Patent Application
20240392575
The invention relates to a building profile comprising
The invention also relates to
Building profiles of the type mentioned above are used, for example, in the form of angle profiles in drywall construction as protective profiles to protect wall edges and corners or as quick plastering profiles for plastering or tiling work. The building profiles are applied to the corresponding edges or corners of masonry or, in the case of quick plaster profiles, over the entire surface of the masonry and plastered in. The profile legs must be relatively thin, especially in the case of protective profiles, as the plaster layers themselves can often only be applied up to a maximum thickness of 3 mm and the building profiles should be completely covered by the plaster. The material apertures in the building profile ensure better anchoring of the building profile in the building plaster. In another application, the building profiles are, for example, support rails or upright profiles for panel-shaped elements that are used when installing ceiling or wall cladding made from such elements.
These types of building profiles are mass-produced, which is why the material costs account for a considerable proportion of the manufacturing costs of the building profiles. The material apertures therefore also ensure that the amount of material is reduced compared to full-surface profile legs.
In building profiles of the type mentioned above that are known on the market, the material apertures are created by working out material in such a way that lumpy pieces of material, material chips or other material particles are produced as material waste.
This material waste can be collected and, after appropriate processing, reused as raw material or as an addition to raw material for building profiles. However, processing the material waste increases the production costs of the building profiles again, as separate process routes with the corresponding processing technology must be provided for this, which in turn require resources and energy for processing.
It is an object of the present invention to provide building profiles of the type mentioned at the outset, which take these ideas into account and can be produced in a more resource-saving manner and with a more favorable energy balance than known building profiles. In addition, the method, the installations, the apparatus and the use, which are mentioned at the outset, are to be provided for this resource-saving and energy-efficient production of the building profiles.
This object is achieved in a building profile of the type mentioned at the outset by
Ideally, through cuts can be produced without material loss and without material waste. The desired material apertures can then be produced from such through cuts using a stretching process; stretching expands the through cuts into the desired material apertures. If material waste is avoided, additional separate process routes are not required for its preparation; accordingly, the resources and energy required for this are saved. This also improves the CO2 balance of the production of the building profile.
Preferably, through windows and/or edge gaps are provided as material apertures. These can advantageously both be created from through cuts.
For the applications mentioned at the outset, it is particularly advantageous if the building profile is an angle profile, in particular with a profile angle α of 90°, or a quick plaster profile, in which one or both profile legs are bent at their free longitudinal edges to form profile wings, or a support rail or a stand profile for holding panel-shaped elements.
In the method of the type mentioned at the outset, the above object is achieved by a method comprising the following steps:
These steps (A) to (D) allow the production of building profiles in a continuous manufacturing process from a raw strip, which can be stored in large quantities, for example on a storage roll. Accordingly, the process can be carried out with a high throughput and, as explained above, in a resource- and energy-efficient manner.
In particular, the through cuts in the precursor strip have an extension of between 0.01 mm and 0.4 mm in its longitudinal direction, preferably between 0.02 mm and 0.3 mm and further preferably between 0.05 mm and 0.2 mm.
Through cuts can be produced with little or very little material waste, for example by punching with correspondingly small-dimensioned punches—in this case, at least less material waste needs to be processed than is required with known techniques for producing material apertures in building profiles. This alone can reduce the amount of resources and energy required.
However, it is particularly advantageous if the cutting process in step (B) is a material-loss-free cutting process, as mentioned above.
For this purpose, the through cuts in step (B) are preferably produced by rotary cutting or laser cutting, wherein rotary cutting is once again preferred.
In the stretching process in step (C), there are the alternative options, each of which is advantageous in itself, of widening the through cuts in the longitudinal direction,
With regard to step (Cb), it can also be advantageous if steps (B) and (Cb) are carried out as a combined cutting and stretching process with blade/displacement elements in a common rotary work step.
