Composite beam

Abstract

The invention relates to a composite beam having a hollow profile (2). The invention relates to a hollow profile (2) comprising or consisting of aluminum or an aluminum alloy or other material, the hollow profile (2) having an inner space (4) and a core (3) arranged in the inner space, the core (3) comprising or consisting of wood. The core (3) is arranged without play in the interior (4) and is pressed against an inner wall (8) of the hollow profile (2) from each side in the cross-sectional direction. The invention also relates to a method and a device.

Description

Technical Field

[0001] This invention relates to a composite beam, as well as a method and apparatus for manufacturing the composite beam. Background Technology

[0002] Beam-like devices or force-transmitting elements are configured to absorb loads. In the prior art, these elements are known to have different design forms, particularly regarding the materials used. Due to their lighter weight, aluminum or aluminum alloys, in addition to iron, steel, and other metals, are also used in the prior art to manufacture beams, which can be obtained, for example, in the form of hollow beams through an extrusion process.

[0003] These types of beams are used for various purposes, primarily as load-bearing or decorative elements in the fields of construction, machinery, equipment manufacturing, and vehicle manufacturing. Examples include beams and profiles frequently used in laboratories or equipment to construct skeletal structures. These profiles have corresponding notches to allow different profiles to be connected to each other using sliding nuts and screws. Other examples include tent poles, stage profiles, round tubes for constructing grandstands, profiles for mounting photovoltaic equipment, fences, handrails, masts, supports, poles (e.g., for flags, traffic signs, power lines), and many other applications.

[0004] In most applications, reducing material usage is sought to optimize cost and weight. This is typically achieved by reducing the wall thickness of hollow profiles. However, to maintain the desired load-bearing strength of aluminum or aluminum alloy-based beams, a minimum wall thickness must be maintained based on the required load-bearing capacity, or reinforcing ribs, i.e., segmented thickened wall sections, must be provided.

[0005] These limitations typically prevent further reductions in the amount of material used. Furthermore, using additional reinforcing ribs increases production costs and reduces efficiency. Finally, in most cases, material reduction is accompanied by some degree of deterioration in mechanical properties, such as increased deflection. Summary of the Invention

[0006] Now, one task can be viewed as overcoming the shortcomings of the prior art and creating a beam that allows for further reduction in material requirements, particularly the requirement for metallic materials, and possesses at least substantially the same mechanical properties as the beams described above. Within the framework of this invention, it is now surprisingly found that these and other tasks can be addressed, depending on the circumstances, by a composite beam comprising a hollow profile made of aluminum or an aluminum alloy and a wood core introduced into the hollow profile. The hollow profile may also comprise other metals (e.g., iron or steel or other light metals) or be composed of other metals. Furthermore, the hollow profile may also comprise plastic or a plastic composite material or be composed of plastic or a plastic composite material. The plastic composite material may include fiber-reinforced plastics or composite materials containing prepregs, etc.

[0007] When the core is seamlessly introduced into the interior space of a hollow profile, the mechanical properties of the wood can be combined with the material properties of the hollow profile in a favorable manner.

[0008] The core can be a single core or a multi-piece core assembled together through material bonding, friction bonding, and / or shape bonding.

[0009] Overall, it must be emphasized that in composite beams, since most of the mechanical load-bearing capacity is provided by the core, the wall thickness of hollow profiles can be kept very thin.

[0010] In particular, this allows for a further reduction in the thickness of the aluminum or aluminum alloy material in the hollow beams. Here, the hollow profile can function as a cladding layer for the wood core, thus combining the advantageous properties of both materials.

[0011] While maintaining or even improving certain mechanical properties, it is possible to forgo the use of reinforcing webs or reinforcing strips, thereby keeping the material thickness of aluminum or aluminum alloys at a low level.

[0012] This webless construction of the inner wall of the hollow profile can also improve the productivity of beam manufacturing because higher throughput can be achieved due to the reduction in geometric complexity (e.g., when extruding hollow profiles).

