triangle-section duct formation. The last convenient point in the structure formation process for joining adjacent sheets may thus be as shown in Figure 6, where the substantially rectangle-wave profile has been formed, and before any urging towards the triangle-section duct form has taken place. The sheets may be arranged to overlap by appropriate delivery and alignment of the sheets 102 after supply from sheet feeders, and/or the sheet feeders (and/or the sheet that they supply) may themselves overlap (e.g. in the second direction) to provide the required overlap at the sheet joiner. In an alternative arrangement, a structure formed from one sheet feeder/structure formation apparatus may, after being formed, be abutted against another structure (e.g. formed from the same or a different sheet feeder/structure formation apparatus). With suitable adhesive or other bonding agent, the structures may be attached to one another at the abutment point, which might conveniently be along/using walls of the triangle section ducts of each respective structure. A capping or cover layer may be applied before or after the abutment and joining.

In one example, the structure has been described as comprising triangle-section ducts, capped on opposite surfaces by one or more cover or capping layers. In another example, only one cover or capping layer may be required in order to maintain the continuous surface of triangle-section ducts on one side of the formation. This may allow the other side of the formation to be non-continuous, for example allowing the structure as a whole to be bent or curved. In another example, the structure may simply be the triangle-section duct formation itself, which may be used in isolation, or covered or capped at some later point in. For instance, the capping or covering described above may not be undertaken by the same integrated apparatus. The triangle-section duct may have a number of different uses in a number of different applications, which applications might be dictated by the nature of the capping or covering layers that are provided, if applicable. For instance, in one example the covering or capping layer may simply be a sheet of paper or card or the like which simply maintains the structure and continuity of the triangle-section ducts. In another example, the cover or capping layer may be initially in fluid form or the like, such as an adhesive or other bond. The covering or capping may be done in the same location as the formation of the triangle-section ducts, or may be undertaken at a building site, or construction project, or the like. That is, the triangle-section formation may be a structure in its own right, for example a reinforcing structure, and it may not be necessary to cover or cap the structure in order for it still to find useful application.

In order to form the required and final triangle-section duct structure, the sheet must at least temporarily (which includes transiently) be provided with a rectangle-wave profile, in accordance with the examples embodiments provided so far. The rectangle-wave profile, and the subsequent urging into the triangle-section duct form is a relatively simple, easy and effective way of realising the triangle-duct section formation, both in terms of methodology and apparatus requirements. This is thus a preferred example. However, in other, more complex embodiments, the rectangle wave profile may not be used. For example, any substantially quadrilateral-like shape profile may, with suitable manipulation, be urged toward and into a substantially triangle wave profile, to form the substantially triangle-section ducts. Again, the sheet may only temporarily (which includes transiently) be provided with a quadrilateral -wave profile. For instance, the quadrilateral-wave profile could be a rectangle-wave profile, as described above, where simple bunching of the rectangle-wave leads to the desired substantially triangle wave profile, to form the substantially triangle-section ducts. However, with suitable urging, a trapezium-wave profile, or a rhombus-wave profile, could be urged into the triangle-section ducts, without the need for a rectangle-wave profile at any point. Any quadrilateral-wave could be manipulated, for example by urging different places/parts at different times, into the triangle-wave profile used to form the triangle-section ducts. All that is required is for the profile to have three walls that can be urged toward the triangular like profile. For example, a rectangle profile may comprise two parallel, vertical walls, and one joining horizontal wall. A trapezium profile may comprise two walls that extend upward and in toward one another (or out away from one another), and a joining horizontal wall. A rhombus profile may comprise two parallel walls that are both angled away from a vertical, and one joining horizontal wall. And so on. All of such shapes can be urged so that, at the same time or in sequence, the more upwardly extending walls are tilted toward one another in some way, to begin to form the more triangle-wave profile.

In the above embodiments, the triangle-wave profile, and the triangle-section ducts, are complete triangles. This is understood to give enhanced structural strength, particularly with equilateral triangles. However, the same or similar strength may be achieved if and when the profile is a substantially triangle-wave profile, and the ducts are substantially triangle-section ducts - that is, with a small gap, or no gap, between the walls that are urged toward one another. If the walls are urged in toward one another from the vertical, and even if they do not touch, strength and stability will be increased in comparison with a configuration where the walls are not angled toward one another (e.g. a rectangle). When such small gaps are present, the substantially continuous surface formed by bases of the ducts will also have small gaps. Of course, a complete triangle and/or a completely continuous surface may be preferred for strength and/or stability purposes, but the presence of small gaps may still result in a useful structure, especially if one or more cover/capping layer will be used as already described above. The apparatus as described is continuous in that a continuous source of one or more sheet materials is used to form the structure, and in a continuous manner. The continuous supply or source of sheet material may be maintained by the use of one or more splicing arrangements, which would be configured to splice sheet from a current sheet feeder (e.g. a current reel) with sheet from a new sheet feeder (e.g. a new reel), to maintain the continuous supply of sheet material.

'Continuous' in terms of sheet feeding, structure formation, and the like, is of course a functional definition. The continuous feeding of material thus includes discrete sheets fed into a profiler in a continuous manner, for example repeatedly feeding sheets to the profiler. Sheets may be attached to one another, for example in the form of a stack of joined sheets. The join(s) and/or continual nature of the sheet(s) might comprise perforations, scoring or folding to assist in close packing of the sheet(s) and or subsequent division/separation. A reel may be a most convenient and/or efficient approach to the continuous provision of material.