The work processes in step (D) open up two manufacturing concepts with two alternative manufacturing routes and preferably include:
In addition, the method advantageously enables one, several or all of the work processes in step (D) to be carried out at the same location or at a different location to steps (A), (B) and (C). The process thus allows individual adaptation to local conditions. A different location can be a different operating site or just a locally different location at one and the same operating site.
In the first installation mentioned at the outset, the above object is achieved by
This installation makes it possible to form the material apertures in the building profile to be manufactured by producing a strip-shaped building profile precursor, namely the profile strip, with the desired material apertures already made, taking into account the resource-saving and energy-efficient process control.
Preferably, the cutting device is configured in such a way that through cuts are produced in the precursor strip which have an extension in the longitudinal direction of between 0.01 mm and 0.4 mm, preferably between 0.02 mm and 0.3 mm and further preferably between 0.05 mm and 0.2 mm.
With the advantages described above, it is advantageous if the cutting device is a rotary cutting device or a laser cutting device.
Advantageous in each case are the alternatives that the stretching device
With regard to the displacer device, it can be advantageous that the device for rotary cutting and the displacer device are combined in a rotary cutting-stretching device, in which the through cuts can be produced by means of combined blade/displacer elements in a rotary working step and can be widened in the longitudinal direction.
In the second installation mentioned at the outset, the above object is achieved by
This installation allows the resource-saving and energy-efficient production of the building profile to be completed in a continuous and effective process.
Accordingly, the above-mentioned object is achieved in the apparatus mentioned at the out-set by comprising the installation explained as the first with some or all of the features explained in relation thereto and the installation explained as the second. The apparatus then has all the essential features for producing the building profiles in an effective manner and with the greatest possible use of resources and energy at one and the same operating site.
According to the invention, with regard to the above-mentioned use of an installation, it was recognized that resources and energy can be saved in the production of building profiles by using an installation comprising
Such installations have so far only been used on the market to produce metal strips that serve as inserts for sealing strips, acting as a kind of carrier for a sealing material and in which the sealing strips are encased in the sealing material.
Embodiments of the invention are explained in more detail below with reference to the drawings. In these:
The profile legs 18, 20 have a thickness of less than 1 mm, in particular between 0.8 mm and 0.2 mm. In practice, the profile legs 18, 20 have a thickness of approximately 0.4 mm.
The building profile 10 shown in
In practice, the building profile 10 is made of aluminum or steel, in particular stainless steel or galvanized steel. If necessary, the building profile 10 can also be provided with a coating, for example made of plastic.
In the present embodiment, the connecting section 22 provides a space 24 extending in the longitudinal direction 14, into which the wall edge or corner to be protected can dip, as it were. For this purpose, the connecting section 22 follows a circular arc in cross-section, so that a circular cylindrical arc 26 is formed, which protrudes outwards in cross-section over the profile legs 18, 20; this can be clearly seen in
At least one, in the present embodiments each profile leg 18, 20 of the building profile 10, has a plurality of material apertures 28. These material apertures 28 are arranged periodically in the longitudinal direction 14, with all distances in the longitudinal direction 14 between two adjacent material apertures 28 in the longitudinal direction 14 being the same in all embodiments shown here. In variations not specifically shown, however, these distances can also be different, although groups of material apertures are or can again be arranged periodically in the longitudinal direction 14; this can result from the manufacturing process, which will be discussed further below.
The material apertures 28 can be in the form of through windows 30 or in the form of edge gaps 32. A through window 30 is to be understood as a passage through the profile leg 18, 20, which is surrounded by material over its entire circumference. In the present embodiments, the through windows 30 are slot-shaped and extend in the transverse direction 16 between an outer end 30a and an inner end 30b with respect to the connecting portion 22.
An edge gap 32, on the other hand, is open towards the side of the profile leg 18, 20 remote from the connecting section 20 and describes an outer, open end 32a and an opposite inner, closed end 32b.