[0013] It may also be stipulated that the cross-sectional area of ​​the hollow profile accounts for only a very small proportion of the total cross-sectional area of ​​the composite beam, that is, particularly less than 10%, and even less in special implementation schemes.

[0014] Unless otherwise used or clearly apparent from the context, in connection with this specification, a surface lying in a plane transverse to the longitudinal extension direction of the composite beam is referred to as a cross section. The longitudinal extension direction is, in particular, the direction corresponding to the maximum geometric extension dimension (i.e., the length of the composite beam).

[0015] Here, the material cross-section specifically refers to the cross-sectional area occupied by a particular material. The cross-section or area of ​​the entire beam is typically defined by the outer contour of the hollow profile.

[0016] The seamless arrangement of the core within the hollow profile's interior space is achieved, in particular, by introducing a core with a low moisture content into the hollow profile's interior space, whereby the core swells as it absorbs moisture. Absorption of water or other liquids that cause swelling can occur passively (e.g., by absorbing moisture from the air) and / or actively (e.g., by spraying liquid water or by targeted contact with water vapor). Swelling can also occur with other polar liquids or gases (commonly referred to as swelling fluids), such as formaldehyde, ammonia, etc. Depending on the circumstances, these substances may also be soluble in water, and the solution can act as a swelling fluid.

[0017] This swelling specifically achieves a compression zone in the core arranged within the hollow profile, where the core material is compacted by pressing against the inner surface of the hollow profile. This compression zone also features a continuous transition to the further uncompressed material within the core.

[0018] Depending on the situation, only a small proportion of the outer periphery of the core does not contact the inner surface of the hollow profile. The core surface can also be designed to be toothed, minimizing the frictional area between the core and the inner wall of the hollow profile. Specifically, the shaping of the contact surface ensures that the core and the hollow profile (sheath) can only be separated from each other in their swollen state by overcoming friction. In particular, for complex internal shapes (ribs, edges, webs, etc.), it is recommended to manufacture cores with corresponding notches to simplify the interlocking process. The contact between the hollow profile and the core allows the composite beam to have exceptionally high mechanical stability.

[0019] In the installed state, i.e. in the working state of the composite beam, the core can particularly have a moisture content of more than 6.0 wt%, particularly more than 8.0 wt%, for example, between 6.0 wt% and 17 wt%, or between 8.0 wt% and 14 wt%.

[0020] For composite beams, compared to a reference composite beam with the same hollow profile external cross-section but without a core, the mass per unit length of the hollow profile can be reduced by at least 20%, specifically by at least 30% or at least 40%. Here, the reference composite beam can be designed to have a load-bearing capacity comparable to that of the composite beam.

[0021] Composite beams may have a sealing element that allows the core fluid to be sealed tightly within the internal space of the hollow profile.

[0022] The sealing element can be, for example, a sealing element manufactured by injection molding. Generally, any plastic, synthetic resin, or metal capable of achieving a fluid seal can be used. The sealing element can also be manufactured by additive manufacturing or by compression molding.

[0023] In one embodiment, the sealing element is a cap, which can be obtained, for example, by injection molding. The cap can be disposed on the end face of the composite profile by a bonding process.

[0024] The cap may be made of materials such as rubber, plastic, metal or silicone, or may include one or more of the above materials.

[0025] As a supplement or alternative, the sealing element can be manufactured by coating it with a liquid sealing material (such as silicone or resin).

[0026] For example, the cap can be bonded to the end face of the composite beam using a sealing adhesive. Alternatively, the end face of a composite consisting of a hollow profile and a core can be immersed in a sealant to obtain a sealing element.

[0027] This sealing element can be used alone or in combination with another sealing element, and is also achieved by carbonizing the end faces of the core. This is specifically used to improve resistance to microorganisms.

[0028] A composite beam with a hollow profile is also described, the hollow profile comprising or composed of aluminum or aluminum alloy, wherein the hollow profile has an internal space and a core disposed in the internal space, wherein the core comprises or is formed of wood.

[0029] As may be specified, the core is arranged without gaps in the internal space and presses against the inner wall of the hollow profile from each side in the cross-sectional direction.

