I-profile prefabricated part and I-profile manufacturing method

Abstract

The object of the present invention is an I-profile preform, comprising an outer wall (1) of a first flange and two inner walls (2) of the first flange arranged relative to the outer wall (1) of the first flange, a first web wall (3) and a second web wall (4) arranged in a plane parallel to the first web wall (3), an outer wall (5) of a second flange and two inner walls (6) of the second flange arranged relative to the outer wall (5) of the second flange, wherein the corresponding walls (1, 2, 3, 4, 5, 6) are arranged relative to each other while maintaining a certain clearance to form a closed empty interior space of the I-profile preform, and wherein a valve element (7) is arranged on at least one of the walls (1, 2, 3, 4, 5, 6). The object of the present invention is also a method for manufacturing an I-profile using the I-profile preform.

Description

[0001] The object of the invention is a method for manufacturing an I-profile and an I-profile prefabricated part. The invention is intended to be used in the construction industry for the manufacture of load-bearing structures such as walls, floors and ceilings, as well as in the engineering or metalworking industries.

[0002] I-profiles are one of the most commonly used parts in construction. They are particularly suitable for forming the most important structural parts, such as pillars, beams, or truss members. The name of the I-profile derives from its characteristic cross-section, which resembles two connected letters T. The I-profile consists of two flanges and a so-called web connecting these flanges. There are a variety of I-profiles with various parameters and intended for a variety of different applications, such as standard (INP), parallel (IPE) or wide flange (HEB, HEA) I-profiles.

[0003] Utility model PL65088Y1 discloses an I-beam, which is composed of two flanges connected by a web, wherein the thickness of the second flange is less than the thickness of the first flange, and preferably 0.75 to 0.95 of the thickness of the first flange. Such an I-beam with two flanges of different thicknesses is used as a rail of an overhead rail system.

[0004] Polish patent PL206365B1 discloses an I-profile manufacturing method, which is used to produce an I-profile, which is an element of a civil engineering structure, especially a building and a house. In the I-profile manufacturing method, a metal plate having a width equal to the sum of the web width and twice the width of two flanges is bent at 90° angles in opposite directions along two edges forming the web profile on both sides, and then the plate is bent at an angle of 180° along the first edge line of each flange, and then the plate is bent at an angle of 180° along the second edge line of each flange toward the inner space of this section.

[0005] Another Polish patent PL213146B1 discloses a method for manufacturing an I-profile with a sandwich flange. In the method for manufacturing an I-profile with a sandwich flange by bending a metal sheet known from patent PL213146B1, a metal sheet (whose width is equal to the sum of the web width, four times the width of the two flanges and twice the thickness) is bent at an angle of 90° on both sides along the two edges forming the web profile, then the sheet is bent at an angle of 90° along a first edge line, then the sheet is bent at an angle of 90° along a second edge line, and further the sheet is bent at an angle of 90° along a third edge line, then the sheet is bent at an angle of 90° along a fourth edge line, and finally the sheet is bent at an angle of 90° on both sides along the two edges forming the web profile. The space within the flange is filled with a filler, in particular in the form of a metal foam.

[0006] The technical problem of the present invention is to provide a method for manufacturing an I-profile that will allow the manufacture of an I-profile with desired characteristics, especially in terms of the strength and stiffness coefficients and the load-bearing capacity to weight ratio of the I-profile, while maintaining high dimensional accuracy. It is desirable that the I-profile manufacturing method has a limited number of technical steps and can be implemented without the use of specialized and complex equipment, thereby directly providing a simplified, time-saving and more affordable economical manufacturing process for I-profiles. It is also desirable that the I-profile manufacturing method has a low material consumption and allows the I-profile to be manufactured from adjusted materials with a variety of geometric parameters, especially with different web heights and different flange widths (symmetrical and asymmetrical). It is also important to provide an I-profile manufacturing method that will allow the shape of the I-profile to be easily modified within a variety of geometric parameters without the need to rearrange the equipment used in the manufacturing process. Another technical problem of the present invention is to provide an I-profile preform that will be used in the I-profile manufacturing method and will provide an I-profile with desired technical parameters.

[0007] A first object of the present invention is an I-profile preform, characterized in that the I-profile preform comprises an outer wall of a first flange and two inner walls of the first flange arranged relative to the outer wall of the first flange, a first web wall and a second web wall arranged in a plane parallel to the first web wall, an outer wall of a second flange, and two inner walls of the second flange arranged relative to the outer wall of the second flange, wherein these corresponding walls are arranged relative to each other while maintaining a certain gap to form a closed empty interior space of the I-profile preform, and wherein a valve element is arranged on at least one wall.

[0008] In a preferred embodiment of the present invention, two inner walls of the first flange are arranged in a first plane parallel to the outer wall of the first flange.

[0009] In another preferred embodiment of the present invention, two inner walls of the first flange are arranged in a first plane parallel to the outer wall of the second flange.

[0010] In another preferred embodiment of the present invention, the outer wall of the first flange, the first inner wall of the first flange, the first web wall, the first inner wall of the second flange, and the outer wall of the second flange are formed by a piece of material to form an E-profile, and the second inner wall of the first flange, the second web wall, and the second inner wall of the second flange are formed by a piece of material to form a C-profile.