In the building profile 10 in
A building profile 10 is obtained from a building profile precursor in the form of a flat profile strip 38, which
For this purpose, work processes are carried out to obtain several building profiles 10 from the building profile precursor in the form of the profile strip 38.
In a first manufacturing process 42, illustrated in
Typical lengths L of a building profile 10 are 0.5 m, 1.0 m, 1.5 m, 2.0 m, etc. and are specified according to requirements. Longer lengths of up to 10 m and more are also possible. However, relatively short building profiles 10 with lengths L of a few centimeters can of course also be produced in order to protect only short wall edge and corner areas. In this case too, however, the profile legs 18 and 20 should be understood to be strip-shaped, as introduced above.
In a second work process of the first manufacturing path 42, these flat profile segments 46 are each formed into the building profile 10 shown in
In an alternative second manufacturing method 50, also illustrated in
This profile strand 54 is then cut to building profiles 10 of length L in a second work process of the second production path 50 with the aid of a strand cutting device 56.
The strand forming device 52 and the strand cutting device 56 are also only schematically indicated; suitable devices are again known as such.
As
In the following, the reference signs assigned to a device also always designate the associated process that is carried out with the device.
The installation 60 comprises a cutting device 62 with which a cutting process 62 is carried out and which, in the present embodiment, is designed as a device 64 for rotary cutting. For this purpose, the device 64 for rotary cutting comprises a cutting roller 66, which carries a plurality of radially projecting cutting blades 70 on its outer surface 68.
The cutting roller 66 works together with a counter roller 72, which is designed to complement the cutting roller 66 and with which it forms a pair of rollers 74. For this purpose, the counter roller 72 can, for example, have at least one outer surface made of a flexible, preferably elastic, material, for example rubber, into which the cutting blades 70 can press. Alternatively, the counter roller 72 can also have apertures complementary to the cutting blades 70, into which the cutting blades 70 can plunge during rotation.
A raw strip 76 is provided, which is unrolled from a supply roller 78 in a conveying direction 80, which corresponds to the longitudinal direction 14 of the building profile 10 to be produced.
For the sake of clarity, the fastening and bearing devices for the rollers 66 and 72 or the supply roller 78 as well as the necessary guides and drives are not shown.
In general terms, a cutting process 62 is carried out by means of the cutting device 62, in which the raw strip 76 is provided with through cuts 58. As a result of this cutting process 62, a precursor strip 82 is produced as an intermediate product, which has the through cuts 58.
In the present embodiment, the raw strip 76 is guided between the cutting roller 66 and the counter roller 72 for this purpose. As it passes through the pair of rollers 74, the raw strip 76 is provided with the through cuts 58.
In practice, the through cuts 58 have a width, i.e. in the conveying direction 80 or in the longitudinal direction 14 an extension between 0.01 mm and 0.4 mm, preferably between 0.02 mm and 0.3 mm and further preferably between 0.05 mm and 0.2 mm. The material thickness of the raw belt 76 on the one hand and the geometry of the cutting blades 70 and their distance from one another in the circumferential direction on the other hand have a particular influence on this width of the through cuts 58.
If the building profile 10 to be produced is to have edge gaps 32, corresponding cutting blades 70 are arranged on the cutting roller 66 in such a way that they produce open through cuts 58 on the outside of the precursor belt 82 in the transverse direction 16.
During rotary cutting in the device 64, the through cuts 82 are produced from the raw strip 76 without any loss of material, i.e. no material waste is produced. This is a material loss-free cutting process.
The cutting process therefore differs from other technical processes that may also be suitable here, such as punching, in which pieces of material are cut out as material waste, or machining processes such as drilling or milling, in which material chips are produced as material waste.
As an alternative for a suitable cutting process without material loss, for example, laser cutting can be considered and the cutting device 62 is a laser cutting device. Even if, strictly speaking, a loss of material occurs there, since the material is thermally removed along the cutting line, this loss of material is negligible, provided that only linear through cuts 58 are produced, as is the case here, and thus no material parts remaining in pieces are cut out and also no material chips or other material particles are produced. Therefore, laser cutting is also understood as a cutting process without material loss when generating through cuts 58.