[0030] As may be specified, more than 60%, preferably more than 80%, and more preferably more than 95% of the cross-sectional periphery of the core is supported on the inner wall of the hollow profile via surface contact or segmented contact (e.g., rib contact).

[0031] As may be specified, the cross-sectional area of ​​the hollow profile material is less than 50% of the cross-sectional area of ​​the composite beam, preferably less than 30%, and more preferably less than 25%.

[0032] As may be specified, the density of the composite beam is less than 1000 kg / m3, preferably less than 500 kg / m3, and more preferably less than 300 kg / m3.

[0033] It may be specified that the inner wall of the hollow profile has no web, that is, specifically no reinforcing web or reinforcing rib extending along the longitudinal extension direction of the hollow profile.

[0034] It may be specified that the hollow profile has a substantially constant cross-section along its entire longitudinal extension, i.e., in particular a constant cross-sectional geometry and a constant cross-sectional area. Depending on the circumstances, joining at the profile and subsequent forming steps may cause changes in the cross-section.

[0035] As may be specified, the hollow profile has a plurality of internal spaces extending in the longitudinal direction of the hollow profile and separated from each other, wherein a core is arranged in each of the internal spaces.

[0036] As may be specified, the hollow profile is an extruded profile.

[0037] As may be specified, the core has a compression zone along its outer cross-sectional periphery, in which the core is compacted due to pressure acting between the inner wall of the hollow profile and the outer surface of the core.

[0038] As may be specified, the hollow profile is formed as a single unit in cross-section and completely surrounds the core.

[0039] As may be specified, the hollow profile may be a closed profile.

[0040] As may be specified, the longitudinal extension direction of the wood fibers in the core is substantially parallel to the longitudinal extension direction of the hollow profile.

[0041] As may be specified, the core may be constructed as a hollow body, wherein the core may be formed by a plurality of components that together form the hollow body.

[0042] As may be specified, the core is a hollow box-shaped profile formed by multiple wooden boards, which are preferably connected to each other with mortise and tenon joints.

[0043] As may be specified, the core may occupy a maximum of 70% of the cross-sectional area of ​​the internal space of the hollow profile.

[0044] As may be specified, the core may be constructed as a box-shaped profile, particularly a two-piece or four-piece box-shaped profile.

[0045] As may be specified, the core may be constructed as a cross beam.

[0046] As required, a sealing element may be provided to seal the core fluid, particularly water vapor, within the internal space.

[0047] As may be specified, the sealing element is formed by a cap, which is bonded to the composite at least one end face.

[0048] As may be specified, the sealing element is formed of a sealing layer, which is coated on at least one end face of the composite.

[0049] As may be specified, the sealing element is formed by a core carbonization zone located on at least one end face of the composite.

[0050] In other similarly disclosed embodiments, the hollow profile may also comprise, or be composed of, materials other than aluminum or aluminum alloys as described above. This may be one or more of the following materials: metals, particularly steel; plastics; wood-plastic composites. The aluminum or aluminum alloy may also be other light metals.

[0051] Hollow profiles can also be obtained by injection molding a core, for example, by injection molding a core with a plastic or wood-plastic composite material. Co-extrusion is an example of a production method in which the core is co-extruded with other materials. Therefore, hollow profiles can also be hollow profiles co-extruded around a core.

[0052] Also disclosed are embodiments of composite beams in which the core comprises or is composed of other lignocellulose-containing materials, such as wood-plastic composites. The core may also be formed, for example, from plywood or pressed wood.

[0053] The core may comprise, or be composed of, a lignocellulose-containing fibrous material that has been chemically and / or physically modified (particularly chemically and / or physically modified wood). The modification may be selected from one or more of the following: acetylation; impregnation (e.g., resin impregnation).

[0054] These other implementation schemes can, depending on the circumstances, also solve at least some of the tasks mentioned at the beginning.

[0055] The composite beams described in this article can be used in various applications. Their advantageous properties are particularly evident when used as bending beams or compression members in both static and dynamic applications.

