Note: Descriptions are shown in the official language in which they were submitted.
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Method for the Manufacture of a Three-Dimensional Structural Body
The invention relates to a method for the manufacture of a three-dimensional
structural body
that is manufactured substantially from plate-shaped material blanks, which
material blanks
are cut to size in sections from at least one material strand and are
subsequently connected to
each other in the form of the structural body.
The structural form of massive wood construction is increasingly used in wood
construction
work. In this type of construction walls or ceilings are manufactured from
solid massive
wooden elements or elements of wooden material. An advantage of this
construction type is,
among other things, the fact that walls or ceilings can be prefabricated
during the
manufacturing work as a finished, joined wall or ceiling element. The massive
wooden
elements or elements of wooden material are first manufactured from several
layers of boards
or of plates by, in particular, crosswise adhering. These massive block panels
are cut to size
in further work steps in accordance with the instructions of the plan to
massive wooden
elements or elements of wooden material.
The conventional manufacturing method is especially disadvantageous during the
insertion of
openings, e.g., for windows or doors, since in this instance the openings are
produced by
sawing them out of the completely planar element.
A continuous process for the manufacture of modular wall elements and ceiling
elements as
are needed, for example, for establishing a cooling chamber was previously
described in
EP 1 992 758 A2. The previously known method provides cutting to size the wall
elements
and ceiling elements needed for the manufacture of a three-dimensional
structural body as
material blanks from an endless material strand in order to connect to each
other the material
blanks used as wall elements and ceiling elements at their sides adjacent to
each other in the
corner areas of the structural body with the aid of connection elements. Since
no planar door
openings or window openings are let into the wall elements and ceiling
elements, the walls
and ceilings of the structure to be produced can be manufactured from
continuous, planar
wall elements or ceiling elements and also the problem of material waste does
not occur in the
method previously known from EP 1 992 758 A2.
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Different modular separating wall systems are already known from WO
2006/039761 Al and
DE 198 46 599 Al in which systems each separating wall is manufactured from an
appropriate number of wall panels, whereby the wall panels are connected to
each other on
their adjacent narrow sides by a fold connection or a groove and spring
connection. Since
even these previously known separating wall systems do not need any planar
door openings
and window openings, the problem of material waste is also not present in
these separating
wall systems.
There is therefore the problem of creating a manufacturing method of the
initially cited type
that is distinguished by a substantially reduced consumption of material.
According to an aspect of the present invention, there is provided a method
for the
manufacture of a three-dimensional structural body that is manufactured
substantially from
plate-shaped material blanks, which material blanks are cut to size in
sections from at least
one material strand and are subsequently connected to each other in the form
of the structural
body, wherein the structural body is subdivided into plate planes that for
their part, are
segmented into plate plane sections oriented in the longitudinal or the
transverse direction of
the plate planes, the dividing lines of the plate plane sections of at least
one plate plane
comprising at least one planar plate plane opening are placed in the
connection area between
plate plane sections oriented in the longitudinal direction and adjacent plate
plane sections
oriented in the transverse direction, which plate plane sections surround a
planar plate plane
opening there, the plate plane sections comprising the same structural
material or work
material are aligned on each other in such a manner that the plate plane
sections of at least one
plate plane can be projected onto at least one material strand, and this at
least one material
strand is subsequently cut to size to the plate plane sections before the
plate plane sections of a
plate plane that are individualized in such a manner from the at least one
material strand are
connected to each other to form the plate plane.
The method in accordance with some embodiments of the invention provides that
the
structural body is subdivided in a first calculating step or intellectual step
into plate planes,
whereby, for example, each wall surface or ceiling surface located in a plane
can form a plate
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plane. The individual plate planes are subsequently segmented in a following
intellectual step
or calculating step into plate plane sections oriented in the longitudinal
direction or the
transverse direction of the plate plane in order to subsequently place the
dividing lines of the
plate plane sections in the connecting area. In a following calculating or
intellectual step the
plate plane sections of at least one plate plane section that are to be
manufactured from the
same construction material or work material are placed on a material strand
that is subsequently
cut to size in accordance with the plate plane sections. The plate plane
sections of a plate plane
individualized in this manner from the at least one material-material strand
can subsequently be
connected to each other to the plate plane in order to connect the plate
planes to the three-
dimensional structural body at the desired site of use in a following work
step.