The sheet material that is used may take any particular form. The sheet material used to form the profiled structure may be different from the material used to form the covering or capping layers. However, the material might be the same, which might make manufacturing and/or ultimate disposal of the structure simpler to implement. Typically, and understandably, the sheet material used to form the structure will be flexible or robust enough to withstand and support manipulation that is required to form the structure. Typically, the sheet material might comprise or be formed from a paper-product. For instance, the material might comprise sheets of paper, or card, or similar. Such material might be easily sourced, and easily recycled. In another example, the material might be polymer based, or be metallic in form, or anything that can be sheet fed and manipulated as described above. Heat may be used to assist in at least the profiling and/or forming, for example by heating the sheet and/or the profiler and/or former apparatus. The sheet material may be in single, non-corrugated/profiled form, which allows for the profiling/forming described above to be undertaken with greater ease, and/or more precision. Alternatively, the sheet material may already be corrugated/profiled, which could add to the strength of the resulting structure. Indeed, the sheet that is used for profiling and forming may be a sheet structure formed in accordance with the invention (e.g. as shown in Figure 6).

Although a few preferred embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1 . A structure formation apparatus, comprising:

a profiler and former assembly, arranged to receive a first sheet from a first sheet feeder, and to profile and form the first sheet to form the structure, the profiling and forming comprising:

profiling the first sheet with a substantially quadrilateral wave profile;

forming the profiled first sheet by manipulating the profiled first sheet to convert the substantially quadrilateral wave profile to a substantially triangle wave profile that forms a plurality of oppositely oriented substantially triangle-section ducts, the bases of which substantially triangle-section ducts together form a first substantially continuous surface with the first sheet;

wherein the profiler and former assembly is arranged to profile and form the first sheet as the first sheet moves through the assembly in a first direction, the sheet also extending in a second direction that is substantially perpendicular to the first direction, and wherein the profile is arranged to extend in the second direction, substantially transverse to the first direction in which the sheet moves.

2. The structure formation apparatus of claim 1 , wherein the profiler and former assembly comprises one or more guides and/or rollers for performing the profiling and/or forming; and wherein a spacing between one or more guides or parts thereof, and/or a spacing between protrusions or recesses of the one or more rollers, decreases from an upstream end of the profiler and former assembly to a downstream end of the profiler and former assembly.

3. The structure formation of the claim 1 or claim 2, further comprising a sheet modifier located upstream of the profiler and former assembly, and arranged to modify the first sheet to introduce fold lines in the first sheet that extend in the first direction, the fold lines being arranged to facilitate subsequent profiling and/or forming.

4. The structure formation of the claim 3, wherein the sheet modifier is arranged to introduce fold lines in the form of one or more of: perforation lines, score lines, and/or crease lines.

5. The structure formation apparatus of any preceding claim, further comprising a sub- sheet joiner, arranged to receive a first sub-sheet travelling in the first direction, and a second sub-sheet travelling in the first direction, an edge of the second sub-sheet being arranged to partially overlap an edge of the first-sub sheet in the first direction, the sub-sheet joiner being further arranged to join the first and second sub-sheets together along the overlap, thereby forming the first sheet.

6. The structure formation apparatus of claim 5, wherein the sub-sheet joiner is located: upstream of the profiler and former assembly; or

within the profiler and former assembly; or

within the profiler and former assembly, after the profiling takes place and before the forming takes place.

7. The structure formation apparatus of any preceding claim, wherein the structure formation apparatus further comprises a first treatment arrangement, arranged to treat the first sheet to maintain continuity of the first substantially continuous surface formed with the bases of the substantially triangle-section ducts.

8. The structure formation apparatus of claim 7, wherein the first treatment arrangement comprises a first cover arrangement, arranged to receive a second sheet from a second sheet feeder, and further arranged to at least partially cover the first substantially continuous surface of the first sheet with the second sheet, and to attach the second sheet to the first substantially continuous surface of the first sheet.

9. The structure formation apparatus of any preceding claim, wherein the manipulation is arranged to result in opposing bases of the substantially triangle-section ducts together forming a second substantially continuous surface with the first sheet, substantially on an opposite side of the substantially triangle-section ducts to the first substantially continuous surface.

10. The structure formation apparatus of claim 9, wherein the structure formation apparatus further comprises a second treatment arrangement, arranged to treat the first sheet to maintain continuity of the second substantially continuous surface formed with the bases of the substantially triangle-section ducts.

1 1 . The structure formation apparatus of claim 10, wherein the second treatment arrangement comprises a second cover arrangement, arranged to receive a third sheet from a third sheet feeder, and further arranged to at least partially cover the second substantially continuous surface of the first sheet with the third sheet, and to attach the third sheet to the second substantially continuous surface of the first sheet.

12. The structure formation apparatus of any preceding claim, wherein the substantially quadrilateral wave profile is a square wave profile, such that the substantially triangle-section ducts, once formed, are equilateral triangle-section ducts.

13. The structure formation apparatus of any preceding claim, wherein the apparatus is arranged to form the structure in a continuous manner.

14. A method of forming a structure, comprising:

profiling and forming a first sheet to form the structure, the profiling and forming comprising:

profiling the first sheet with a substantially quadrilateral wave profile;

wherein the profiling and forming is undertaken as the first sheet moves in a first direction, the sheet also extending in a second direction that is substantially perpendicular to the first direction, and wherein the profile is arranged to extend in the second direction, substantially transverse to the first direction in which the sheet moves.

15. A structure formed using the apparatus or method of any preceding claim.

16. A structure formation apparatus, and/or a method of forming a structure, and/or a structure formed using that apparatus or method, substantially as described herein according to the present invention, or substantially as described herein with reference to the accompanying Figures and as according to the present invention, or substantially as shown in the accompanying Figures according to the present invention.