[0056] Exemplary applications include: garden fencing; stairs; railings; equipment; machinery (e.g., conveyor technology, machine frames, guide rails, etc.); vehicle manufacturing (e.g., battery trays, frame structures); ladders; photovoltaic profiles; system architecture; scaffolding erection; shelving manufacturing; furniture manufacturing; container manufacturing; mesh boxes; and facade construction.

[0057] Other potential applications include beams and profiles frequently used in laboratories or equipment to construct skeletal structures. These profiles have corresponding notches to allow different profiles to be connected to each other using slider nuts and screws. Other examples include tent poles, stage profiles, round tubes for building grandstands, profiles for mounting photovoltaic equipment, fences, handrails, masts, supports, poles (e.g., for flags, traffic signs, wires, etc.), and profiles used in frame or support structures in automobile or aircraft manufacturing.

[0058] Therefore, structures comprising at least one composite beam as described herein are also disclosed. The composite beam contained in these structures may have any of the features disclosed herein in connection with composite beams.

[0059] Exemplary structures include: a vehicle body (also referred to as a space frame) having load-bearing beams made of the composite beams; a ladder having treads and / or side rails made of the composite beams; and photovoltaic equipment, wherein photovoltaic modules are arranged on a support structure comprising one or more composite beams.

[0060] Especially in the case of profiles that mainly bear buckling stress through lateral forces (such as handrails, balcony railings, etc.), the walls of hollow profiles can be kept particularly thin.

[0061] A fence profile comprising a composite beam having one or more of the features disclosed herein is also disclosed. A fence comprising multiple such fence profiles is also disclosed.

[0062] A window frame profile is also disclosed, comprising a composite beam having one or more of the features disclosed herein. A window frame comprising a plurality of such window frame profiles interconnected with each other is also disclosed.

[0063] A tent pole is also disclosed, comprising or consisting of a composite beam having one or more of the features disclosed herein.

[0064] A mechanical engineering profile is also disclosed, comprising or consisting of a composite beam having one or more of the features disclosed herein.

[0065] A circular profile is also disclosed, comprising or consisting of a composite beam having one or more of the features disclosed herein.

[0066] In addition, a method for manufacturing composite beams is disclosed, which may include the following steps, depending on the circumstances: (a) Provide hollow profiles; (b) Providing a core having a sub-dimension relative to the internal space of the hollow profile; (c) Introducing the core into the internal space of the hollow profile; and (d) The core is swollen in the internal space of the hollow profile, thereby the core is arranged in the internal space without gaps and presses against the inner wall of the hollow profile from each side in the cross-sectional direction.

[0067] In this method, in particular, the hollow profile and / or core may have one or more of the features described herein in conjunction with the composite beam.

[0068] In one particular embodiment of the method, the core is hollow or has a cavity. In this case, swelling can be achieved by introducing a swelling fluid (especially water) into the cavity, for example, using a spray gun.

[0069] The hollow core can be manufactured as a single piece, for example, by drilling or milling out the cavity. A hollow core can also be obtained by joining two half-shells together. Furthermore, a hollow core can be obtained by joining multiple (e.g., 3 to 10, preferably 4) hollow box-shaped elements. These hollow box-shaped elements can in particular be flat components, such as planks, columns, or beams.

[0070] To form a hollow box or hollow core, the joints of hollow box-shaped components can be connected using tongue and groove, semi-circular groove, V-groove, W-groove, interlocking profiles similar to flooring, or adhesive joints. For adhesive joints, all known and suitable adhesive or friction welding connections can be used.

[0071] The undersized core can be achieved by drying the core, specifically by reducing the moisture content of the core before it is introduced into the interior space of the hollow profile.

[0072] Before being introduced into the interior space of a hollow profile, the core can be pretreated or prepared, for example by trimming, planing, shaping and / or drying.

[0073] In an intermediate step, a core blank can be formed, the shape of which approximates the shape of the core to be introduced into the interior space of the hollow profile.

[0074] The hollow profile and the core can be joined by fixing the hollow profile and driving the core in, either by using a glue-applying roller or a hydraulic device that drives a punch at the end of the hollow profile. Alternatively, the core can be fixed and the hollow profile can be pushed through the core using a glue-applying roller or a punch.

