Method for manufacturing a multi-chamber profile and multi-chamber profile

Abstract

The present invention relates to a method for producing a multi-chamber profile with at least three profile chambers, wherein a first central chamber is arranged between two outer chambers, wherein a roll forming machine is supplied with either a first metal strip and a second metal strip, the first metal strip and a second metal blank, or a first metal profile bar and the second metal strip.

Description

[0001] The present invention relates to a method for producing a multi-chamber profile with at least three, preferably three, profile chambers according to claim 1 and a multi-chamber profile according to claim 15.

[0002] Multi-chamber metal profiles are important components in vehicle construction and are used, among other things, as equipment parts to dampen the impact of collisions or as components of undercarriages. Known methods for manufacturing such multi-chamber profiles include, for example, the extrusion of aluminum multi-chamber profiles.

[0003] However, there is still a need for methods for the efficient production of multi-chamber profiles that exhibit high stability and allow for different manufacturing materials.

[0004] The present invention therefore aims to provide such a method with which efficient production of stable multi-chamber profiles can be achieved.

[0005] The problem is solved by the features of claim 1. In the inventive method for producing a multi-chamber profile with at least three, preferably three, profile chambers, wherein a first central chamber is arranged between two outer chambers, a roll forming machine is connected either - a first metal band and a second metal band, - the first metal band and a second metal plate or - a first metal profile bar and the second metal strip are supplied, wherein the first metal strip or the first metal profile bar has two first edges in a cross-sectional direction of the first metal strip or the first metal profile bar and the second metal strip or the second metal sheet has two second edges in a cross-sectional direction of the second metal strip or the second metal sheet, wherein the first edges are brought into contact with the second metal strip or the second metal sheet by the roll forming machine in such a way and the first metal strip is joined to the second metal strip, the first metal strip to the second metal sheet or the first metal profile bar to the second metal strip thermally or mechanically at two first joining points along the two first edges in a first joining step in such a way that the first middle chamber is formed and closed, wherein the first middle chamber has a first wall,which is formed by the first metal strip or the first metal profile bar, and has a second wall formed by the second metal strip or the second metal sheet, wherein the second metal strip or the second metal sheet is formed by the roll forming machine after the first joining step in such a way that the two outer chambers are formed, or the second metal strip is formed by the roll forming machine before the first joining step in such a way that the two outer chambers are formed in front of the first middle chamber.

[0006] This method can be carried out efficiently and with different metals as the material for the metal strips, the metal plate and / or the metal profile bar.

[0007] A metal strip according to the invention is a flat and long metal strip that is fed to the roll forming machine, wherein the metal strip has a multiple of the length of the finished, cut-to-length multi-chamber profile and thus basically enables an endless metal strip feed into the roll forming machine.

[0008] A metal plate according to the invention is a flat metal rectangle with a length limited in the longitudinal direction, wherein the length of the metal plate preferably corresponds to the length of the finished multi-chamber profile or at most three times the length of the finished multi-chamber profile.

[0009] A metal profile bar according to the invention is a profile formed before being fed into the roll forming machine, with a length limited in the longitudinal direction, wherein the length of the metal profile bar preferably corresponds to the length of the finished multi-chamber profile or at most three times the length of the finished multi-chamber profile.

[0010] According to the invention, a profile chamber is formed when a cavity of the profile chamber is surrounded in the cross-sectional direction by walls, whereby the individual walls or sections of the walls only need to be in contact and do not necessarily have a materially bonded connection.

[0011] A profile chamber according to the invention is closed when the walls surrounding the cavity of the profile chamber are joined by means of thermal or mechanical joining.

[0012] The roll forming machine according to the invention can also consist of several roll forming machines arranged one behind the other or one above the other, whereby, for example, thermal and mechanical joining can take place between the roll forming machines, but also within the roll forming machine.

[0013] According to the invention, an edge in a cross-sectional direction is preferably a free edge in the cross-sectional direction of the respective metal strip, metal sheet, or metal profile bar. However, the free edge can be folded over, for example, before the roll forming machine for the respective metal profile or after the roll forming machine for the respective metal strip or metal sheet, by a fold. In this case, the fold point is considered the edge in the cross-sectional direction according to the invention.

[0014] Advantageous embodiments of the present invention are the subject of the dependent claims.

[0015] According to a particularly preferred embodiment of the present invention, the first metal strip or the first metal profile bar and / or the second metal strip or the second metal sheet are made of steel. Firstly, the process can be carried out efficiently by using steel as the material. Secondly, the multi-chamber profile produced results in positive properties when using steel. Preferably, the first metal strip or the first metal profile bar and / or the second metal strip or the second metal sheet are made of steel with a yield strength of at least 550 MPa, more preferably at least 900 MPa, and even more preferably at least 1200 MPa. The multi-chamber profile produced is thus very stable and can nevertheless be manufactured efficiently using the process according to the invention.Preferably, the first metal strip or profile bar and the second metal strip or sheet are made of steel of different grades. This allows the properties of the manufactured multi-chamber profile to be precisely adjusted.

