The present invention relates to a thin-walled cold formed lightweight sectional element, in particular a dry construction section, a section for the face of a building, a plaster section, a base section, a screed section, a tile section or a cable carrier section or a frame rail or drainage rail, having an elongated section body which is in particular metal or comprises plastic and in which a plurality of openings are formed. The invention is furthermore directed to a method for manufacturing such a thin-walled cold formed sectional element.
Thin-walled cold formed sectional elements of this type are used, for example, as C-shaped upright sections for dry construction, wherein the openings provided in the section body of the sectional element can serve, for example, as leadthrough openings for cables, lines or other elongated band-shaped or rope-shaped elements as well as pipes or other hollow bodies. These openings can furthermore also serve for ventilation or to allow the passing through of filler materials such as insulating material.
In known thin-walled cold formed sectional elements, these openings are introduced by a punching procedure, for example. It is disadvantageous in this that the punched out material forms waste, whereby the manufacturing costs for such thin-walled cold formed sectional elements are increased.
It is an object of the present invention to provide a thin-walled cold formed sectional element of the initially named kind which can be manufactured in a simple and inexpensive manner and with reduced material effort. Furthermore, a method for manufacturing such a thin-walled cold formed sectional element will be provided.
Starting from a thin-walled cold formed sectional element of the initially named kind, the object relating to the sectional element is satisfied in that the section body includes at least two separately formed longitudinal portions, in that each longitudinal portion includes a meandering longitudinal edge, in that the longitudinal portions each include an elongated portion as well as a plurality of connection portions which project laterally beyond the elongated portion and which are bordered by the meandering longitudinal edge, in that the connection portions of the one longitudinal portion face the connection portions of the other longitudinal portion and are welded thereto end-to-end or are mutually connected along bent-over abutment edges, in that the openings are at least regionally bordered by portions of the meandering longitudinal edges, in that stiffening beads extending in the longitudinal direction of the longitudinal portions and stiffening beads extending transverse thereto are formed in the longitudinal portions, in that the transverse extending stiffening beads are in communication with the stiffening beads extending in the longitudinal direction, and in that the transverse extending stiffening beads extend into the connection portions.
The part of the object relating to the method is satisfied, starting from a method of the initially named kind, in that two separate longitudinal portions each having a meandering longitudinal edge are provided to produce the profile body, wherein the longitudinal portions each include a meandering longitudinal edge, wherein the longitudinal portions each include an elongated portion as well as a plurality of connection portions which project laterally beyond the elongated portion and which are bordered by the meandering longitudinal edge, in that the longitudinal portions are moved apart transverse to their longitudinal extent, in that the connection portions of the one longitudinal portion are welded end-to-end to the connection portions of the other longitudinal portion such that the openings are formed between portions of the meandering longitudinal edges, and in that stiffening beads extending in the longitudinal direction of the longitudinal portions and stiffening beads extending transverse thereto are formed in the longitudinal portions, wherein the transverse extending stiffening beads are in communication with the stiffening beads extending in the longitudinal direction, and the transverse extending stiffening beads extend into the connection portions.
In accordance with the invention, no waste is thus generated for the production of the openings of the section body so that material can be saved with respect to a production by punching out, for example. In other words, a wider design of the sectional element is achieved with the same quantity of material by the moving apart of two separately formed longitudinal portions. It is possible due to the connection portions respectively projecting laterally over the elongated portions of the two longitudinal portions to move apart the longitudinal portions transverse to their longitudinal portions so that a connection of the two longitudinal portions is possible despite this moving apart so that ultimately a larger width is achieved than the width of the original material portion. In this respect, the term “transverse” is to be understood as any direction which does not extend only in the longitudinal direction of the sectional element or its longitudinal portions. The term “transverse” can thus in particular mean perpendicular or also oblique to the longitudinal extent of the sectional element or of the longitudinal portions. The connection portions are furthermore welded to one another end to end or are connected to one another along bent-over abutment edges so that there are no larger overlapping regions, but rather substantially edge connections between the two longitudinal portions. An ideal material utilization is also thereby achieved. It is ensured in an ideal manner by the stiffening beads arranged and mutually connected in accordance with the invention that a stiffening takes place directly at the regions of the sectional element weakened by the openings so that the stiffness of the sectional element is of equal quality to known sectional elements or is even improved with respect to them. The torsional strength and the deflection strength of a sectional element made in accordance with the invention can in particular be increased by the stiffening beads.