[0075] When the core is introduced into the interior space of the hollow profile, the moisture content of the core can be between 0% by weight and 10% by weight, preferably between 3.0% by weight and 6.0% by weight.

[0076] After the core is introduced, a swelling fluid (especially water) can be applied to it to achieve a water content between 6.0% and 17% by weight (e.g., between 8.0% and 14% by weight).

[0077] Advantageously, the moisture content when the core is introduced into the interior space of the hollow profile should be lower than the moisture content after introduction or when the composite beam is in operation. Here, the moisture content can be at least 1.0% by weight, at least 2.0% by weight, or at least 3.0% by weight lower.

[0078] After the swelling fluid is applied, sealing elements can be arranged on the end face of the composite beam to seal the core fluid (especially water seal and / or water vapor seal) within the internal space of the hollow profile.

[0079] Sealing components can be achieved, for example, by installing a cap, by carbonizing the end face, by sealing the end face, or by other measures that can achieve fluid sealing.

[0080] Examples of manufacturing sealing components are as follows: Thermoplastic and / or reactive resins (especially by injection molding) are injection molded onto the end face of the composite beam.

[0081] The end face of the composite beam is welded and / or brazed to a metal cap.

[0082] The end face of the composite beam is bonded to the cap (especially a metal or plastic cap) using an adhesive.

[0083] Press the end face of the composite beam against the cap (especially a metal or plastic cap).

[0084] The end faces of the composite beam are sealed by applying adhesives and / or sealants.

[0085] Use thermosetting plastic to seal the end face.

[0086] As a supplement or alternative to the above measures, the end face of the core may be modified, for example by carbonization (e.g., flame surface treatment) or by steam explosion (e.g., acoustic steam explosion).

[0087] Composite beams can undergo post-treatment after being enclosed, such as coating and / or moisture treatment.

[0088] A method for manufacturing composite beams is also disclosed, comprising the following steps: - Provide hollow profiles, said hollow profiles comprising or composed of aluminum or aluminum alloys; - Provide a core, the core comprising or composed of wood, wherein the core has a sub-dimension compared to the internal space of the hollow profile; - Introducing the core into the internal space of the hollow profile; and - By means of a swelling fluid, particularly water, the core is swollen in the internal space of the hollow profile, thereby allowing the core to be arranged without gaps in the internal space and pressed against the inner wall of the hollow profile from each side in the cross-sectional direction.

[0089] As may be specified, the core may have a cavity into which the swelling fluid is introduced.

[0090] As may be specified, the swelling fluid may be introduced via a spray gun inserted into the cavity.

[0091] As appropriate, the water content of the core may be measured before it is introduced into the internal space, and the amount of the swelling fluid may be controlled to accommodate a predetermined target water content of the core.

[0092] As may be specified, the core may be sharpened at its end face and introduced into the internal space with the sharpened end face facing forward.

[0093] As appropriate, the core may be pre-treated before being introduced into the internal space, in particular by planing, milling and / or cutting.

[0094] As may be specified, the core is formed by joining multiple components.

[0095] As may be specified, the core has a moisture content between 0% by weight and 10% by weight, particularly between 3.0% by weight and 6.0% by weight, when introduced into the internal space, and / or the core has a moisture content between 6.0% by weight and 17% by weight, particularly between 8.0% by weight and 14% by weight, after swelling.

[0096] Furthermore, an apparatus for manufacturing composite beams is described. This apparatus can be specifically configured or adapted to manufacture the composite beams described herein. Where a composite beam or a component thereof is described herein, any features described in connection with the composite beam or its component may be specified in this respect.

[0097] The device may have a storage area. This storage area may store raw materials, specifically blanks for the composite beam core. The blanks for the core may be wooden pillars, planks, or beams. The blanks may also be any other blocks of wood, or generally blocks comprising or composed of lignocellulose-containing materials.