[0016] According to another preferred embodiment, the first metal strip or profile bar and the second metal strip or sheet have different thicknesses. This allows the properties of the manufactured multi-chamber profile to be precisely adjusted.

[0017] According to a further preferred embodiment, the first metal strip or the first metal profile bar and the second metal strip or the second metal plate have thicknesses in the range of 0.5 to 4 mm, preferably in the range of 0.5 to 2.5 mm, and more preferably in the range of 0.5 to 1.5 mm. Such thicknesses allow for efficient production of the multi-chamber profile with good stability of the produced multi-chamber profile.

[0018] In a further particularly preferred embodiment, the first metal strip or the first metal profile bar is fed into the roll forming machine above the second metal strip or the second metal blank. This allows for a space-saving arrangement of the roll forming machine. Furthermore, the first joining step can be made more efficient.

[0019] According to a further particularly preferred embodiment, first slots, preferably punched, are cut into the cross-sections of the first metal strip or the first metal profile bar and / or the second metal strip or the second metal sheet before they are fed into the roll forming machine. After the profile chambers have been closed, the multi-chamber profile is cut to length by punching at these slots. This allows for more efficient and precise cutting. Particularly preferably, the first metal profile bar or the second metal sheet has a length corresponding to the length of the multi-chamber profile to be produced. This eliminates the need for cutting the first metal profile bar or the second metal sheet to length.

[0020] Preferably, the first slots are pre-cut into the first metal strip or profile bar and / or the second metal strip or sheet before being fed into the roll forming machine using a pre-cutting press. This results in an efficient manufacturing process.

[0021] Preferably, after the first joining step, further sections in the cross-sections are separated by punching, with each punch passing through the initial slots. This allows for efficient further separation in the cross-sections without completely compromising the longitudinal integrity of the multi-chamber profile to be produced before final cutting to length. Particularly preferably, the second metal strip or sheet is subsequently formed or further formed by the roll forming machine. The at least partial longitudinal integrity of the multi-chamber profile to be produced is advantageous for the roll forming process.

[0022] In a particularly preferred embodiment, the first metal profile bar is designed as a hat, C, or U profile, or the first metal strip is formed into the hat, C, or U profile by the roll forming machine before the hat, C, or U profile is joined to the second metal strip or the second metal sheet along the two first joining points in the first joining step, thereby closing the first middle chamber, wherein sections in the cross-sectional direction of the second metal strip or the second metal sheet between the respective second edges and the first joining points are formed by the roll forming machine after the first joining step such that the two edge chambers are formed, each of which shares a wall formed by the first metal strip or the first metal profile bar with the first middle chamber, wherein in a second joining step the respective section, preferably the respective second edge,The two outer chambers are thermally or mechanically joined at a second joint point with the first metal strip or the first metal profile bar to close the two outer chambers. This method allows for a very efficient production of the multi-chamber profile.

[0023] The sections can be formed in the cross-sectional direction of the second metal strip or the second metal sheet by the roll forming machine in such a way that each section forms a second edge chamber, the walls of which are formed by the second metal strip or the second metal sheet itself and which are closed by thermally or mechanically joining the respective section, preferably the respective second edge, to the second metal strip or the second metal sheet at a third joining point in a third joining step. This allows further profile chambers in the form of edge chambers to be produced.Furthermore, a third metal strip or a third metal profile bar can be fed into the roll forming machine, wherein the third metal strip or the third metal profile bar has two third edges in a cross-sectional direction of the third metal strip or the third metal profile bar, wherein the third edges are each brought into contact with a wall of the second edge chambers in such a way that a second middle chamber is formed, wherein the third edges are joined to the respective wall of the second edge chamber at two fourth joining points along the two third edges in a fourth joining step, thermally or mechanically, in such a way that the second middle chamber is closed. In this way, a multi-chamber profile with six profile chambers, wherein two profile chambers are middle chambers and four profile chambers are edge chambers, can be efficiently produced.

[0024] Furthermore, at least one, preferably both, of the sections can be formed in the cross-sectional direction of the second metal strip or the second metal sheet by the roll forming machine before the second or third joining step such that a respective end section between the respective second edge and the respective second or third joining point of at least one of the sections is formed into a flange that projects from the profile chambers, preferably at right angles. The multi-chamber profile can advantageously be attached to other elements by means of the flange(s).