The part of the object relating to the method is also satisfied in accordance with the invention, starting from a method of the initially named kind in that at least two separate longitudinal portions each having a meandering longitudinal edge are provided to produce the section body, wherein the longitudinal portions each include an elongated portion as well as a plurality of connection portions which project laterally beyond the elongated portion and which are bordered by the meandering longitudinal edge, in that the longitudinal portions are arranged so that they contact one another in a flat manner and respective connection edges of the connection portions of the one longitudinal portion extending in the longitudinal direction directly contact connection edges of the connection portions of the other longitudinal portion extending in the longitudinal direct, in that the connection portions of the one longitudinal portion are connected, in particular welded, to the connection portions of the other longitudinal portion, in that one of the two longitudinal portions is pivoted about the connection edges with respect to the other longitudinal section so that the connection portions are mutually connected along bent-over abutment edges and the openings are formed between portions of the meandering longitudinal edges, and in that stiffening beads extending in the longitudinal direction of the longitudinal portions as well as stiffening beads extending transverse thereto are formed in the longitudinal portions, wherein the transverse extending stiffening beads are in communication with the stiffening beads extending in the longitudinal direction, and the transverse extending stiffening beads extend into the connection portions.
In accordance with an advantageous embodiment of the invention, the connection portions of the two longitudinal portions each include connection edges or bent-over abutment edges which are adjacent to one another and extend substantially parallel to one another. The longitudinal portions can ultimately be connected to one another via these connection edges or bent-over abutment edges. The connection edges in this respect preferably extend substantially parallel, perpendicular or oblique, for example at a 45° angle, and the bent-over abutment edges parallel to the longitudinal extent.
In accordance with a further advantageous embodiment of the invention, the connection portions are T-shaped, web-shaped, trapezoidal shaped or triangular or include hexagonal regions. Preset properties of the sectional element, for example its stiffness, can be influenced by a corresponding design of the connection portions. Furthermore, dependent on the selected shape of the connection portions, a respective different kind of connection of the two longitudinal portions is made possible, as will be described in more detail in this application.
A respective connection portion of the one longitudinal portion is preferably disposed opposite a connection portion of the other longitudinal portion. Alternatively or additionally, connection portions can also be provided which are arranged alternatingly in the longitudinal direction of the sectional element. The arrangement of the connection portions in the final sectional element is in turn dependent on different connection kinds which will likewise be described in the further text.
The longitudinal portions advantageously have a thickness of approximately between 0.5 mm and 3 mm. The sectional elements in accordance with the invention are thus lightweight sections which can be used in different manners. For example, in addition to the initially named uses, applications are also conceivable in the automotive sector, in switch cabinet construction, in cover systems or even as vine supports or wine posts.
The weld connection between the connection portions is advantageously made as a discontinuous laser weld seam. A better strength in the center region of the sectional element, which is in particular weakened by the openings, is achieved by the design as a laser weld seam. The laser weld seam can be made with a reduced extent in the transverse direction with respect to a usual weld connection. Due to the reduced extent and the heat concentration which thereby arises in a very small space a very good hardness is achieved after the cooling in the zone of the sectional element melted during laser welding. Furthermore, the seam can be generated by the laser welding exactly at the center between the connection edges mutually connecting end-to-end so that the adjoining regions of the sectional element are not impaired by the welding process and furthermore a very smooth transition is achieved between the two longitudinal portions.
In accordance with a further advantageous embodiment, at least some of the stiffening beads extend beyond the weld seams between the connection portions. An additional reinforcement of the weld connections is thereby achieved.
A stiffening bead formed in a longitudinal portion and extending in a longitudinal direction is preferably connected to a stiffening bead formed in the other longitudinal portion and extending in the longitudinal direction via one or more of the transverse extending stiffening beads. The stiffening beads can thereby form a kind of ladder structure by which the openings are completely surrounded. The stiffness of the sectional element is thereby particularly increased in a strain-optimized manner in the regions weakened by the openings.