[0011] Preferably, the first inner wall of the first flange, the first web wall, the first inner wall of the second flange, the outer wall of the second flange, the second inner wall of the second flange, the second web wall and the second inner wall of the first flange are formed from one piece of material to form an incomplete intermediate I-profile.

[0012] It is also preferred that the first inner wall of the first flange, the first web wall and the first inner wall of the second flange are formed from one piece of material to form a C-profile, and / or the second inner wall of the second flange, the second web wall and the second inner wall of the first flange are formed from one piece of material to form a C-profile.

[0013] In a preferred embodiment of the invention, all walls are formed from one piece of material, forming a complete intermediate I-profile.

[0014] In another preferred embodiment of the present invention, the outer wall of the first flange and / or the outer wall of the second flange is formed by a flat strip.

[0015] In another preferred embodiment of the present invention, the walls forming the first flange and / or the second flange taper in the longitudinal direction, thereby defining a cylindrical or hourglass shape.

[0016] Preferably, the unconnected wall edges are sealed with a seal in order to form a closed, gas-tight, empty interior of the I-profile preform.

[0017] Also preferably, the seal is a fusion weld, a pressure weld, an adhesive layer, or a lap joint.

[0018] In a preferred embodiment of the invention, the first flange has a different width than the second flange.

[0019] In another preferred embodiment of the invention, the valve element is a pneumatic or hydraulic connection.

[0020] In another preferred embodiment of the present invention, the valve element is arranged on the first web wall or the second web wall.

[0021] A second object of the present invention is a method for manufacturing an I-shaped profile, characterized in that the method comprises the following steps:

[0022] a) providing an I-profile preform as defined in the first object of the present invention;

[0023] b) sealing the unconnected wall edges with a seal to form a closed, airtight empty interior space of the I-profile preform;

[0024] c) connecting a source of pressurized fluid to the valve element;

[0025] d) inserting the I-profile preform between the pressure plates so that the pressure plates are in contact with the flanges of the I-profile preform;

[0026] e) Introducing a pressurized fluid into the interior space of the I-profile preform.

[0027] In a preferred embodiment of the invention, step b) is achieved by fusion welding, pressure welding, gluing or crimping. In the case of fusion welding, any technique considered suitable for the purpose may be used, including TIG, MIG, MAG, CMT or laser techniques.

[0028] In another preferred embodiment of the invention, the fluid is air, oil, water, fluid concrete or fluid plastic, in particular one-component, two-component or three-component foam, for example of the type flex 140. In particular, the fluid concrete can be concrete reinforced with polypropylene fibers, glass fibers, carbon fibers or steel fibers.

[0029] In another preferred embodiment of the invention, during step d), a force is applied to the pressure plate in the direction of the I-profile preform.

[0030] Preferably, step e) is carried out at room temperature or at elevated temperature.

[0031] It is also preferred that the pressure of the fluid introduced to the I-profile preform is 5 bar.

[0032] More preferably, in step e), the pressurized fluid is introduced into the inner space of the I-profile preform for 1 minute, followed by maintaining a constant pressure in the I-profile preform for 30 seconds.

[0033] The I-profile manufacturing method according to the invention using the I-profile preform according to the invention allows the manufacture of an I-profile having desired characteristics, in particular in terms of the stiffness coefficient and torsional strength of the I-profile and the load-bearing capacity to weight ratio. In particular, due to the use of an I-profile preform mainly manufactured from relatively thin metal sheets, the I-profile manufactured using the method according to the invention allows a significantly increased load-bearing capacity to profile weight ratio to be obtained compared to conventional solutions known in the art. In addition, due to the use of thicker flat strips as the outer wall of the first and / or second flange of the I-profile preform, an I-profile with improved usefulness in these areas can be manufactured. In addition, the I-profile manufacturing method according to the invention is implemented by using uncomplicated machinery, which translates into economic benefits and a significantly simplified I-profile manufacturing process. A small number of seals increases the speed of the I-profile manufacturing process and reduces the labor intensity. In addition, the I-profile manufacturing based on the introduction of a pressurized fluid into the airtight internal space of the I-profile preform allows the parameters of the manufactured I-profile to be modified in a wide range, in particular with respect to its final geometry.

[0034] The solution according to the invention has been shown in the following exemplary embodiments and is illustrated in the accompanying drawings, in which:

[0035] Figure 1 A to Figure 1 C is an axonometric view of the subsequent steps of the I-profile manufacturing method according to an embodiment of the present invention,

[0036] Figure 2 A to Figure 2 C is Figure 1 A to Figure 1 C is a cross-sectional view of a subsequent step in the I-profile manufacturing method,

[0037] Figure 3 A to Figure 3 D is a cross-sectional view of a subsequent step for manufacturing a portion of an I-profile preform according to an embodiment of the present invention,

[0038] Figure 4 A to Figure 4 H is a cross-sectional view of a subsequent step for manufacturing an I-profile preform according to another embodiment of the present invention,