[0025] In another particularly preferred embodiment, prior to the first joining step, two edge sections in the cross-sectional direction of the second metal strip, comprising the respective second edges, are formed by the roll forming machine such that the edge sections form the two edge chambers, wherein the walls of the two edge chambers are formed by the respective edge section in the cross-sectional direction of the second metal strip itself, wherein the respective second edge of the respective edge section in the cross-sectional direction of the second metal strip is thermally or mechanically joined to the second metal strip at a fifth joining point in a fifth joining step in order to close the edge chamber, before the first metal strip or the first metal profile bar is joined to the second metal strip at the first edges in the cross-sectional direction by means of the first joining step such that the first middle chamber is formed and closed.This method allows for a very efficient production of the multi-chamber profile.

[0026] According to a preferred embodiment, the thermal or mechanical joining is carried out using a laser welding process. This enables highly efficient joining that can be integrated into the roll forming machine.

[0027] Preferably, one laser is used per joining step, which is split between the two joining points by means of an optical system. This makes the process more cost-effective.

[0028] Preferably, the joints feature a T-joint, a longitudinal linear contact, or a longitudinal planar contact. The longitudinal linear contact and the longitudinal planar contact resemble a flanged joint. This enables efficient joining and a stable material bond. For this purpose, the first metal strip or profile bar and / or the second metal strip or sheet are formed and joined in such a way that a T-joint or a linear contact is present in the cross-sectional direction at the respective joint.

[0029] According to a preferred embodiment, the profile chambers are each formed with four walls arranged at right angles to each other.

[0030] The invention further relates to a multi-chamber profile with at least three, preferably three, profile chambers, wherein a first central chamber is arranged between two outer chambers, manufactured according to a method according to one of the embodiments described above. The multi-chamber profile has advantageous properties and can be manufactured efficiently and cost-effectively.

[0031] In addition, the invention relates to a second method for producing a second multi-chamber profile with three profile chambers, wherein a middle chamber is arranged between two outer chambers, wherein a roll forming machine is either - a first metal band and a second metal band, or - a first metal profile bar and the second metal strip are supplied, wherein the first metal strip or the first metal profile bar has two first edges in a cross-sectional direction of the first metal strip or the first metal profile bar and the second metal strip has two second edges in a cross-sectional direction of the second metal strip, wherein two first edge sections in the cross-sectional direction of the first metal strip or the first metal profile bar, which comprise the respective first edges, preferably one of the first edges, are brought into contact with the second metal strip by the roll forming machine at a first contact point in such a way and the first metal strip is joined to the second metal strip or the first metal profile bar to the second metal strip thermally or mechanically at two first joining points along the first contact point in a first joining step in such a way that the middle chamber is formed and closed,wherein the middle chamber has a first wall formed by the first metal strip or the first metal profile bar, and a second wall formed by the second metal strip, wherein, prior to the first joining step, two second edge sections in the cross-sectional direction of the second metal strip, comprising the respective second edges, are formed by the roll forming machine such that the two second edge sections form the two edge chambers, wherein walls of the two edge chambers are formed by the respective second edge section in the cross-sectional direction of the second metal strip itself, wherein the respective second edge of the respective second edge section in the cross-sectional direction of the second metal strip is thermally or mechanically joined to the second metal strip at a fifth joining point in a fifth joining step to close the respective edge chamber,before the first metal strip or the first metal profile bar is joined to the second metal strip by means of the first joining step in such a way that the first middle chamber is formed and closed.

[0032] According to a preferred embodiment of the second method, the first metal strip or the first metal profile bar and / or the second metal strip are made of steel. Firstly, the method can be carried out efficiently by using steel as the material. Secondly, the second multi-chamber profile produced using steel offers additional advantages. Preferably, the first metal strip or the first metal profile bar and / or the second metal strip are made of steel with a yield strength of at least 550 MPa, more preferably at least 900 MPa, and even more preferably at least 1200 MPa. The second multi-chamber profile produced is thus very stable and can still be manufactured efficiently using the method according to the invention. Preferably, the first metal strip or the first metal profile bar and the second metal strip are made of steel of different grades.This allows the properties of the manufactured second multi-chamber profile to be precisely adjusted.

[0033] According to a further preferred embodiment of the second method, the first metal strip or the first metal profile bar and the second metal strip have different thicknesses. This allows the properties of the produced second multi-chamber profile to be precisely adjusted.

[0034] According to a further preferred embodiment of the second method, the first metal strip or the first metal profile bar and the second metal strip have thicknesses in the range of 0.5 to 4 mm, preferably in the range of 0.5 to 2.5 mm, and more preferably in the range of 0.5 to 1.5 mm. Such thicknesses allow for the efficient production of the second multi-chamber profile while maintaining good stability of the produced second multi-chamber profile.

