Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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W02012/143381 Al
SECTION ELEMENT AND METHOD OF MANUFACTURING A SECTION
ELEMENT
The present invention relates to a section element, in particular to a
construction section, for example a dry construction section, a facade
section, a plaster section, a skirting section, a screed section a tile
section
or a cable carrier section, a stiffening section, in particular an automotive
section, or a shelf rail or a drainage rail, having an elongated section body
which in particular comprises metal or plastic. The invention is
furthermore directed to a method of manufacturing such a section
element.
Section elements of this kind are used, for example, as upright C sections
for dry construction, but can also be configured as any other lightweight
construction section elements. In many cases, the section elements, on
the one hand, have to have a predefined stiffness, but, on the other hand,
have to have a weight which is as low as possible. To reduce weight,
openings are frequently produced, for example punched, in the section
element, which has the disadvantage, however, that the punched out
pieces represent waste pieces. On the one hand, the problem of disposal
results in this respect and, on the other hand, the costs for the
manufacture are increased by the additional punching process. Since
furthermore the costs of such section elements are frequently
substantially determined by the material costs, the waste pieces are
undesired in the production of the holes.
It is an object of the present invention to provide a section 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 section element should be provided.
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This objet is satisfied in accordance with the invention by a section
element having an elongated section body which in particular comprises
metal or plastic and which comprises at least two separately formed
longitudinal portions, wherein each longitudinal portion comprises a
meandering longitudinal edge as well as a straight-line longitudinal edge
disposed opposite the meandering longitudinal edge and wherein the
longitudinal portions are connected to one another via the straight-line
longitudinal edges. A further section element in accordance with the
invention has an elongated section body which in particular comprises
metal or plastic and which comprises at least two longitudinal portions,
wherein each longitudinal portion has a meandering longitudinal edge,
wherein the section body has a substantially U-shaped or V-shaped cross-
section having two section limbs and a section web connecting the section
limbs, wherein the section limbs are formed by the bent over regions of the
longitudinal portions comprising the meandering longitudinal edges and
the respective section limbs are made at least regionally double walled
having an outer wall and an inner wall disposed toward the interior of the
U-shaped or V-shaped cross-section, and wherein the meandering
longitudinal edges extend at least regionally in the inner walls of the
double-walled section limbs.
In accordance with the method in accordance with the invention, two
separate longitudinal portions each having a meandering longitudinal
edge and a straight-line longitudinal edge disposed opposite the
meandering longitudinal edge are provided for generating the section
element, wherein the longitudinal portions are connected to one another
via the straight-line longitudinal edges. In a further method in accordance
with the invention, an elongated strip-shaped starting material having two
respective outwardly disposed meandering longitudinal edges are provided
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for producing the section element and longitudinal portions of the material
strip bounded by the meandering longitudinal edges are bent over for
producing the section limbs until the meandering longitudinal edges at
least regionally come into contact with portions of the section body
disposed between the meandering longitudinal edges, whereupon they are
connected to them.
In accordance with the invention, a weight reduction of the section
element is thus achieved in that, in contrast to a full-area design, the
section element comprises two meandering longitudinal edges so that the
weight of the section element is reduced with respect to a full-area design.
A relatively large-area region in the center of the section element is
produced by the connection of the two longitudinal portions via their
respective straight-line longitudinal edge disposed opposite the respective
meandering longitudinal edge or by a correspondingly single-part design of
the two longitudinal portions, said relatively large area region having a
high stiffness, whereas the meandering longitudinal edges each form the
outer edges of the section element at which outer edges no corresponding
stiffness is required in many applications. Furthermore, such a design is
frequently also advantageous for visual reasons since the center region of
the section element is formed as a closed surface in this manner. In
particular when the marginal regions are deformed, for example bent over,
by a further processing and are thereby no longer visible from the outside,
a full-area impression of the section element is created even though
material can be saved by the meandering longitudinal edge. A structure
which is open or perforated at one side can thus be produced.
A particularly stiff section having a U-shaped or V-shaped cross-section is
produced by the double-walled production of the section limbs of the
further section element in accordance with the invention, with the desired
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weight reduction of the section element being achieved by the extent of the
meandering longitudinal edges at least regionally in the inner walls of the
double-walled section limbs despite the increase in the stiffness.
In accordance with an advantageous embodiment of the method in
accordance with the invention, 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 is
introduced into an elongated strip-shaped starting material. No waste
material which would increase the manufacturing costs arises by the
production of the two longitudinal portions in this mariner. In this respect,
it is both possible that the two longitudinal portions produced from the
originally uniform starting material are connected to one another via their
straight-line longitudinal edges to produce the same section element and
that two longitudinal portions which are produced in a corresponding
manner from a different starting material are connected to one another to
form the section element in accordance with the invention. In both cases,
both the production of the waste material and the above-named further
advantages are achieved.