[0098] The storage area may have air conditioning equipment for adjusting or setting air humidity and / or ambient temperature. For example, the air conditioning equipment may be configured to adjust the air humidity and / or temperature so that the wood stored in the storage area reaches a predetermined equilibrium moisture content, such as 12% by weight.

[0099] The device may also have a preparation area. This preparation area may have at least one (preferably multiple) devices that allow the preparation or pretreatment of raw materials to give them a shape corresponding to the final core shape or core blank.

[0100] The preparation area may include a defect identification station. This station is specifically configured to identify defects in the blank intended for manufacturing the core. Such defects may be, for example, knots in a wooden beam or post. The defect identification station may also include a marking device configured to mark the defects identified in the raw material.

[0101] After the defect identification station, a cutting station, particularly a severing station, can be set up where the identified defects can be removed from the material block (i.e., from the blank).

[0102] The preparation area may also include a processing station equipped with a connecting device and / or a planing device. The connecting device allows multiple portions of the raw material to be joined together, for example, to obtain the desired length, thickness, and / or geometry of the core from multiple blocks of wood. The joining in the connecting device can be performed, for example, by means of finger jointing. The planing device allows the raw material to be processed into the desired shape or at least into its original shape (i.e., in the form of a core blank). This core blank, in particular, can have an interference fit compared to the core to be introduced into the interior space of the hollow profile.

[0103] The core blank can also be a hollow core blank assembled from multiple components. Its base material can be a wooden board or wooden column that has been split, cut, or segmented into smaller components.

[0104] A buffer station can be set up after the preparation area, where the prepared raw materials, especially the core blank, can be stored in an intermediate manner. For example, any adhesive joints formed in the connecting device can be cured in the buffer station.

[0105] The apparatus may include a post-drying zone in which the material subsequently used as the core (i.e., particularly the core blank) is dried. Specifically, the post-drying zone is configured to reduce the moisture content of the core. For this purpose, the post-drying zone may have control devices for air humidity and / or temperature. In particular, heating devices may be provided to over-dry the core, for example, to a moisture content of approximately 6% by weight.

[0106] The device then specifically includes a joining station where, if necessary, the prepared core can be introduced into the interior space of the hollow profile.

[0107] A finishing station or forming station may be set up before the joining station to bring the core blank to its final shape (i.e., to form the core). A measuring station may be assigned to the finishing station to measure the dimensions and / or moisture content of the core blank. The core blank can be processed based on the measurements obtained from the measuring station.

[0108] The finishing station may include a planing device. The planing device may be configured to give the core blank its final shape before it is introduced into the interior space of the hollow profile.

[0109] The joining station may include a holding device for the hollow profile and a conveying device for the core. In particular, the joining station is configured to introduce the core into the interior space of the hollow profile.

[0110] An application device may be installed in or before the bonding station, configured to apply an adhesive (particularly a bonding agent) to specific areas of the core. For example, this adhesive can be used to bond multiple parts of the core together.

[0111] A swelling station can be arranged after the joining station. This swelling station is specifically equipped with a device configured to increase the water content of the core.

[0112] In one embodiment, the swelling station may have a spray gun used to apply a swelling fluid (particularly water) to the core. Advantageously, the spray gun is configured to be inserted into the cavity of the core. The spraying device can also be installed in front of the stack of composite beams. In this process, a fan is used to transport the swelling fluid into or through the cavity.

[0113] A weighing device can be installed to determine the weight of the composite formed by joining the core and the hollow profile. If the moisture content of the core is known from measurements taken before joining, the amount of water required to achieve the predetermined target moisture content of the core can be determined using the value obtained from the weighing device.

[0114] Quality control can be carried out using a weighing device, which involves checking whether enough water has been introduced to achieve the desired moisture content.

[0115] A sealing station can be included in the equipment to seal the composite beam at its end faces after joining. This sealing station may include an injection molding device.

[0116] A post-processing station may be set up as needed to apply a coating or perform other post-treatments on the composite beam.