The construction materials or work materials used for cutting the plate plane
sections to size
can differ in the material, in the material thickness and/or in the surface
coating or in any
other suitable feature. In the method in accordance with some embodiments, the
plate planes
serving as wall- or ceiling element are prefabricated from several plate plane
sections taking
into consideration their planar openings. The plate plane sections
prefabricated in this manner
can be assembled in a special joining method to the plate plane serving, for
example, as a
wall- or ceiling element. Since the planar window or door openings do not have
to be
manufactured in the method in accordance with the invention by being sawed out
of the
completely planar wall element or ceiling element, the method in accordance
with the
invention is distinguished by a significant saving of material.
In order to be able to use even especially loadable structural materials or
work materials in
especially stressed partial areas of the three-dimensional structural body it
is advantageous if
the plate plane sections of at least one plate plane of the structural body
are cut to size from at
least two material strands consisting of different construction materials.
The plate plane sections cut to size from the material strand can be connected
in an especially
simple and permanent manner to the plate plane serving, for example as wall
element or
ceiling element if the plate plane sections are provided with a joining
profile at least in the
area of their dividing lines.
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In order that even plate plane sections can be connected to each other that do
not necessarily
have to have parallel plate edges, it is advantageous if the clamping force
required for fixing
the plate plane sections of a plate plane is applied vertically to the plate
plane and/or if the
acting direction of the amount of pressure applied required for connecting the
plate plane
sections of a plate plane takes place parallel to the plate plane.
A preferred embodiment in accordance with the invention provides that the
plate plane
sections are connected to each other by a suitable selection of positive fit,
non-positive fit and
same-substance fit. Whereas the positive fit can be brought about, for
example, by a wedge
dovetailing in the case of a gluing profile and whereas the non-positive fit
takes place by the
force applied during the pressing together or by the force acting on the wedge
plane of the
dovetailing, the same-substance fit can be produced, for example, by gluing or
welding. If the
joints between the plate plane sections are connected to each other by
positive and/or same-
substance connection methods, even a permanently joint-tight connection can be
readily
produced.
The joints between the plate plane sections can be differently formed, e.g.,
straight or curved,
with or without support projection. In order to achieve an improved diminution
of load in the
area of the connection joint, a trapezoidal joint design is also possible. It
is therefore
advantageous if the dividing lines between the plate plane sections to be
connected to each
other are constructed from a suitable selection of straight, curved or
trapezoidal joints.
It is advantageous if the plate plane sections are cut to size in a cutting
separating method.
Here, the separating of the material strand previously produced in an endless
manner takes
place by a cutting procedure running at a right angle to and/or at a relative
angle to the plate
planes. The separating can take place, for example, by sawing or milling. For
door or
window cutaway portions braces can be introduced to secure the cutaway
portions of the plate
plane during the manufacturing process.
Other features of some embodiments of the invention result from the following
description of
an exemplary embodiment in accordance with the invention in combination with
the
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drawings. The present invention will be explained in detail using the
following exemplary
embodiments.
The individual method steps of the manufacturing method of examples of
embodiments of the
invention will be described in detail using figures 1 to 8, in which:
5 Figure 1 shows a perspective view of a structural body formed in
accordance with an
embodiment of the present invention;
Figure 2 shows an example of plate planes projected onto one material strand;
Figure 3 shows an example of plate plane sections which have been segmented on
a material
strand in the longitudinal or transverse direction;
Figure 4 shows an example of plate plane sections that are aligned adjacent
one another and
can be projected onto at least one material strand;
Figure 5 shows an example of plate plane sections having a joining profile
according to an
embodiment of the present invention;
Figure 6 shows plate plane sections having a joining profile according to
another embodiment
1 5 of the present invention;
Figure 7 shows an example of plate planes being connected together under
pressure; and
Figure 8 shows an example of an arrangement of plate plane sections joined at
appropriate
positions in a material strand.