[0035] In a further particularly preferred embodiment of the second method, the first metal strip or the first metal profile bar is fed into the roll forming machine above the second metal strip. This allows for a space-saving arrangement of the roll forming machine. Furthermore, the first joining step can be made more efficient.

[0036] According to a further particularly preferred embodiment of the second method, first slots, preferably punched, are introduced into the cross-sections of the first metal strip or the first metal profile bar and / or the second metal strip before it is fed into the roll forming machine. The second multi-chamber profile is then cut to length by punching at these slots after the profile chambers have been closed. This allows for a more efficient and precise cutting process. Particularly preferably, the first metal profile bar has a length corresponding to the length of the second multi-chamber profile to be produced. This eliminates the need for the first metal profile bar to be cut to length.

[0037] Preferably, the first slots are cut into the first metal strip or the first metal profile bar and / or into the second metal strip using a pre-cutting press before being fed into the roll forming machine. This results in an efficient manufacturing process.

[0038] Preferably, after the fifth joining step and before the first joining step, further sections in the cross-sections are separated by punching, with a respective punch passing through the first slots. This allows further separation in the cross-sections to be achieved efficiently without completely compromising the integrity of the second multi-chamber profile to be produced in the longitudinal direction before the final cutting to length.

[0039] According to a further particularly preferred embodiment of the second method, at least one of the two first edge sections is formed in the cross-sectional direction of the first metal strip by the roll forming machine before the first joining step such that a respective end section between the respective first edge and the respective first joining point of the at least one of the two first edge sections forms a flange that projects from the profile chambers, preferably at right angles. The second multi-chamber profile can advantageously be attached to other elements by means of the flange(s).

[0040] According to another particularly preferred embodiment of the second method, the first metal profile bar is provided such that at least one of the two first edge sections has, in the cross-sectional direction of the first metal profile bar, a respective end section between the respective first edge and the respective first joint of the at least one of the two first edge sections, which forms a flange projecting from the profile chambers, preferably at right angles. The second multi-chamber profile can advantageously be attached to other elements by means of the flange(s).

[0041] According to a preferred embodiment of the second method, the thermal or mechanical joining is carried out using a laser welding process. This enables highly efficient joining that can be integrated into the roll forming machine.

[0042] Preferably, one laser is used per joining step, which is split between the two joining points by means of an optical system. This makes the process more cost-effective.

[0043] Preferably, the joints feature a T-joint, a longitudinal linear contact, or a longitudinal planar contact. The longitudinal linear contact and the longitudinal planar contact resemble a flanged joint. This enables efficient joining and a stable material bond. For this purpose, the first metal strip or profile bar and / or the second metal strip or sheet are formed and joined in such a way that a T-joint or a linear contact is present in the cross-sectional direction at the respective joint.

[0044] According to a preferred embodiment of the second method, the profile chambers are each formed with four walls arranged at right angles to each other.

[0045] The invention further relates to a second multi-chamber profile with three profile chambers, wherein a first central chamber is arranged between two outer chambers, manufactured according to the second method according to one of the embodiments of the second method described above. The second multi-chamber profile has advantageous properties and can be manufactured efficiently and cost-effectively.

[0046] Exemplary embodiments of the method of the present invention are explained in more detail below with reference to the drawings.

[0047] They show: Fig. 1a to d Cross-sectional views of the forming steps of a first embodiment of a method according to the invention without the tools used, Fig. 2 Cross-section through the roll forming machine at a point in time of the first embodiment of the method, Fig. 3 Cross-sectional view of a multi-chamber profile, produced according to a second embodiment of the method according to the invention, Fig. 4a to k Cross-sectional view of the forming steps of a third embodiment of a method according to the invention without the tools used, Fig. 5a to m Cross-sectional view of the forming steps of a fourth embodiment of a method according to the invention without the tools used, Fig. 6 Cross-sectional view of a multi-chamber profile, produced according to a fifth embodiment of the method according to the invention, Fig. Figures 7a to f show a cross-sectional view of the forming steps of a sixth embodiment of a method according to the invention, without the tools used. Fig. 8a to f Cross-sectional view of the forming steps of a seventh embodiment of a method according to the invention without the tools used, and Fig. 9 Cross-sectional view of a multi-chamber profile, produced according to an eighth embodiment of the method according to the invention.

[0048] In the following explanations, identical parts are designated by the same reference numerals. If a figure contains reference numerals that are not further explained in the corresponding figure description, reference is made to preceding or subsequent figure descriptions. Furthermore, identical parts within series of figures are not always repeatedly marked with the same reference numerals.