In connection with the device 64 for rotary cutting, the geometries, arrangements and dimensions of the material apertures 28 of the building profile 10 or of the preceding profile strip 38 depend on the geometries, arrangements and dimensions of the cutting blades 70 on the cutting roller 66. The geometries explained above for the through windows 30 and edge gaps 32 are therefore to be understood as purely exemplary. The cutting roller 66 is shown here only as an example with identical cutting blades 70 in a regular sequence and arrangement in order to explain the formation of the specific embodiment of the building profile 10 shown in
Now the precursor strip 82 is subjected to a stretching process in which the through cuts 58 are widened in the longitudinal direction 14 to form the material apertures 28, so that the profiled strip 38 comprising the material apertures 28 is obtained as the building profile precursor.
For this purpose, the installation 60 comprises a stretching device 84, in which the through cuts 58 of the precursor strip 82 are widened until the material apertures 28, here the through windows 30 and otherwise possibly also edge gaps 32, are formed as they are then to be present in the finished building profile 10.
As explained at the beginning, the stretching process 84 can be carried out in various ways.
Otherwise, the technique of roll stretching is known as such, which is why no further explanation is necessary.
As a result of this roll stretching process 84.1 in the roll stretching device 84.1, the profiled strip 38 is then present, from which building profiles 10 are then obtained using the working processes described above with reference to
Alternatively, the stretching device 84 can be a displacer device 84.2 and the precursor strip 82 can be subjected to a displacement process 84.2 in which a displacer structure is pressed into a respective through cut 58. Such a displacer structure can be, for example, a conical cross-section indenting punch which has an immersion end complementary to the through cut 58 to be expanded and widens in the opposite direction to the direction of indentation. When such indenting punches then plunge into the through cuts 58 and are pressed in further, the indenting punches widen the through cuts 58 until the material apertures 28 and thus the profiled strip 38 are formed.
The displacer device 84.2 can, for example, operate rotationally and for this purpose have a displacer roller, on the outer surface of which the displacer structures are present and which cooperates with a correspondingly complementary counter roller, as described analogously above for the device for rotational cutting 64. In this case, the displacer roller and the precursor belt 82 must be synchronized so that the displacer structures meet the through cuts 58.
The device for rotary cutting 64 and the displacer device 84.2 can also be combined in a rotary cutting-stretching device 88, in which the through cuts 58 can be produced by means of combined blade/displacer elements 90 in a rotary working step and can be widened in the longitudinal direction 14. In
In
In this cutting-stretching process 88, the cutting process 62 for a through cut 58 is completed when the blade/displacer element 90 has penetrated the raw strip 76. From this moment, the displacement process 84.2 begins; the through cuts 58 are widened by the displacer structure 92, which is then pressed in further.
The profiled strip 38 is then present as the result of this cutting-stretching process 88 in the cutting-stretching device 88. The separate stretching device 84 shown in
As a further alternative, the stretching device 84 can be a lengthening device 84.3, in which the precursor strip 82 can be subjected to a lengthening process in which the precursor strip 82 is subjected to tensile stress in the longitudinal direction 14. As a result of the elongation thus achieved, the through cuts 58 widen in the longitudinal direction towards the material apertures 28 until the corresponding profiled strip 38 is present.
Again alternatively, the stretch device 84 may be a stretch-straightening device 84.4 in which the precursor strip 82 is subjected to a stretch-straightening process 84.4. In a stretch-straightening process, the precursor strip 82 is clamped in a defined area and then subjected to tensile stresses beyond the yield point.
As yet another alternative, the stretching device 84 can be a roll straightening device 84.5, in which the precursor strip 82 can be subjected to a roll-straightening process 84.5. In a roll straightening-process, the precursor strip 82 is subjected to increasingly smaller alternating bends and is guided through a corresponding roller arrangement for this purpose.