The stiffening beads extending in the longitudinal direction advantageously extend over the total length of the respective longitudinal portion. The improved stiffness can thereby be achieved uniformly over the whole length of the sectional element. It is generally also possible that the stiffening beads extending in the longitudinal direction are interrupted once or a multiple of times as long as the desired stiffness is maintained in so doing.
The material of the section body bordering the openings can in particular be deep drawn. An increased stiffness of the sectional element is thereby in turn achieved particularly in the weakened region of the openings. The edges of the section body bordering the openings can advantageously be bent over, in particular made as flanged edges.
It is also possible that, in another embodiment, the connection portions of the one longitudinal portion are connected to the connection portions of the other longitudinal portion via an intermediate element arranged between the longitudinal portions so that there is an indirect connection between the connection portions. The connection between the connection elements and the intermediate element can in this respect take place end-to-end or overlapping. The intermediate element can in this respect preferably be made as an elongated strip-shaped element. The intermediate element can in this respect in particular have a thickness which is of the same magnitude as the thickness of the longitudinal portions.
In accordance with a further advantageous embodiment of the invention, the intermediate element has longitudinal edges extending substantially parallel to the longitudinal extent of the longitudinal portions. A simple connection of the connection edges of the connection elements to the longitudinal edges of the intermediate element is thereby possible.
The connection portions are preferably connected to the intermediate element by a pressure joining process such as by clinching or crimping, by clamping, squeezing, pressing, welding, screwing, adhesive bonding, riveting or folding or by a plug-in connection. The weld connection can in particular also again advantageously be made here as a laser weld connection with the named advantages.
The intermediate element can also advantageously have a thickness of approximately 0.5 mm and 3 mm.
In accordance with a further advantageous embodiment of the invention, the intermediate element can be made of a different material than the longitudinal portions. The intermediate element can in particular be made of plastic, in particular of PVC, and the longitudinal portions of metal, in particular of aluminum. The weight of the total section can be further reduced by the use of plastic, on the one hand, and a good thermal insulation is possible, on the other hand. Furthermore, costs can be reduced by the use of plastic.
The separate longitudinal portions can already be originally manufactured from separate material portions. They can, for example, have the same or different material thicknesses and can also comprise the same or different materials.
The separate longitudinal portions can advantageously be manufactured from an originally uniform material portion. In this case, at least one meandering slit which extends in the longitudinal extent of the starting material and by which the starting material is divided into two separate longitudinal portions can be introduced into an elongated strip-shaped starting material. It is also possible that at least two strip-shaped material portions are placed onto one another in a flat manner and that, in a cutting process, a meandering slit passing through both material portions is introduced so that at least four longitudinal portions are produced in one cutting process. A respective two of these can, for example, be connected to form a profile body.
The longitudinal portions are advantageously moved apart substantially perpendicular to their longitudinal extent. A moving apart is, however, generally also conceivable oblique to the longitudinal extent of the longitudinal sections.
Whereas generally, in particular in dependence on the shape of the connection portions, the connecting of the longitudinal portions can take place directly after the moving apart of the longitudinal portions transverse to their longitudinal extent, in accordance with a further embodiment of the invention the longitudinal portions can be substantially mutually displaced in the longitudinal direction in addition to the moving apart of the longitudinal portions transverse to their longitudinal extent. This longitudinal displacement of the longitudinal portions can in this respect take place before, after or simultaneously with the moving apart of the longitudinal portions transverse to their longitudinal extent. Such a longitudinal displacement can be necessary, for example, to bring the connection edges of two oppositely disposed connection portions into contact in order thus to enable a connection of the connection portions of the two oppositely disposed longitudinal portions.
Generally, the connection portions of the one longitudinal portion can be directly connected to the connection portions of the other longitudinal portion, in particular end-to-end or overlapping. In accordance with a further embodiment, it is, however, also possible that the longitudinal portions are moved apart until a spacing arises between the longitudinal portions, that an in particular elongated strip-shaped intermediate element is positioned between the spaced apart longitudinal portions, and that the connection portions of the two longitudinal portions are connected to the intermediate element, in particular end-to-end or overlapping. Even larger widths of the sectional element can be achieved in this manner.