In accordance with an advantageous embodiment of the invention, the
straight-line longitudinal edges are connected to one another directly or at
least via one intermediate element. The straight-line longitudinal edges
can, for example, be connected to one another or optionally to the
intermediate element by welding, clamping, crushing, pressing, screwing,
adhesive bonding, riveting, rebating or by a pressure joining process such
as clinching or crimping. The intermediate element can in this respect
advantageously be made as an elongated strip-shaped element. The
intermediate element can in particular also have a thickness which is
equal in size to the thickness of the longitudinal portions.
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In accordance with a further preferred embodiment, the meandering
longitudinal edges of the longitudinal portions are made complementary to
one another. This, for example, results automatically when the
5 longitudinal portions are manufactured from the same starting material in
that a meandering longitudinal portion is introduced into the two
longitudinal portions to divide the starting material.
The longitudinal portions preferably comprise the same material. This also
results automatically when the two longitudinal portions are
manufactured from the same starting material. In this case, the
longitudinal portions form two contiguous portions of an originally
uniform material strip along the meandering longitudinal edges.
The section body is advantageously formed as a thin-walled cold-formed
section body. The sectional elements in accordance with the invention are
thus lightweight construction sections which can be used in different
manners. Applications are also conceivable, for example, in addition to the
initially named uses, in the automotive sector, in switch cabinet
construction, in ceiling systems or even as vine supports, wine posts or
the sector of guard rails. The longitudinal portions in this respect
advantageously have a thickness of approximately between 0.5 mm and 3
mm.
In accordance with a further advantageous embodiment of the invention,
the straight-line longitudinal edges extend substantially parallel to the
longitudinal extent of the longitudinal portion. An oblique extent is
generally also conceivable as long as the longitudinal portions can be
connected to one another.
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In accordance with a further advantageous embodiment of the invention,
the meandering longitudinal edges are connected to one another directly
or via at least one further intermediate element. A closed section can be
produced in this manner, for example. The straight-line longitudinal edges
can in this respect preferably be connected to one another at least
regionally or optionally to the further intermediate element by welding,
adhesive bonding, crushing, pressing, screwing, adhesive bonding,
riveting, rebating or by a pressure joining process such as clinching or
crimping.
In accordance with a further preferred embodiment of the invention, the
meandering longitudinal edges are connected at least regionally to
portions of the section body disposed between the meandering
longitudinal edges. The portions can in this respect preferably lie
substantially in the region of a longitudinal central axis of the section
body. It is, however, also possible that the portions lie outside the
longitudinal central axis. The portions can in particular each lie, for
example, in the marginal region of the section body facing the respective
meandering longitudinal edge. The regions of the longitudinal portions
bounded by the meandering longitudinal edges can in this manner form
support elements which are supported, for example, at the rear side of the
section element in its central region or in its marginal regions. The
stiffness of a corresponding section element can thereby be increased.
In the case of a separate design of the longitudinal portions, the mutually
connected straight-line longitudinal edges advantageously extend through
the portions.
The portions can in particular be configured as areal portions and can be
connected to connection regions of the longitudinal portions bounded by
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the meandering longitudinal edges. A further increase in the stiffness as
well as a stronger connection of the connection regions to the remaining
region of the section element are achieved by the areal connection. The
connection can in this respect be configured, for example, as a weld
connection or as an adhesive bond connection. Other types of connection
are, however, also possible such as a plug-in connection, a stamped
connection, a connection by a pressure joining process such as clinching
or crimping or a riveting or screwing.
In accordance with a further advantageous embodiment of the invention,
the section body has a substantially U-shaped or V-shaped cross-section
having two section limbs and a section web connecting the section limbs,
wherein the limb sections are each formed by bent-over regions of the
longitudinal portions comprising the meandering longitudinal edges. The
section limbs can in this respect preferably be made at least regionally
with double walls having an outer wall and an inner wall disposed toward
the interior of the U-shaped or V-shaped cross-section and the
meandering longitudinal edge can in each case extend at least regionally
in the inner wall of the double-walled section limb. A particularly stiff
section having a U-shaped or V-shaped cross-section is thereby achieved.
A hollow space extending in the longitudinal direction of the section limb
is advantageously respectively formed between the walls of the double-
layer section limb. A further increase in the stiffness is thereby ensured
with a simultaneous material reduction and reduced weight with respect
to a full section.
In accordance with a further preferred embodiment of the invention, the
mutually connected straight-line longitudinal edges of the longitudinal
portions are in particular arranged centrally within the section web. A
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symmetrical design of the section element is achieved in this manner by
which the stiffness is also further increased.