[0049] In Fig. Figure 1 shows cross-sectional views of the forming steps of a first embodiment of a method according to the invention, without the tools used. Only cross-sectional views of the components to be formed are shown. In the first embodiment, to produce a multi-chamber profile 1 with three profile chambers 2, wherein a first central chamber 3 is arranged between two outer chambers 4, a first metal strip 5 and a second metal strip 6 are fed to a roll forming machine. The first metal strip 5 has two first edges 7 in a cross-sectional direction of the first metal strip 5, and the second metal strip 6 has two second edges 8 in a cross-sectional direction of the second metal strip 6. The first metal strip 5 and the second metal strip 6 are fed to the roll forming machine as flat metal strips, with the first metal strip 5 being fed into the roll forming machine above the second metal strip 6.

[0050] In Fig. Figure 1a shows a first forming step by the roll forming machine, in which the first metal strip 5 is formed from a flat metal strip 5a into a U-profile 9 in several forming steps. One of these forming steps is shown in Fig. Figure 2 shows a cross-section through the roll forming machine, the first metal strip 5 which has already been partially formed and the second metal strip 6 which is still undeformed.

[0051] Fig. Figure 1b shows how the first edges 7 are brought into contact with the second metal strip 6 by the roll forming machine in such a way that the first middle chamber 3 is formed. In this position of the U-profile 9 and the second metal strip 6, the first metal strip 5 is then joined to the second metal strip 6 by laser welding at two first joining points 10 along the two first edges 7 in a first joining step, such that the first middle chamber 3 is closed. The first middle chamber 3 thus has four walls arranged at right angles to each other, with three walls formed by the first metal strip 5 / U-profile 9 and one wall by the second metal strip 6.

[0052] Fig. Figure 1c then shows how, after the first joining step, sections 11 are progressively formed in the cross-sectional direction of the second metal strip 6 between the respective second edges 8 and the first joining points 10 by the roll forming machine in such a way that the two edge chambers 4 are formed, each of which shares a wall formed by the first metal strip 5 with the first middle chamber 3. To close the edge chambers 3, in a second joining step, the respective second edge 8 is then joined to the first metal strip 5 at a respective second joining point 12 along the second edges 8 by means of laser welding.

[0053] Fig. Figure 1d shows the finished multi-chamber profile 1, in which the edge chambers 3 each have four walls arranged at right angles to each other. Due to the selected forming operations, T-joints are present between the first metal strip 5 and the second metal strip 6 at the first and second joints 10 and 11 in the first embodiment of the method.

[0054] Fig. Figure 3 shows a cross-sectional view of a finished multi-chamber profile 1, which is produced according to a second embodiment of the method according to the invention, similar to the first embodiment of the method according to the invention described above. In contrast to the first embodiment, one of the sections 11 is gradually formed in the cross-sectional direction of the second metal strip 6 between the respective second edge 8 and the first joining points 10 by the roll forming machine after the first joining step such that one of the sections 11 is joined to the first metal strip 5 at the second joining point 11 by means of laser welding and an end section 25 of one of the sections 11 between the second edge 8 and the respective second joining point 11 of one of the sections 11 is formed into a flange 26, which projects at right angles from the profile chambers 2.

[0055] In Fig. Figure 4 shows cross-sectional views of the forming steps of a third embodiment of a method according to the invention, without the tools used. Again, only cross-sectional views of the components to be formed are shown. In the third embodiment, to produce a multi-chamber profile 1 with three profile chambers 2 – the first central chamber 3 and the two edge chambers 4 – a first metal profile bar 13 and the second metal strip 6 are fed to a roll forming machine, wherein the first metal profile bar 13 has two first edges 7 in one cross-sectional direction and the second metal strip 6 has two second edges 8 in one cross-sectional direction of the second metal strip 6.

[0056] The second metal strip 6 is supplied to the roll forming machine as a flat second metal strip 6a, as shown in Fig. 3a shown, supplied. In the Fig. Figures 3b to 3i show how two edge sections 14 in the cross-sectional direction of the second metal strip 6, which comprise the respective second edges 8, are gradually formed by the roll forming machine such that the edge sections 14 form the two edge chambers 4, wherein the walls of the two edge chambers 4 are formed by the respective edge section 14 in the cross-sectional direction of the second metal strip 6 itself.

[0057] To close the two edge chambers 4, the respective second edge 8 of the respective edge section 14 is then joined in the cross-sectional direction of the second metal strip 5 at a fifth joining point 15, as shown in Fig. 4i, along the second edges 8 with the second metal strip 6 in a fifth joining step by means of laser welding. A longitudinally planar contact exists between the respective second edge 8 and the second metal strip 6 at the respective fifth joining point 15.

[0058] The first metal profile bar 13 with a U-profile 9 is placed in the roll forming machine above the second metal strip 6, as shown in Fig. 4j shown, fed. Alternatively, the first metal profile bar 13 of the roll forming machine can also be fed simultaneously with the second metal strip 6.