The invention will be described in more detail in the following with reference to embodiments and to the drawings; there are shown in these:
A plurality of openings 5 are formed in the section web 3 which can serve, for example, as passage openings for cables or other elements to be laid. The openings 5 of the sectional element 1 are manufactured without material loss in accordance with the invention, as will be explained in more detail in the following with reference to
A meandering slit 9 which extends in the longitudinal extent of the material strip 6 and by which the material strip 6 and thus the section body 2 is divided into two separate longitudinal portions 10, 11 is formed in the material strip 6. The longitudinal portions 10, 11 are each given meandering longitudinal edges 12, 13 by the meandering slit 9 which contact one another seamlessly in the representation in accordance with
Web-shaped connection portions 14, 15 of the longitudinal portions 10, 11 are respectively formed by the meandering longitudinal edges 12, 13 and are each connected in one piece to elongated portions 16, 17 of the longitudinal portions 10, 11 and project laterally beyond them. As can furthermore be recognized from
To produce the final shape of the section web 3, the two longitudinal portions 10, 11 are moved apart in accordance with two arrows 18, 19 transverse to the longitudinal extent of the material strip 6 until they adopt the position shown in
In accordance with
Subsequently, the longitudinal portions 10, 11 are welded to one another, for example laser welded, along the mutually contacting connection edges 20, 21, whereby the final shape of the section web 3 with the openings 5 is achieved.
For better clarity, the same reference numerals as in
The embodiment in accordance with
To produce the final shape of the section web 3, in this embodiment, the two longitudinal portions 10, 11 are in turn pulled apart in accordance with arrows 18, 19 transverse to their longitudinal extent, as is shown in
It is, however, also possible that, in a further method step, the longitudinal portions 10, 11 are additionally displaced in the longitudinal direction in accordance with arrows 25, 26 until they reach the positions shown in
In a further embodiment, the longitudinal portions 10, 11 from
In a similar manner as already described with respect to
The connection edges 20, 21 of the connection portions 14, 15 are subsequently connected, for example welded, to the longitudinal edges 28, 29 of the intermediate element 27 so that the final shape of the sectional element 3 and the openings 5 are formed.
Whereas in
A corresponding areal fold connection between the web 27 and the connection portion 14 is shown broken away in a detailed view by way of example in
Stiffening beads 30 such as are only shown in
The intermediate element 27 can be made without interruption or with openings, not shown. These openings can be achieved, for example, by punched portions. The intermediate element 27 can advantageously also be provided with openings and widened by a corresponding stretching process. Furthermore, stiffening elements, for example in the form of embossed portions or stiffening beads, can likewise be formed in the intermediate element 27.
The embodiment in accordance with
In the embodiment in accordance with
The connection edges 20, 21 contact one another end-to-end and are, analog to the embodiment in accordance with
In the embodiment in accordance with
The embodiment shown in
It is schematically shown in
In
For this purpose, after producing the meandering slit 9, the longitudinal portions 10, 10′ lying over one another are separated from the respective other longitudinal portions 11, 11′ in order together to form sectional elements independent of one another.
In
The mutually connected connection edges 57 are bent over by the pivoting so that they form bent-over abutment edges 56 via which the longitudinal portions 11, 11′ are connected to one another end-to-end. At the same time, the openings 5 are formed by the pivoting between portions of the meandering longitudinal edges 12, 13, without this being associated with material loss.
The connection between the bent-over abutment edges 56 can generally also be produced by other kinds of connection such as overlap welding, folding, adhesive bonding, clinching, riveting or clamping. In addition, the pivoting of the longitudinal portions can also take place about an angle different from 180°, in particular about a smaller or also larger angle, depending on which shape the final sectional element should have. The manufacture of the sectional element by folding open was admittedly only explicitly described in connection with the web-shaped connection portions 14, 15, but this manufacture is also possible with the other connection portions described within the framework of this application as long as the connection edges to be connected extend in the longitudinal direction of the material strip.
Number | Date | Country | Kind |
---|---|---|---|
10 2009 047 958.9 | Oct 2009 | DE | national |
10 2009 048 152.4 | Oct 2009 | DE | national |
10 2010 026 320.6 | Jul 2010 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2010/005891 | 9/27/2010 | WO | 00 | 5/31/2012 |