A section element in accordance with the invention can advantageously be
used as a force absorber, in particular as a bumper, for example of an
automobile or of another vehicle. Due to the design in accordance with the
invention, a weight reduction can be achieved with respect to a full-area
design of a section element with approximately the same stiffness. A
section element in accordance with the invention can also advantageously
be used as a replacement for an upright C section.
Further advantageous embodiments are set forth in the dependent claims.
The invention will be described in more detail in the following with
reference to embodiments and to the drawings; in which are shown:
Fig. 1 a material portion having a cutting pattern to produce
a section element formed in accordance with the
invention;
Fig. 2 a section element formed in accordance with the
invention in an intermediate step of the manufacture;
Figs. 3 a) and b) a respective part view of a section element formed in
accordance with the invention in a perspective
representation, once with and once without covered
edges being shown;
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Figs. 4 a) and b) the section element in accordance with Fig. 3 in a
respective different part view, once with and once
without covered edges being shown;
Fig. 5 a further section element which is not manufactured in
accordance with the invention;
Fig. 6 a bumper with a section element formed in accordance
with the invention; and
Fig. 7 a further section element formed in accordance with
the invention.
Fig. 1 shows a material strip 1, for example a sheet metal strip, which
serves as a starting material for a section element in accordance with the
invention. A meandering slit 2 which extends in the longitudinal extent of
the material strip 1 and by which the material strip 1 is divided into two
separate longitudinal portions 3, 4 is formed in the material strip 1. The
longitudinal portions 3, 4 are each given a meandering longitudinal edge
5, 6 by the meandering slit 2 which contact one another seamlessly in the
representation in accordance with Fig. 1. The meandering longitudinal
edges 5, 6 each include edge portions extending in the longitudinal
direction and extending perpendicular thereto. Other meandering extents
of the longitudinal edges can also be used within the framework of this
invention, for example having obliquely extending edge portions which are
curved or which are entwined with one another.
Web-shaped connection regions 7, 8 of the longitudinal portions 3, 4 are
respectively formed by the meandering longitudinal edges 5, 6 and are
each connected in one piece to elongated portions 9, 10 of the longitudinal
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portions 3, 4 and project laterally beyond them. As can furthermore be
seen from Fig. 1, the web-shaped connection regions 7 are bounded by the
meandering longitudinal edge 5 and the web-shaped connection regions 8
are bounded by the meandering longitudinal edge 6.
5
The longitudinal portion 3 comprises a straight-line longitudinal edge 11
which is disposed opposite the meandering longitudinal edge 5 and which
simultaneously forms a first outer edge of the material strip 1. In a
corresponding manner, the longitudinal portion 4 comprises a straight-
10 line longitudinal edge 12 which is disposed opposite the meandering
longitudinal edge 6 and which forms the second outer edge of the material
strip 1.
To produce the section element in accordance with the invention, the
material strip 1 is divided into the two longitudinal portions 3, 4 by
introducing the meandering slit 2, for example by a laser cutting process,
a rotary cutting process or another suitable cutting process, and the two
longitudinal portions 3, 4 are subsequently arranged such that their
straight-line longitudinal edges 11, 12 contact one another as is shown in
Fig. 2. In this position, the two longitudinal portions 3, 4 are connected to
one another, for example, welded, in partiuclar laser welded, to one
another along the mutually connecting straight-line longitudinal edges 11,
12. An overlapping connection is also possible in this respect.
Subsequently, the longitudinal portions 3, 4 are each bent over along
bend lines 13 to 17 shown by dashed lines and extending in the
longitudinal direction of the longitudinal portions 3, 4 until a section body
18 of the section element arises which has a U-shaped cross-section such
as is shown in Figs. 3 and 4. The longitudinal portions 3, 4 are in this
respect bent lover in the same direction by 90 in each case along the
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bend lines 13, 14, while a bending by only approximately 45 takes place
in the same direction along the bend lines 15 and 16. The two longitudinal
portions 3, 4 are finally bent over by 900 in the opposite direction about
the bend line 17 so that end portions 19 of the web-shaped connection
portions 7, 8 come into contact areally with the rear side of the central
region of the section body 18.
This central region forms a section web 20 of the section body 18 which
respective substantially symmetrically formed section limbs 21 laterally
adjoin.
The section limbs 21 are formed as double-walled, with the respective
outwardly disposed outer wall 22 being formed by the regions of the
longitudinal portions 3, 4 disposed between the bend lines 13, 14 and by
the inner wall 23 disposed toward the interior of the U-shaped cross-
section being formed by the bent over connection regions 7, 8.
A respective hollow space 24 which extends in the longitudinal direction of
the section limbs 21 and which extends over the total length of the section
body 18 is formed between the outer walls and inner walls 22, 23.