[0117] Furthermore, an apparatus for manufacturing composite beams is described, which includes the following equipment parts: - A storage area for storing raw materials for the core of composite beams, wherein the storage area specifically includes air conditioning equipment for setting a predetermined temperature and / or humidity; -Preparation area for forming a core blank from the raw materials, wherein the core blank may have an interference dimension compared to the core; - Post-drying zone, used to reduce the moisture content of the core blank and form the core; - A bonding station for introducing the core into the interior space of the hollow profile; and - a swelling station for bringing the core into contact with a swelling fluid (particularly water).

[0118] As may be specified, the preparation area may include one or more of the following devices: - A defect identification station for identifying defects in the raw materials used for the core; and a defect removal station, such as a cutting station, which may be assigned to the defect identification station as appropriate. - A connection station for joining multiple components of the raw material; - Planing station; - Cutting station.

[0119] As may be specified, the post-drying zone may include air conditioning equipment for setting a predetermined temperature and / or humidity, wherein the air conditioning equipment includes heating equipment.

[0120] As may be specified, a finishing station may be arranged after the post-drying zone, wherein the finishing station includes one or more of the following devices: - A humidity measuring device for measuring the moisture content of the core blank or the core before the core is introduced into the internal space of the hollow profile; - Planing device; - Milling device.

[0121] As may be specified, the swelling station includes a spray gun for contacting the core with the swelling fluid, wherein the spray gun is specifically configured to be inserted into the cavity of the core.

[0122] As may be specified, the equipment may also include a sealing device for fluid sealing of the end face of the composite beam.

[0123] Other features are derived from the patent claims, drawings, and description of the embodiments. Attached Figure Description

[0124] The topics described herein will be discussed in detail below with the aid of exemplary embodiments.

[0125] in: Figure 1 A schematic cross-sectional view of the composite beam according to the first embodiment is shown; Figure 2 A schematic cross-sectional view of the composite beam according to the second embodiment is shown; Figure 3 A schematic cross-sectional view of the composite beam according to the third embodiment is shown; Figure 4 A schematic diagram of a composite beam according to the fourth embodiment is shown; Figure 5 A schematic cross-sectional view of the composite beam according to the fifth embodiment is shown; Figure 6 A schematic view of the composite beam according to the sixth embodiment is shown; Figure 7 A schematic diagram of a device according to one embodiment is shown; Figure 8 A schematic cross-sectional view of the composite beam according to the seventh embodiment is shown; Figure 9 A schematic cross-sectional view of the composite beam according to the eighth embodiment is shown; Figure 10 A schematic cross-sectional view of the composite beam according to the ninth embodiment is shown; and Figure 11 A schematic cross-sectional view of a composite beam according to the tenth embodiment is shown.

[0126] Unless otherwise specified, the following features are shown in the accompanying drawings: composite beam 1; hollow profile 2; core 3; internal space 4 (belonging to hollow profile 2); compression zone 5; sealing element 6; longitudinal extension direction 7 (belonging to hollow profile 2); inner wall 8 (belonging to hollow profile 2); cavity 9 (belonging to core 3); component 10 (belonging to core 3); storage area 11; preparation area 12; post-drying area 13; joining station 14; swelling station 15; shape-fitting connection 16; defect identification station 17; connection station 18; planing station 19; finishing station 20; sealing device 21; buffer station 22; drying chamber 23; buffer chamber 24; post-processing station 25; wood board 26. Detailed Implementation

[0127] Figure 1 A schematic cross-sectional view of a composite beam 1 according to a first embodiment is shown. The composite beam 1 includes a hollow profile 2 and a core 3 disposed within an internal space 4 of the hollow profile 2.

[0128] The hollow profile 2 is an extruded aluminum profile. The core 3 is formed of wood and assembled from two parts 10, thereby forming a box-shaped profile with a cavity 9 in its center. The two parts 10 of the core 3 are connected and glued together via a form-fitting connection 16.

[0129] A compression zone 5 extends along the outer periphery of the core 3, in which the material of the core 3 is compacted. This compaction is caused by the pressure applied by the core 3 to the inner wall 8 of the hollow profile 2. This pressure is caused by increasing the moisture content of the core 3 after the core is introduced into the internal space 4 of the hollow profile. Here, the fiber direction of the wood in the core 3 extends substantially along the longitudinal direction of the composite beam 1 or the hollow profile 2.