[0039] Figure 5 A to Figure 5 F is a cross-sectional view of a subsequent step for manufacturing an I-profile preform according to another embodiment of the present invention,

[0040] Figure 5 G is in Figure 5 A to Figure 5 Axonometric view of the I-profile preform manufactured in step F,

[0041] Figure 6 A to Figure 6 B is a cross-sectional view of a subsequent step for manufacturing an I-profile preform according to another embodiment of the present invention,

[0042] Figure 6 C is Figure 6 A to Figure 6 Axonometric view of the I-profile preform manufactured in step B,

[0043] Figure 7 A to Figure 7 F is an axonometric view and a cross-sectional view of another embodiment of an I-profile preform and a corresponding I-profile manufactured from the I-profile preform,

[0044] Figure 8 A to Figure 8 C is a cross-sectional view of another embodiment of an I-profile preform,

[0045] Fig. 9 A to Fig. 9 C is an axonometric view of yet another embodiment of an I-profile preform,

[0046] Fig.10 A to Fig.10 B is a cross-sectional view of a subsequent step of a method for manufacturing an I-shaped material according to another embodiment of the present invention,

[0047] Fig.11One of the manufacturing steps of an I-shaped material according to an embodiment of the present invention is shown.

[0048] Example 1

[0049] Figure 1 A to Figure 1 C and Figure 2 A to Figure 2 C schematically shows an I-profile manufacturing method according to a first embodiment of the present invention. The presented embodiment of the I-profile manufacturing method is based on an I-profile preform according to one of the possible embodiments of the present invention, and does not limit the scope of the present invention. In alternative embodiments of the I-profile manufacturing method according to the present invention, different I-profile preforms can be used, in particular the I-profile preforms shown in other embodiments of the present invention.

[0050] Generally, the I-profile manufacturing method includes the steps of providing an I-profile preform ( Figure 1 Axonometric drawing and Figure 2 A is a cross-sectional view along plane AA). Figure 1 A and Figure 2 As shown in A, the preform includes an outer wall 1 of a first flange and two inner walls 2 of the first flange arranged in a plane parallel to the outer wall 1 of the first flange, a first web wall 3 and a second web wall 4 arranged in a plane parallel to the first web wall 3, an outer wall 5 of the second flange and two inner walls 6 of the second flange arranged in a plane parallel to the outer wall 5 of the second flange, wherein these corresponding walls (i.e., the outer wall 1 of the first flange and the two inner walls 2 of the first flange and the first web wall 3 and the second web wall 4, and the outer wall 5 of the second flange and the two inner walls 6 of the second flange) are arranged relative to each other while maintaining a certain gap to form a closed empty internal space of the I-profile preform.

[0051] In this embodiment, the I-profile preform is formed from two separate profiles which are appropriately bent from a metal sheet and form an E-profile and a C-profile, wherein the web height of the E-profile substantially corresponds to the web height of the C-profile. The E-profile comprises an outer wall 1 of a first flange, a first inner wall 2 of the first flange, a first web wall 3, a first inner wall 6 of the second flange and an outer wall 5 of the second flange of the I-profile preform. On the other hand, the C-profile comprises a second inner wall 2 of the first flange, a second web wall 4 and a second inner wall 6 of the second flange of the I-profile preform.

[0052] E-profiles and C-profiles are formed from cold-bent metal sheets. Figure 3 A to Figure 3 The subsequent manufacturing steps of the E profile are schematically shown in D. In particular, the preparation of the E profile starts with providing a metal sheet of appropriate size ( Figure 3A), the width of the metal sheet corresponds to the sum of the lengths of all the sides forming the E-profile. Subsequently, the metal sheet is bent inwards at an angle of 90° along two parallel bending lines at the positions indicated by the arrows, thereby forming the web of the E-profile between the bent portions, which corresponds to the first web wall 3 of the I-profile preform (see Figure 3 B) In the next step of bending the E-profile, the parts of the metal sheets extending parallel to each other are placed in Figure 3 The positions indicated by the arrows in B are bent 90° in directions away from each other (see Figure 3 C). The length between the last bend and the adjacent previous bend corresponds to half the length of the E-profile flange (as long as the length of the E-profile flange is symmetrical with respect to the web) and is the first inner wall 2 of the first flange and the first inner wall 6 of the second flange of the I-profile preform. In the next step, the outwardly extending portion of the metal sheet is further bent 90° in the direction consistent with the previous bend, thereby forming an overlapping portion, which is half of the formed E-profile flange, wherein these bent sections of the metal sheet form the outer wall 1 of the first flange and the inner wall 5 of the second flange of the I-profile preform (such as Figure 3 D).