[0059] As in Fig. As shown in Figure 4k, the first edges 7 of the first metal profile bar 13 are brought into contact with the second metal strip 6 by the roll forming machine to form the first middle chamber 3, wherein the first metal profile bar 13 is then joined at the first edges 7 by means of the first joining step at the first joining points 10 along the first edges 7 with the second metal strip 6 to close the first middle chamber 3.

[0060] In Fig. Figure 5 shows cross-sectional views of the forming steps of a fourth embodiment of a method according to the invention, without the tools used. Only cross-sectional views of the components to be formed are shown. In the fourth embodiment, to produce a multi-chamber profile 1 with six profile chambers 2, wherein a first central chamber 3 is arranged between two outer chambers 4 and a second central chamber 16 is arranged between two second outer chambers 17, a first metal strip 5, a second metal blank 18, and a third metal profile bar 19 are fed to a roll forming machine. The first metal strip 5 has two first edges 7 in a cross-sectional direction of the first metal strip 5, the second metal blank 18 has two second edges 8 in a cross-sectional direction of the second metal blank 18, and the third metal profile bar 19 has two third edges 21 in a cross-sectional direction of the third metal profile bar 19.The third metal profile bar 19 is then fed into the roll forming machine above the first metal strip 5, and the first metal strip 5 is fed into the roll forming machine above the second metal blank 18. The third metal profile bar 19 and the second metal blank 18 are only shown in the figures where they are brought into contact with the first metal strip 5 and the second metal blank 18, respectively, by the roll forming machine.

[0061] In the Fig. Figures 5a to d show a first forming step by the roll forming machine, in which the first metal strip 5 is formed by the roll forming machine from a flat first metal strip 5a to a first C-profile 20 in several forming steps.

[0062] Fig. Figure 5e shows how, next, the first edges 7 of the first metal strip 5 are brought into contact with the second metal sheet 18 by the roll forming machine in such a way that the first middle chamber 3 is formed. In this position of the C-profile 20 and the second metal sheet 18, the first metal strip 5 is then joined to the second metal sheet 18 by laser welding at two first joining points 10 along the two first edges 7 in a first joining step, such that the first middle chamber 3 is closed.

[0063] Fig. Figures 5f to k then show how sections 11 in the cross-sectional direction of the second metal sheet 18 between the respective second edges 8 and the first joining points 10 are progressively formed by the roll forming machine after the first joining step in such a way that the two edge chambers 4 are formed, each of which shares a wall formed by the first metal strip 5 with the first middle chamber 3. At the same time, the sections 11 are also formed by the roll forming machine in such a way that one of the second edge chambers 17 is formed in each case, the walls of which are formed by the second metal sheet 18 itself.To close the two edge chambers 3, in a second joining step the section 11 is joined to the first metal strip 5 at a respective second joining point 12 by means of laser welding, and to close the two second edge chambers 17, in a third joining step the respective second edge 8 is joined to the second metal plate 18 at a third joining point 22 along the respective second edge 8 by means of laser welding.

[0064] As in Fig. 5m shown, the third edges 21 of the third metal profile bar 19 are then brought into contact with the second metal sheet 18 by the roll forming machine to form the second middle chamber 16, wherein the third metal profile bar 19 is then joined at the third edges 21 by means of a fourth joining step as laser welding at fourth joining points 23 along the third edges 21 to the second metal sheet 18 in order to close the second middle chamber 16.

[0065] Fig. Figure 6 shows a cross-sectional view of a finished multi-chamber profile 1, which is produced according to a fifth embodiment of the method according to the invention, similar to the fourth embodiment of the method according to the invention described above. In contrast to the fourth embodiment, the sections 11 in the cross-sectional direction of the second metal sheet 18 between the respective second edges 8 and the first joining points 10 are gradually formed by the roll forming machine after the first joining step into the two edge chambers 4 and the two second edge chambers 17, such that the sections 11 are joined to the second metal sheet 18 at the third joining point 22 by means of laser welding and end sections 25 of the respective section 11 between the respective second edge 8 and the respective third joining point 22 of the respective section 11 are each formed into a flange 26 which projects at right angles from the profile chambers 2.

[0066] The first, second, third, fourth and fifth embodiments do not address cutting the multi-chamber profile 1 to length after forming and closing the respective profile chambers 2. However, such a step will usually be necessary to bring the multi-chamber profiles 1 to the desired length.

[0067] The in the Fig. 7, Fig. 8 and Fig. The nine embodiments of the method according to the invention are described in detail below. They address possible cutting processes that are advantageous for the method according to the invention. For illustrative purposes, the embodiments shown in the illustrations are based on the following: Fig. 7 and Fig. 8 embodiments shown on the first embodiment of the method according to the invention with a first metal strip 5 and a second metal strip 6 and the one shown in the Fig. 9 shown embodiment on the fifth embodiment of the method according to the invention with a first metal strip 5, a second metal strip 5 and a third metal profile bar 19.