The method presented here is provided for manufacturing a three-dimensional
structural
body 1. The structural body 1 is shown in figure 1 by way of example in the
form of a rough
construction. The structural body 1 is manufactured substantially from plate-
shaped material
blanks that are cut to size in sections from at least one material strand and
subsequently
connected to each other in the form of the structural body 1.
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It can be recognized in figure 1 that the structural body 1 is subdivided in
the first calculating
step or intellectual step into plate planes A, B, C, D, E and F, whereby, for
example, each wall
surface or ceiling surface located in a plane can form a plate plane A, B, C,
D, E or F.
These plate planes, lined up adjacent to each other in figure 2 in a projected
strand are
subsequently segmented - as will become clear from figure 3 - in plate plane
sections 2
oriented in the longitudinal direction or the transverse direction of the
plate planes.
It is indicated in figure 4 that the plate plane sections 2 consisting of the
same structural
material or work material are aligned adjacent to each other in another
calculating step or
intellectual step in such a manner that the plate plane sections can be
projected on at least one
material strand.
The plate planes A, B, C, D, E and F provided, for example, as wall- or
ceiling elements are
understood to be assembled structural parts, whereby in the assembly of the
plate plane
sections 2 the formation of planar door or window openings can be considered
to be material-
saving. Each plate element section 2 can be manufactured under the aspect of
material
optimization by the joining together of the plate plane sections 2 of a plate
plane provided as a
total structural part. Thus, a considerable saving of material can be achieved
by the
manufacturing method presented here, which saving essentially takes place by
the waste-
saving (pre) segmentation of each plate plane A, B, C, D, E and F into plate
plane sections 2.
The dimensioning of the plate plane sections 2 takes place by the preceding
cutting to size of
standardized raw elements and/or by a measurement-related production of the
plate plane
sections 2. The plate planes A, B, C, D, E and F can have a homogeneous or an
inhomogeneous composition, whereby the plate plane sections 2 of at least one
plate plane of
the structural body 1 can also be cut to size from at least two material
strands consisting of
different construction materials. The method shown here can be used in the
working of all
plate-shaped construction materials or work materials. However, a preferred
usage of the
method shown consists in that the plate-shaped construction materials or work
materials
consist of wood or of a wooden work material. The plate plane sections 2 can
therefore be
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manufactured as massive wooden elements or can also be produced, for example,
from OSB,
FPY, or a combination of these materials.
The construction materials or work materials used for cutting the plate plane
sections 2 to size
can differ in material, and the material thickness and/or in the surface
coating or in any other
suitable feature. Therefore, the plate plane sections 2 to be assembled to a
total element A, B,
C, D, E or F do not have to be manufactured from the same material or
construction material.
As soon as the plate plane sections 2 of at least one plate plane that are to
be manufactured
from the same construction material or work material have been projected onto
the material
strand consisting of the desired material the at least one material strand can
subsequently be
cut to size to the plate plane sections 2 before the plate plane sections of a
plate plane A, B, C,
D, E and F individualized in such a manner from the at least one material
strand is are
connected to each other to the plate plane.
The plate planes broken down during the preparation of the work into the
necessary plate
plane sections 2 and serving later, for example, as wall element or ceiling
element are
manufactured by the aid of optimized cutting-to-size systems from
prefabricated panels
(cf. figure 3).
Figures 5 and 6 indicate that the plate plane sections 3 can be provided in
another work step
with a joining profile 3 that facilitates the subsequent joining together of
the plate plane
sections 2 to an endless strand.
The manufacture of the joining profile can take place in a work process
connected in
beforehand by a cutting method, whereby for example, a work procedure with the
work steps
"profile milling", "gluing", "transport", "gluing", "clamping", "pressing" can
be selected.
The joining together of the plate plane sections 2 to a strand takes place in
a subsequent
working step. It is also possible that the cutting manufacture of the joining
profile precedes
the subsequent joining process in a clamping procedure so that the work
procedure also could
comprise the work steps "clamping (horizontal-vertical)", "milling", "gluing",
"pressing".
Another possibility consists in that the joining profile is provided in the
preceding
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manufacturing process of the particular plate plane section, for example, by
gluing in a profile
fitting strip.