[0053] return Figure 1 A and Figure 2 A, the E-profile thus formed is matched with the C-profile in such a way that the webs of the corresponding E-profile and C-profile (i.e., the first web wall 3 and the second web wall 4 of the I-profile preform) extend parallel to each other, and the E-profile flange and the C-profile flange form the I-profile preform (the outer surface of which is formed by the metal sheet), while maintaining a certain gap inside the I-profile preform, i.e., a small distance between adjacent walls of the elements of the I-profile preform. The C-profile is also formed by the metal sheet, but since the metal sheet only needs to be repeated Figure 3 A is not shown in detail, therefore the method for manufacturing the C-profile is not shown. It is important that the C-profile, preferably in the middle of the metal sheet forming the C-profile, is provided with a valve element 7. The valve element 7 is a pneumatic or hydraulic connection and allows leak-proof fastening of the supply pipe 9 from an external pressurized fluid source. In some embodiments of the invention, the valve element 7 can be a valve, in particular a check valve. The position of the valve element 7 is not a limitation on the scope of the invention, and in alternative embodiments, the valve element 7 can be arranged at any position of the metal sheet of the E-profile and the C-profile (or in any position of any wall 1, 2, 3, 4, 5, 6 in other embodiments), as long as the position allows connection with the internal space of the I-profile preform.

[0054] Figure 1 B and Figure 2B shows the E-profile and C-profile matched to each other. In the next step of the I-profile manufacturing method, the I-profile preform is sealed to form a sealed, airtight interior space. After the E-profile and C-profile are matched to each other, the edges of the metal sheets forming these profiles are sealed. Therefore, in this embodiment, the longitudinal edges of the E-profile and C-profile matched to each other are sealed, such as Figure 2 B is schematically shown. In this embodiment, the sealing is performed by welding the corresponding edges together, so as to form in particular a longitudinal weld seam to form a seal 8. In addition, the edges of the E-profile and C-profile that match each other, the front and rear of the I-profile preform are sealed. By sealing all the edges listed above, a leak-proof and airtight interior space is formed in the I-profile preform, such as Figure 2 B. In this case, the type of seal 8 is not a limitation to the scope of the invention, and any type of seal 8 can be used in alternative embodiments as long as a leakproof inner space is formed in the I-profile preform, for example by pressure welding, soldering, gluing, bending, or pressing.

[0055] In the next step, an external source of pressurized fluid is connected to the valve element 7 via the supply conduit 9 (see Figure 1 B). In this embodiment, the fluid is air, the pressurized fluid source is a compressor, and the supply pipe 9 forms a pneumatic connection with the valve element 7. The type of external pressurized fluid source and the connection device are not limiting to the scope of the present invention, and in alternative embodiments, water, fluid cement, motor oil, fluid plastics such as one-component, two-component or three-component foam (such as flex 140 type), etc. and connection devices and pressurized fluid sources suitable for these fluids can be used. The less compressible the fluid, the more controllable the deformation conditions of the I-profile preform.

[0056] The next step of the I-profile manufacturing method according to the present invention comprises placing the I-profile preform between pressure plates so that the pressure plates are in contact with the flanges of the I-profile preform, such as Fig.11 The pressure plate can be a working element of a mechanical press. In this case, a controlled force can be applied to the pressure plate, in particular in the direction toward the I-profile preform.

[0057] In the next step of the I-profile manufacturing method according to the invention, a fluid under a defined pressure is delivered to the sealed inner space of the I-profile preform while the I-profile preform is held between the pressure plates. The technique of introducing a pressurized fluid to a closed, sealed chamber element made of sheet metal in order to deform it and provide it with its final shape is known in particular from patent application number EP2110189A1. Due to the delivery of the pressurized fluid into the inner space of the I-profile preform, the walls of the I-profile preform are deformed, wherein the maximum deformation level is located in the middle of the I-profile, in the web region, such as Figure 1C Best in Show. Figure 2 C schematically shows a cross section of an I-profile manufactured from an I-profile preform. As can be observed, the first web wall 3 and the second web wall 4 of the I-profile preform are significantly deformed. In addition, the two inner walls 2 of the first flange and the two inner walls 6 of the second flange of the I-profile preform are also deformed. Figure 1 In the cross section indicated by C, the I-profile manufactured by the preform of the present invention and by the method of the present invention has a shape similar to a lantern. Fig.11 It is demonstrated that by holding the I-beam preform between pressure plates of a press during the step of delivering pressurized fluid into the interior space of the I-beam preform, the plane-parallel shape of the I-beam flange can be maintained, thereby maintaining the functional properties of the I-beam so manufactured.

[0058] It should be noted that while the pressurized fluid is introduced into the interior space of the I-beam preform at a cold technique (ie, room temperature), this is not a limitation on the scope of the invention and in alternative embodiments the process may be performed at elevated or high temperatures.

[0059] In one embodiment of the invention, the step of introducing a pressurized fluid is performed using the following process parameters:

[0060] -Process temperature -20°C;

[0061] - operating pressure – 5 bar;

[0062] - Deformation time - 1 minute until the pressure in the I-profile preform is balanced;

[0063] -Pressure holding time - 30 seconds;

[0064] -Total deformation time - 1.5 minutes.

[0065] Example 2

[0066] Figure 4 A to Figure 4 A further embodiment of the I-profile preform according to the invention is shown in H, wherein a further production step of the I-profile preform, namely a bending step, is also illustrated.

[0067] In general, the structure of the I-profile preform is substantially similar to that of the I-profile preform shown in the first embodiment, except that the I-profile preform according to this embodiment is formed of a complete intermediate I-profile, rather than of matching E-profiles and C-profiles. This solution is advantageous because a smaller number of longitudinal seals 8 are required to hermetically close the inner space of the I-profile preform.