[0068] In Fig. Figure 7 shows cross-sectional views of the forming steps of a sixth embodiment of a method according to the invention without the tools used, wherein this includes possible, advantageous cutting operations for the method according to the invention and is based on the first embodiment of the method according to the invention with a first metal strip 5 and a second metal strip 6. In the Fig. The 7 cross-sectional views shown are cross-sections where the multi-chamber profile 1 is cut to length after the profile chambers 2 have been closed.

[0069] As in Fig. As shown in Figure 7a, the second metal strip 6 with first slots 24, which are shown as a dashed line, is fed to the roll forming machine. The first slots 24 can preferably be punched before the roll forming machine.

[0070] After the first joining step, as in Fig. As shown in Figure 7b, once the first middle chamber 3 has been closed, a punching of sections, here of the first metal strip 5, takes place through one of the first slots 24, with a respective punch passing through the corresponding first slot 24. This is indicated by the now dashed line of the first metal strip 5 in Fig. 7c is shown.

[0071] Connecting is done as described in the Fig. Figures 7d and e show the forming of the second metal strip 6 to create the two edge chambers 4 by the roll forming machine and the closing of the edge chambers 4 by the second joining step.

[0072] Finally, the multi-chamber profile 1 is completely cut to length in the cross-sections, preferably by punching, as shown in Fig. 7f is represented by the overall dashed cross-section.

[0073] The in Fig. The seventh embodiment of a method according to the invention, shown in Figure 8, is similar to the sixth embodiment. It differs in that only one first slot 24, as in Figure 8, is shown. Fig. Figure 8a shows that the second metal strip 6 is inserted into the cross-sections at which the multi-chamber profile 1 is cut to length after the profile chambers 2 have been closed, and before the second metal strip 6 is inserted into the roll forming machine. In addition, after the first joining step has been completed and the first middle chamber 3 has been closed, only a portion of the first metal strip 5 is separated by punching through one of the first slots 24, as shown in Figure 8a. Fig. 8c is shown.

[0074] Fig. Figure 9 shows a cross-sectional view of a multi-chamber profile 1, produced according to an eighth embodiment of the method according to the invention, which is based on the fifth embodiment of the method according to the invention, wherein a second metal strip 6 is processed instead of a second metal sheet 18. In the Fig.The cross-sectional view shown in Figure 9 depicts a cross-section from which the multi-chamber profile 1 is cut to length after the profile chambers 2 have been closed. In this embodiment, the second metal strip 6, with first slots 24 (represented as wide, descending diagonals), is fed to the roll forming machine. The first slots 24 can preferably be punched before the roll forming machine. After the first metal strip 5 has been joined to the second metal strip 6 in the first joining step, thus forming and closing the first middle chamber 3, the first metal strip 5 is cut to length by punching, as shown by the dark, ascending diagonals. Subsequently, the sections 11 of the second metal strip 6 are formed into the outer chambers 4 and second outer chambers 17, the outer chambers 4 and second outer chamber 17 are closed by the second and third joining steps, and the second middle chambers 16 are formed and closed.Only then is the multi-chamber profile 1 completely cut to length in the cross-sections, preferably by means of punching. Reference symbol list 1 Multi-chamber profile 2 profile chambers 3 first middle chamber 4 marginal chamber 5 first metal band 5a flat first metal band 6 second metal band 6a flat second metal band 7 first edge 8 second edge 9 U-profile 10 first joint 11 sections 12 second joining point 13 first metal profile bar 14 marginal sections 15 fifth joint 16 second middle chamber 16 17 second marginal chamber 18 second metal plate 19 third metal profile bar 20 C-Profi 21 third margin 22 third joint 23 fourth joints 24 first slots 25 Final section 26 flange