The end portions 19 of the connection regions 7, 8 are connected, in
particular welded, to the section web 20, so that a high stiffness of the
total section body 18 is achieved.
It can furthermore be recognized from Fig. 3 that two stiffening beads 25
are formed in the section web 20 which extend in the longitudinal extent
and which additionally increase the stiffness of the section body 18. In
this respect, the bent over end portions 19 of the connection regions 7, 8
are arranged between the stiffening beads 24 and are thus connected to
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portions 26 (Fig. 2) of the section body 18 which are arranged, with
respect to the representation in accordance with Fig. 2, centrally between
the outwardly disposed meandering longitudinal edges 5, 6. As can
furthermore be recognized from Fig. 2, the mutually connected straight-
line longitudinal edges 11, 12 extend through the portions 26. The
portions 26 can generally also be arranged off-center so that e.g. a more or
less large spacing is present between the respective mutually oppositely
disposed end portions 19 of the respective connection regions 7, 8. Section
elements having a wider section web 20 can thereby also be formed.
The bend lines 13 to 17 do not have to be arranged exactly as described,
but can rather be arranged at larger or smaller spacings from one another
as required. Furthermore, in particular the bend lines 15, 16 can also be
replaced with a single bend line about which a bending takes place by
preferably 900 so that ultimately a U-shaped cross-section of the section
body 18 is in turn produced. The inner walls 22, 23 can also be made
extending obliquely so that the section body 18 has a V-shaped cross-
section.
It is generally also possible that the connection regions 7, 8 are fastened,
for example welded, directly to the section web 20 at their outwardly
disposed regions of the meandering longitudinal edges 5, 6 so that an
abutting edge to face connection without bent over end portions 19 is
realized. Other types of connection are also possible, such as a plug-in
connection with slits and tongues or a connection by a pressure joining
process.
The section element in accordance with Figs. 3 and 4 can be used instead
of an upright C section, for example. Further uses are also possible, in
particular also as force absorbers in accordance with Fig. 6.
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Fig. 6 shows a section body 27 which was not formed in accordance with
the invention, but rather from a uniform, full-area material strip without
meandering longitudinal edges and thus without openings by a
corresponding bending. With respect to the section body 18 in accordance
with the invention, the section body 27 is heavier, on the one hand, and a
higher material effort is required to produce the section body 27, on the
other hand.
In Fig. 6, a bumper 28 is shown which is made as a force absorber and
which comprises a section element formed in accordance with the
invention and having a section body 18. Fastening elements 29, via which
the bumper 28 can be fastened in a normal manner, for example, to a
motor vehicle, are formed at the two lateral, slightly bent ends of the
section body 18.
Despite the small material consumption, the section element formed in
accordance with the invention has the required stiffness since the
connection regions 7, 8 bounded by the meandering longitudinal edges 5,
6 form support elements which reliably take up forces which usually arise
from the front on the bumper 28 on an accident.
While it has been described up to now that the longitudinal portions 3, 4
are each formed separately and are connected to one another via their
straight-line longitudinal edges 11, 12, the longitudinal portions 3, 4 can
also be made in one piece with one another in all described embodiments.
The lines of the longitudinal edges 11, 12 shown in the Figures in this
case do not represent longitudinal edges, but only the imaginary center
line of the longitudinal portions 3, 4, formed in one piece with one
another.
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Accordingly, a section element in accordance with the invention is shown
in Fig. 7 which can replace an upright C section, for example. In this
respect, elements which are the same or similar are designated by the
same reference numerals as with respect to the previously described
embodiments. The section element shown is configured in a similar
manner to the section element of Figs. 3 and 4, with the longitudinal
portions 3, 4, however, being made in one piece with one another.
Furthermore, the section web 20 is wider than in Figs. 3 and 4 so that
there is a larger spacing between the mutually respectively oppositely
disposed end portions 19 of the connection regions 7, 8 so that, if
required, openings and/or stiffening beads can be formed in the section
web 20. Additional stiffening beads can also be provided in the section
limbs 21. This also applies to the previously described embodiments. The
section element in accordance with Fig. 7 can generally also have
separately formed longitudinal portions 3, 4.
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Reference numeral list
1 material strip
2 meandering slit
3 longitudinal portion
5 4 longitudinal portion
5 meandering longitudinal edge
6 meandering longitudinal edge
7 connection regions
8 connection regions
10 9 elongated portion
10 elongated portion
11 straight-line longitudinal edge
12 straight-line longitudinal edge
13 bend line
15 14 bend line
15 bend line
16 bend line
17 bend line
18 section body
19 end portions
20 section web
21 section limb
22 outer walls
23 inner walls
24 hollow spaces
25 stiffening beads
26 portions
27 section body
28 bumper
29 fastening elements