[0068] exist Figure 4 A to Figure 4H schematically shows in successive steps a method for obtaining an I-profile preform according to this embodiment of the invention. The method first involves providing a metal plate with a mounted valve element 7 and placing it in a Figure 4 The position indicated by the arrow in A is bent at an angle of 90° along the line (extending in the longitudinal direction of the I-profile preform). Figure 4 B) will correspond to the second inner wall 2 of the first flange of the finished I-profile preform. In the next step, Figure 4 The position indicated by the arrow in B is bent longitudinally twice at 90° along parallel lines. The short side of the intermediate product (such as Figure 4 C) corresponds to the second web wall 4 of the finished I-profile preform, which has the installed valve element 7. In the next step, the second longer bend (at Figure 4 C) is bent at an angle of 90° in the opposite direction to the previous bending, thereby forming the outer wall 1 of the first flange of the finished I-profile preform. Figure 4 Another 90° bend is performed at the position indicated by the arrow in D to form the first inner wall 2 of the first flange of the I-profile preform. In the next step, the intermediate product section corresponding to the outer wall 1 of the first flange of the I-profile preform is bent 90° in the opposite direction to the previous bend to form an overlapping portion, which is the first inner wall 2 of the first flange of the finished I-profile preform and the outer wall 1 of the first flange, as shown in FIG. Figure 4 F. In the next step, Figure 4 F shows that two bends are made in the middle area between the first web wall 3 and the second web wall 4 at the positions indicated by the arrows. These bends are made inwards at an angle of 90° to form Figure 4 The intermediate element shown in G defines the outer wall 5 of the second flange of the finished I-profile preform. In the next step, Figure 4 The position indicated by the arrow in G is bent twice, wherein the bending is completed inward at an angle of 90° to form a complete finished intermediate I profile, i.e., an I profile preform, such as Figure 4 H displayed.

[0069] Similar to Example 1, all free edges (including one longitudinal edge) of the I-profile preform thus formed are sealed to form a leakproof and airtight interior space of the I-profile preform. The other manufacturing steps are similar to those presented in Example 1, so they will not be repeated for the clarity of this disclosure.

[0070] Example 3

[0071] Figure 5 A to Figure 5A further embodiment of the I-profile preform according to the invention is shown in G, wherein a further manufacturing step of the I-profile preform, namely the bending step, is also illustrated.

[0072] In general, the structure of the I-profile preform is substantially similar to that of the I-profile preform shown in the first and second embodiments, except that the I-profile preform according to this embodiment is formed by an incomplete intermediate I-profile, rather than by two matching E-profiles and C-profiles or a complete intermediate I-profile. This solution is advantageous because it is possible to use the outer wall 1 of the first flange of the I-profile preform with different technical characteristics (such as thickness and / or material type), which translate into functional characteristics of the manufactured I-profile.

[0073] exist Figure 5 A to Figure 5 F schematically shows in successive steps a method for obtaining an I-profile preform according to this embodiment of the invention. The method first provides a preform having a valve element 7 ( Figure 5 A) and bend it twice at 90° along parallel lines (extending in the longitudinal direction of the I-profile preform) to obtain Figure 5 The intermediate product shown in B. The formed bend corresponds to the inner wall 2 of the first flange of the finished I-profile preform. In the next step, Figure 5 The intermediate product of B is along the previous bend ( Figure 5 C) bend the first web wall 3 and the second web wall 4 of the finished I-profile preform at 90° along two bending lines in the same direction to form the first web wall 3 and the second web wall 4 of the finished I-profile preform. Figure 5 As shown in FIG. 1 , two bends are made in the middle region between the first web wall 3 and the second web wall 4 in the opposite direction to the previous bends. These bends are made inwards at an angle of 90° to form the inner wall 6 of the second flange and the outer wall 5 of the second flange of the finished I-profile preform. In the next step (as shown in FIG. Figure 5 D), further bend another 90° in the same direction along the previous bending line to form an overlapping portion, which corresponds to Figure 5 The second flange of the incomplete finished I-profile shown in E (i.e., the two inner walls 6 of the second flange and the outer wall 5 of the second flange). Figure 5 The incomplete I-shaped material shown in E matches the flat strip of the outer wall 1 as the first flange, thereby forming Figure 5 The finished I-profile preform shown in F.

[0074] Analogously to Example 1, all free edges of the I-profile preform thus formed, including the two longitudinal edges (between the flat strips between the outer wall 1 of the first flange and the inner wall 2 of the first flange of the I-profile preform), are sealed (with seals 8), such as Figure 5 F, to form a leak-proof and airtight inner space of the I-profile preform. The other manufacturing steps are similar to those presented in Example 1, so they will not be repeated for the clarity of the present disclosure.

[0075] Figure 5 G is an axonometric view of the I-profile preform according to this embodiment of the invention before sealing the longitudinal edges and the front edge of the I-profile preform.