Claims

Method for producing a multi-chamber profile with at least three, preferably three, profile chambers, wherein a first central chamber is arranged between two edge chambers, wherein a roll forming machine is supplied with either a first metal strip and a second metal strip, the first metal strip and a second metal blank, or a first metal profile bar and the second metal strip, wherein the first metal strip or the first metal profile bar has two first edges in a cross-sectional direction of the first metal strip or the first metal profile bar, and the second metal strip or the second metal blank has two second edges in a cross-sectional direction of the second metal strip or the second metal blank, wherein the first edges are brought into contact with the second metal strip or the second metal blank by the roll forming machine, and the first metal strip is brought into contact with the second metal strip.The first metal strip is joined to the second metal sheet, or the first metal profile bar is joined to the second metal strip, thermally or mechanically at two first joining points along the two first edges in a first joining step, such that the first middle chamber is formed and closed, wherein the first middle chamber has a first wall formed by the first metal strip or the first metal profile bar, and a second wall formed by the second metal strip or the second metal sheet, wherein the second metal strip or the second metal sheet is formed by the roll forming machine after the first joining step in such a way that the two edge chambers are formed, or the second metal strip is formed by the roll forming machine before the first joining step in such a way that the two edge chambers are formed in front of the first middle chamber. Method according to claim 1, wherein the first metal strip or the first metal profile bar and / or the second metal strip or the second metal plate are made of steel, wherein the steel preferably has a yield strength of at least 550 MPa, more preferably of at least 900 MPa, more preferably of at least 1200 MPa. Method according to claim 1 or 2, wherein the first metal strip or the first metal profile bar is fed into the roll forming machine above the second metal strip or the second metal blank. Method according to one of claims 1 to 3, wherein first slots, preferably punched, are introduced into the first metal strip or the first metal profile bar and / or into the second metal strip or the second metal sheet before being fed into the roll forming machine, in cross-sections at which the multi-chamber profile is cut to length by punching after the profile chambers have been closed. Method according to claim 4, wherein after the first joining step further partial areas in the cross-sections are separated by punching, wherein a respective punch passes through the first slots, wherein preferably the second metal strip or the second metal sheet is then formed or further formed by the roll forming machine. A method according to any one of claims 1 to 5, wherein the first metal profile bar is designed as a hat, C, or U profile, or the first metal strip is formed into the hat, C, or U profile by the roll forming machine before the hat, C, or U profile is joined to the second metal strip or the second metal sheet along the two first joining points in the first joining step, thereby closing the first middle chamber, wherein sections in the cross-sectional direction of the second metal strip or the second metal sheet between the respective second edges and the first joining points are formed by the roll forming machine after the first joining step such that the two edge chambers are formed, each of which shares a wall formed by the first metal strip or the first metal profile bar with the first middle chamber, wherein in a second joining step the respective section, preferably the respective second edge,at a respective second joining point, the first metal strip or the first metal profile bar is thermally or mechanically joined to close the two edge chambers. Method according to claim 6, wherein the sections are formed in the cross-sectional direction of the second metal strip or the second metal sheet by the roll forming machine such that the sections each form a second edge chamber, the walls of which are formed by the second metal strip or the second metal sheet itself and which are closed by thermally or mechanically joining the respective section, preferably the respective second edge, to the second metal strip or the second metal sheet at a third joining point in a third joining step. Method according to claim 6 or 7, wherein at least one, preferably both, of the sections are formed in the cross-sectional direction of the second metal strip or the second metal sheet by the roll forming machine in such a way before the second joining step or the third joining step that a respective end section between the respective second edge and the respective second joining point or the respective third joining point of the at least one of the sections is formed into a flange which projects from the profile chambers, preferably at right angles. The method of claim 7, wherein a third metal strip or a third metal profile bar is fed to the roll forming machine, wherein the third metal strip or the third metal profile bar has two third edges in a cross-sectional direction of the third metal strip or the third metal profile bar, wherein the third edges are each brought into contact with a wall of the second edge chambers in such a way that a second middle chamber is formed, wherein the third edges are joined thermally or mechanically to the respective wall of the second edge chamber at two fourth joining points along the two third edges in a fourth joining step in such a way that the second middle chamber is closed. A method according to any one of claims 1 to 5, wherein, prior to the first joining step, two edge sections in the cross-sectional direction of the second metal strip, comprising the respective second edges, are formed by the roll forming machine such that the edge sections form the two edge chambers, wherein walls of the two edge chambers are formed by the respective edge section in the cross-sectional direction of the second metal strip itself, wherein the respective second edge of the respective edge section in the cross-sectional direction of the second metal strip is thermally or mechanically joined to the second metal strip at a fifth joining point in a fifth joining step in order to close the edge chamber, before the first metal strip or the metal profile is joined to the second metal strip at the first edges in the cross-sectional direction by means of the first joining step such that the first middle chamber is formed and closed. Method according to any one of claims 1 to 10, wherein the thermal or mechanical joining is carried out by means of a laser welding process. Method according to claim 11, wherein a laser is used for each joining step, which is split between the respective two joining points by means of an optical system. Method according to claim 11 or 12, wherein a T-joint, a longitudinally linear contact or a longitudinally planar contact is present at the respective joining points. Method according to any one of claims 1 to 13, wherein the profile chambers are each formed with four walls arranged at right angles to each other. Multi-chamber profile with at least three, preferably three, profile chambers, wherein a first middle chamber is arranged between two edge chambers, manufactured according to a method according to one of claims 1 to 14.

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