When using the stretch-straightening process 84.4 or the roll-straightening process 84.5, it is avoided in particular that a profiled strip 38 curved in the longitudinal direction 14 is produced. These work processes can be carried out at the location of the installation 60. In particular, the devices 44 and 48 or 52 and 56 required for this purpose can be combined with the installation 60 to form an overall device for producing a building profile from a raw strip 76, so that the entire production of building profiles 10 can be carried out as a continuous manufacturing process at one and the same operating location.
Alternatively, the profiled strip 38 can also initially be stored temporarily, for example as a roll of profiled strip, and transported to another location. The necessary devices are then installed at this other location, with which the building profiles 10 can then be manufactured from the profiled strip 38 in the manner explained above. On the one hand, another location can be another operating site, but on the other hand it can also be merely a locally different location, for example another production hall, at one and the same operating site.
In the stretching processes, the precursor strip 82 is enlarged in the longitudinal direction 14 and possibly also in the transverse direction 16, while at the same time the material thickness is at least partially reduced. The dimensions of the raw strip 76 in the transverse direction 16 are therefore adjusted so that the profiled strip 38 obtained after the roll stretching process has such dimensions in the transverse direction 16 that the building profile 10 with the desired dimensions of the profile legs 18, 20 can be obtained therefrom, taking acceptable tolerances into account.
The profiled belt 38 is produced in a continuous process in which the raw belt 76, the precursor belt 82 with the through cuts 58 and the profiled belt 38 are continuously conveyed in the conveying direction 80.
The building profile 10 produced in this way shows the manufacturing process with a cutting process 62, in particular with a cutting process without material loss, and a subsequent stretching process 84. The skilled person can recognize this by the nature of the material structure and in particular by the edge contours formed and by the ends 30a, 30b of the material apertures 28.
In the case of the quick plaster profile 94, the angle α between the profile legs 18, 20 is, by way of example, approximately 30°; in addition, the profile legs 18, 20 are each bent again at their free longitudinal edges in the transverse direction 16 to form curved profile wings 96 and 98 respectively, which define a support plane in which the quick plaster profile 88 is placed against a wall.
In the section between the connecting section 22 and the profiled wings 96, 98, the profiled legs 18, 20 each have through windows 30.4 extending in the transverse direction 16. For their part, the profile wings 96, 98 each have passage windows 30.5 also extending in the transverse direction 16. The passage windows 30.5 are somewhat shorter in the transverse direction 16 than the passage windows 30.4. The passage windows 30.4 and 30.5 correspond in their basic geometry to the passage windows 30.1 and 30.3 of the angle profile 12, which have a hexagonal contour; the above applies here too. Here too, the passage windows generally designated 30 can have a “bicorner” geometry, as described above for the passage windows 30.2; this is illustrated in
In a modification not shown here, the building profile can also be designed as a support rail or upright profile for panel-shaped elements, for example ceiling panels or wall panels. Such support rails or stand profiles are angled in cross-section in the manner required to accommodate the panel-shaped elements and form the desired ceiling or wall. In particular, U-shaped, C-shaped or T-shaped cross-sections are often used here. For such a support rail or such an upright profile with a T-shaped cross-section, the quick plastering profile 94 can be modified, for example, in such a way that the profile wings 96, 98 are not curved but flat, and the sections of the profile legs 18, 20 between the connecting section 22 and the profile wings 96, 98 run largely parallel to one another. This means that the profile angle α is very small in this case and is only a few degrees or can even be zero.
Building profiles that are to be used as protective profiles or quick plastering profiles can also be manufactured with cross-sections other than those specifically described here, depending on the intended use and location, and in particular also with a U-shaped, C-shaped or T-shaped cross-section.
Accordingly, the precursor strip 82 shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 125 645.3 | Oct 2021 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/077513 | 10/4/2022 | WO |