[0076] Alternatively, the step of introducing the fluid into the airtightly closed interior space of the I-profile preform may be performed using fluidized concrete, such as Fig.10 A to Fig.10 B. After the fluid concrete under appropriate pressure is introduced into the inner space of the I-profile precast member, the first web wall 3 and the second web wall 4, as well as the first inner wall 2 and the second inner wall 6 of the first flange and the first inner wall 6 of the second flange are deformed respectively. Fig.10 This is shown in section B. After the concrete has set, the I-profile thus formed is a wasting formwork (wasting frame).

[0077] Example 4

[0078] Figure 6 A to Figure 6 C shows another embodiment of the I-profile preform according to the invention.

[0079] In general, the structure of the I-profile preform is substantially similar to that of the I-profile preform shown in the third embodiment, except that the I-profile preform according to this embodiment is formed by two matching C-profiles, the webs of which correspond to each other, which are the first web wall 3 and the second web wall 4 of the I-profile preform, and the two flat strips are respectively the outer wall 1 of the first flange and the outer wall 5 of the second flange of the I-profile preform. This solution is advantageous because it is possible to use the outer wall 1 of the first flange and the outer wall 5 of the second flange of the I-profile preform with different technical characteristics (such as thickness and / or material type), which translate into the functional characteristics of the manufactured I-profile.

[0080] Figure 6 A schematically shows the steps of matching two C-profiles, where the valve element 7 is installed in the web of one profile. The two matching C-profiles corresponding to the web are supplemented with two flat strips as the outer wall 1 of the first flange and the outer wall 5 of the second flange of the I-profile preform. Figure 6In the next step shown in B, the free edges of the parts of the I-profile preform are sealed, and a seal is provided in the form of a seal 8 to the longitudinal edge between the outer wall 1 as the first flange and the upper flange of the matching C-profile, and correspondingly to the longitudinal edge between the flat strip of the outer wall 5 as the second flange and the lower edge of the matching C-profile, as shown in FIG. Figure 8 C Best in Show.

[0081] Figure 6 C is an axonometric view of the I-profile preform according to this embodiment of the invention before sealing the longitudinal edges and the front edge of the preform.

[0082] Example 5

[0083] exist Figure 7 A to Figure 7 A further non-limiting embodiment of an I-profile preform is shown in the axonometric view in C, while Figure 7 D to Figure 7 F shows an axonometric view of an I-profile manufactured using an I-profile preform. Each I-profile preform shown and each I-profile manufactured using an I-profile preform shown is accompanied by a corresponding cross section drawn in a plane intersecting the middle of the I-profile in the longitudinal direction. Figure 7 A to Figure 7 Each I-beam preform shown in C can be constructed according to any of the methods shown in Examples 1-4.

[0084] exist Figure 7 In A, the I-profile preform comprises an upper flange and a lower flange, which are rectangular in shape, and whose longitudinal edges are parallel to each other, and Figure 7 D shows an I-profile manufactured from this preform.

[0085] exist Figure 7 In B, the upper and lower flanges of the I-profile preform are shaped with concave longitudinal edges, similar to an hourglass shape, while Figure 7 F shows an I-profile manufactured from this preform.

[0086] exist Figure 7 In C, the upper and lower flanges of the I-profile preform are shaped with convex longitudinal edges, similar to a cylinder, while Figure 7 E shows an I-profile manufactured from this preform.

[0087] Figure 8 A to Figure 8 A further non-limiting embodiment of an I-profile preform is shown in C. The structure of the I-profile preform shown corresponds to the structure of the I-profile preform shown in Example 3, i.e. the structure is that the outer wall 1 of the first flange of the I-profile preform is a flat strip having a thickness greater than the wall forming the incomplete intermediate I-profile. However, Figure 8 A to Figure 8 The embodiment shown in C can also be implemented with other I-beam preform structures disclosed herein.

[0088] like Figure 8 A to Figure 8 As shown in Figure C, the I-profile preform can have flanges of different, symmetrical and asymmetrical widths, and webs of different heights. Figure 8 In the embodiment shown in A, the width of the first (upper) flange of the I-profile preform is greater than that of the second (lower) flange. Figure 8 The first flange of the I-profile preform shown in B similarly has a width greater than the second flange, and the web height is greater than Figure 8 The web height of the I-profile preform shown in A. Furthermore, Figure 8 The web of the I-section preform shown in C is shorter than Figure 8 B shows a web, and the width of the second (lower) flange is greater than the width of the first (upper) flange.

[0089] exist Fig. 9 A to Fig. 9 A further embodiment of an I-profile preform is shown in the axonometric view in C. Fig. 9 A to Fig. 9 Each I-beam preform shown in C can be constructed according to any of the methods shown in Examples 1-4. Fig. 9 A to Fig. 9 The embodiment of the I-profile preform shown in C has different flange geometries, wherein Fig. 9 The I-profile preform shown in A has a first (upper) flange having a rectangular first width and a second (lower) flange having a rectangular second width, the second width being smaller than the first width. Fig. 9 B shows an I-profile preform having a cylindrical first (upper) flange and a rectangular second (lower) flange. Fig. 9 The I-profile preform shown in C has a first (upper) flange that is hourglass-shaped and a second (lower) flange that is rectangular and has a significant width.