It is clear from a comparison of the figures 5 and 6 that the joining profile
does not necessarily
have to run over the entire structural part but rather it can be sufficient
that the plate plane
sections 2 are provided only in the area of their dividing lines with a
joining profile. As a
result of the particularity of an insertable tool, joining profiles can also
be introduced only into
the cross-sectional areas of the structural parts necessary for connecting the
plate plane
sections 2.
It is indicated in figure 7 that the amount of pressure required during the
gluing of the plate
plane sections 2 to the plate plane is applied vertically to the plate plane.
This makes it
possible to connect plate plane sections 2 to plate edges that are not
necessarily parallel.
The connecting of the individual plate plane sections 2 can take place by a
non-positive fit, a
positive fit and/or a same-substance fit. The positive fit and/or same-
substance fit connection
of the joints present between the plate plane sections 2 makes possible a
permanent, joint-tight
connection.
A same-substance connection can take place by gluing or welding. For a
positive fit
connection a wedge dovetailing or a gluing profile can be used. A non-positive
connection
takes place by the pressure force required during the pressing together of the
structural
elements or by the force acting on the wedge plane of the dovetailing.
In some embodiments, the manufacture of a plate plane serving, for example, as
a wall
element or ceiling element takes place taking into consideration conduits or
recesses that are
introduced horizontally as well as vertically into the plate planes and that
can be used, for
example, as installation conduits.
It is clear from figure 1 that the joints between the plate plane sections 2
adjacent to each
other can be differently formed, for example, straight, curved or with or
without support
projection. It is shown in figure 1 in the area of the window openings that
the joint
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constructions can also be designed to be trapezoidal in order to achieve an
improved
diminution of load in the area of the connecting joint.
The manufacture of the same-substance connection takes place with the aid of
adhesives or
other suitable joining agents whose connection quality takes place under the
availability of
pressure, heat and/or time. The connection between the plate plane sections 2
can also take
place by pressing or glue with or without the supply of heat. Other
connections such as, for
example, double butt strap joints or dowel connections are also possible.
The geometry of the openings provided in the plate planes, for example, as
window or door
opening do not have to necessarily be at a right angle.
It is indicated in figure 7 that the total pressing force required to connect
the plate plane
sections 2 can be achieved by partially adjustable partial pressures that are
to be adapted to the
amounts of pressure required for the cross section of the plate plane sections
2.
It is possible by the manufacturing method shown here to manufacture joint-
tight angular
connections or wall ceiling connections. Such joint-tight angular connections
are
advantageous, for example, in the areas of "wall-to-wall", "ceiling-to-wall"
or "ceiling-to-
roof'. The plate plane sections can be connected to each other, for example,
by joining them
together with the aid of special angle pieces (e.g., T-connection).
After the plate plane sections 2 have been projected onto the material strands
associated with
them the separation of the element strand produced at first as an endless
strand takes place in a
cutting procedure running at a right angle and/or at a relative angle to the
plate plane. In the
case of roof plates the cutting procedure can become necessary in the cutting
procedure
arranged at an angle relative to the plate plane. The separation can take
place by sawing or
milling. For door or window cutaway portions braces can also be introduced to
secure the
appropriate structural parts during the manufacturing process. Such braces are
intended to
prevent the "folding together" of the structural parts.
Figure 8 shows that the plate plane sections, that are optionally provided
with a suitable
joining profile corresponding, for example, to the intended use, are joined
together at the
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appropriate position to an endless strand in order that the strand can be
subsequently separated
into the required wall elements and/or ceiling elements of the plate planes
and cut to length.
The application range of the manufacturing method presented here goes beyond
the use as a
constructive or non-constructive wall element or ceiling element in the
construction area. This
5 application range also comprises residential construction and industry
construction. Further,
application ranges in the construction area are, e.g., bridge construction.
The plate-shaped
construction elements manufactured with the method in accordance with some
embodiments
of the invention can be used in building construction but also as a façade
system, sound-
proofing elements or the like. Other applications in modular construction are
conceivable, for
10 example, caravan construction, internal ship construction, measuring
stand construction,
weekend garden houses, modular buildings (school containers, residential
containers or work
containers).