[0090] Example 6

[0091] The I-profiles manufactured by the method according to the present invention were subjected to comparative tests (based on numerical calculations) with standard I-profiles commonly used in the art. The results of the comparative tests are presented in Table 1. The I-profiles manufactured by the method according to the present invention tested are designated as IPEF and IPEF* in Table 1. The IPEF I-profile is a profile made entirely of steel plate with a thickness of 0.8 mm (Young's modulus of 207 GPa), so that each wall 1, 2, 3, 4, 5, 6 is a steel plate with the same thickness of 0.8 mm, as shown in Example 1. The IPEF*I-profile is a profile made of steel plate with a thickness of 1 mm (Young's modulus of 207 GPa), wherein the outer wall 1 of the upper flange and the outer wall 5 of the lower flange are flat bars of the same steel with a thickness of 3 mm, which corresponds to the I-profile manufactured by the I-profile preform constructed in Example 4. The length L of the IPEF and IPEF*I profiles and the comparative standard I profiles (IPE 100, IPE AA 100, IPE AA 80) is equal to 875 mm.

[0092] Each of the compared I-profiles also has substantially the same (external) geometric dimensions.

[0093]

[0094] Table 1-I Technical parameters of profiles

[0095] The following reference symbols are used in the table:

[0096] SSC - Calculated Stiffness - Compression

[0097] SSK - Calculated Stiffness - Torsion

[0098] SZ - Calculated Stiffness - Bending

[0099] W / SK-Buckling / Calculation of critical forces

[0100] L-Length

[0101] m-mass

[0102] MOD-abbreviation of model

[0103] Real-Actual

[0104] Comparing IPEF profiles made of steel sheets with a thickness of 0.8 mm with the standard I-profile IPE 100 (which has corresponding geometrical dimensions), it is observed that IPEF has almost three times higher torsional stiffness SSK at a mass of 0.31 for IPE 100. Its higher torsional stiffness SSK is due to its spatial geometry, which is more similar to a closed profile. The significantly lower compressive stiffness SSC is a result of the lower mass, smaller cross-sectional area, and convex geometry of the IPEF profile. The lower bending stiffness SZ is also a result of the smaller cross-sectional area.

[0105] The situation is similar when compared to the standard IPE AA 100I profile. The SSK, SSC and SZ stiffnesses of the IPE AA 100I profile are lower than those of the IPE 100I profile because the IPE AA 100I profile has a smaller thickness of flange and web.

[0106] When comparing I-profiles of the same length and very similar mass, it can be observed that the stiffness of the FIDU I-profile is significantly increased compared to the standard I-profile.

[0107] Furthermore, the torsional stiffness SSK of the IPEF*I profile, whose outer wall 1 of the first flange and the outer wall 5 of the second flange are flat strips with a thickness of 3 mm and whose other walls 2, 3, 4, 6 are made of steel sheets with a thickness of 1 mm (obtaining a total mass of 4.19 kg), is almost 20 times higher than that of the I profile IPE AA 80 (mass of 4.26 kg). This is due to the significantly larger moment of inertia of the area for very similar cross-sectional areas. When subjected to compression, the stiffness of the IPEF*I profile decreases significantly, which is caused by the convex geometry. The flexural stiffness SZ of the IPEF*I profile is increased by a factor of 6.5 due to a better distribution of the wall thickness in the profile and the larger volumetric dimensions, while maintaining a similar mass.

[0108] Due to its non-uniform geometry and thin walls, the IPEF I profile is susceptible to buckling W. The calculated critical force SK is 6.5 kN. On the other hand, the calculated critical force SK for the IPEF*I profile is 75.6 kN. It is higher than the calculated critical force SK for the IPE AA 80I profile and slightly lower than the critical force SK for the PE AA 100I profile (which has similar volumetric dimensions but a larger mass).

[0109] The calculations are based on the actual geometry of IPEF and IPEF* profiles, whereas the geometry of standard IPE profiles does not take into account imperfections, which could have a negative impact on the stiffness values ​​SSK, SSC and SZ as well as the calculated critical force value SK. When determining the stiffness of bent I-profiles, points located in the lower tension layer are taken into account, where the applied forces do not cause local deformations.

[0110] Reference numerals list:

[0111] 1-I The outer wall of the first flange of the profile

[0112] 2-Inner wall of the first flange of the I profile

[0113] 3-I The first web wall of the profile

[0114] 4-I Second web wall of profile

[0115] 5-I The outer wall of the second flange of the profile

[0116] 6-Inner wall of the second flange of the I profile

[0117] 7-Valve element

[0118] 8-Seals

[0119] 9- Supply pipeline

Claims

1. An I-profile prefabricated part, characterized in that: The prefabricated part comprises The outer wall (1) of the first flange and two inner walls (2) of the first flange arranged in adjacent relationship relative to the outer wall (1) of the first flange, a first web wall (3), wherein said first web wall (3) extends perpendicularly to said outer wall (1) of said first flange, and a second web wall (4) arranged in a plane parallel to the first web wall (3), wherein the second web wall (4) is arranged away from the first web wall (3) in a direction perpendicular to the plane, an outer wall (5) of a second flange, wherein said outer wall (5) of said second flange extends perpendicularly to said plane, and two inner walls (6) of the second flange arranged in adjacent relationship relative to the outer wall (5) of the second flange, wherein the walls (1, 2, 3, 4, 5, 6) each comprise a deformable metal sheet and are arranged relative to each other in a coupled relationship to provide a fluid seal in cross section, forming a closed empty I-shaped interior space of the I-profile preform, and, A valve element (7), wherein the valve element (7) is arranged on one of the walls (1, 2, 3, 4, 5, 6) and is configured to transmit the metal plate deforming fluid pressure to the inner space through the valve element (7).

2. The I-profile preform according to claim 1, characterized in that: Each of the two inner walls (2) of the first flange is arranged in a common plane extending parallel to the outer wall (1) of the first flange.

3. The I-profile preform according to claim 1, characterized in that: Each of the two inner walls (6) of the second flange is arranged in a common plane extending parallel to the outer wall (5) of the second flange.

4. The I-profile preform according to any one of claims 1 to 3, characterized in that: The outer wall (1) of the first flange, the first inner wall (2) of the first flange, the first web wall (3), the first inner wall (6) of the second flange, and the outer wall (5) of the second flange are formed from a piece of material to form an E-profile, while the second inner wall (2) of the first flange, the second web wall (4) and the second inner wall (6) of the second flange are formed from a piece of material to form a C-profile.

5. The I-profile preform according to any one of claims 1 to 3, characterized in that: The first inner wall (2) of the first flange, the first web wall (3), the first inner wall (6) of the second flange, the outer wall (5) of the second flange, the second inner wall (6) of the second flange, the second web wall (4), and the second inner wall (2) of the first flange are formed from a piece of material to form an incomplete intermediate I-profile.

6. The I-profile preform according to any one of claims 1 to 3, characterized in that: The first inner wall (2) of the first flange, the first web wall (3) and the first inner wall (6) of the second flange are formed from one piece of material to form a C-profile, and / or the second inner wall (6) of the second flange, the second web wall (4) and the second inner wall (2) of the first flange are formed from one piece of material to form a C-profile.

7. The I-profile preform according to any one of claims 1 to 3, characterized in that: All walls (1, 2, 3, 4, 5, 6) are formed from one piece of material, forming a complete intermediate I-profile.

8. The I-profile preform according to any one of claims 1 to 3, characterized in that: The outer wall (1) of the first flange and / or the outer wall (5) of the second flange are formed by flat strips.

9. The I-profile preform according to any one of claims 1 to 3, characterized in that: The walls (1, 2, 5, 6) forming the first flange and / or the second flange converge in the longitudinal direction, thereby defining a cylindrical or hourglass shape.

10. The I-profile preform according to any one of claims 1 to 3, characterized in that: The edges of the unconnected walls (1, 2, 3, 4, 5, 6) are sealed with a seal (8), thereby forming a closed, airtight, empty interior space of the I-profile preform.

11. The I-profile preform according to claim 10, characterized in that: The sealing member (8) is a fusion weld, a pressure weld, an adhesive layer, or a lap joint.

12. The I-profile preform according to any one of claims 1 to 3, characterized in that: The first flange has a different lateral width than the second flange.

13. The I-profile preform according to any one of claims 1 to 3, characterized in that: The valve element (7) is a pneumatic or hydraulic connection.

14. The I-profile preform according to any one of claims 1 to 3, characterized in that: The valve element (7) is arranged on the first web wall (3) or the second web wall (4).

15. A method for manufacturing an I-profile, characterized in that: The method comprises the following steps: a) providing an I-profile preform as defined in any one of claims 1 to 14; b) sealing the edges of the unconnected walls (1, 2, 3, 4, 5, 6) with a seal (8) to form a closed, airtight, empty interior space of the I-profile preform; c) connecting a source of pressurized fluid to said valve element (7); d) inserting the I-profile preform between pressure plates so that the pressure plates are in contact with the flanges of the I-profile preform; e) introducing the pressurized fluid into the interior space of the I-profile preform.

16. The method for manufacturing an I-shaped material according to claim 15, characterized in that: In the step b), the sealing is achieved by fusion welding, pressure welding, gluing or crimping.

17. The method for manufacturing an I-shaped material according to claim 15, characterized in that: In the step e), the fluid includes air, engine oil, water, fluid concrete, or fluid plastic.

18. The method for manufacturing an I-shaped material according to claim 15, characterized in that: During said step d), a force is applied to said pressure plate in the direction of said I-profile preform.

19. The method for manufacturing an I-shaped material according to claim 15, characterized in that: The step e) is achieved at room temperature or at high temperature.

20. The method for manufacturing an I-shaped material according to claim 15, characterized in that: The pressure of the fluid introduced to the I-profile preform was 5 bar.

21. The method for manufacturing an I-shaped material according to claim 15, characterized in that: In the step e), a pressurized fluid is introduced into the inner space of the I-profile preform for 1 minute, and then a constant pressure is maintained in the I-profile preform for 30 seconds.

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