[0130] The core 3 presses against the inner wall 8 of the hollow profile 2 from all sides with its outer periphery, and its entire outer periphery is in contact with the inner wall 8. In other words, there is no gap between the inner wall 8 and the core 3.

[0131] In this embodiment, the water content of the core is approximately 12% by weight.

[0132] Figure 1 The composite beam 1 shown can be obtained through a method embodiment described in detail below. The method steps can be combined as follows. Figure 7 Execute in the described device.

[0133] In the first step, the raw materials used for the core are adjusted to a predetermined moisture content. This can be carried out in storage area 11, which is suitably equipped with air conditioning.

[0134] The core 3 is then supplied from this raw material. For this purpose, the raw material is pretreated. Any material defects present in the wood are removed, and a core blank is formed, which has a larger dimension than the core 3, i.e., it has an interference fit. This can be carried out in the preparation area 12 of the equipment.

[0135] Next, the core blank is over-dried, in this embodiment to a moisture content of approximately 6% by weight. This can be done in the post-drying zone 13 of the apparatus.

[0136] The moisture content of the over-dried core blank was then measured and it was finished. For this purpose, the area forming the cavity 9 was milled out, the element for the shape-fitting connection 16 was milled in, and the end face of the core blank was beveled to form a tip. This formed the two components 10 of the core 3.

[0137] Before the core 3 is introduced into the interior space 4 of the hollow profile 2, the two components 10 are glued together along the shape connection 16.

[0138] These steps can be performed in the equipment's finishing station.

[0139] Then, the core 3 with its pointed tip is introduced into the interior space 4 of the hollow profile 2 with the tip facing forward. This can be done at the joint station 14 of the device.

[0140] Subsequently, a swelling fluid (e.g., water) is introduced into cavity 9, which can be done using the spray gun of device swelling station 15. The amount of water is controlled according to the previously measured moisture content of core 3 to achieve a predetermined target moisture content of core 3. In this embodiment, the target moisture content is approximately 12% by weight.

[0141] Subsequently, a sealing element is installed on the composite beam 1 to fluid-tightly seal the core 3 inside the hollow profile 2 and keep the moisture content as constant as possible.

[0142] This sealing element is obtained through direct injection molding of polyurethane caps. The manufacturing and properties of the sealing element are combined... Figure 6 The content provides a detailed description. Other closure methods, as described below, can also be configured.

[0143] A coating may be applied to the sealed composite profile 1, if necessary. The seal may be partially reopened for this purpose to prevent damage to the composite beam 1 during the temperature rise during the coating process. After coating, any swelling agent lost due to temperature rise can be replenished. Reverse weighing can be performed to determine the amount of lost swelling agent.

[0144] Figure 1 The composite beam 1 shown can be used as a fence profile, for example, for garden fences.

[0145] Therefore, the hollow profile 2 can be made of aluminum, while the core 3 can be made of wood.

[0146] Compared to conventional fence profiles with the same external geometry, the design of composite profile 1 allows for a reduction in the amount of aluminum used (approximately 50%) and a decrease in weight (approximately 22%) while maintaining mechanical properties.

[0147] Figure 2 A schematic cross-sectional view of a composite beam 1 according to a second embodiment is shown. The composite beam 1 is a tent profile.

[0148] As already described in detail in conjunction with the first embodiment, the composite beam 1 includes a hollow profile 2 and a core 3 having a cavity 9.

[0149] The hollow profile is made of aluminum alloy. The core 3 is made of wood.

[0150] Compared to conventional tent profiles with the same external geometry, the design of composite profile 1 allows for a reduction in the amount of aluminum alloy used (approximately 50%) while simultaneously improving mechanical properties and only slightly increasing weight (approximately 13%). For example, the deflection of this tent profile can be reduced by approximately 10% compared to conventional tent profiles.

[0151] Figure 3 A schematic cross-sectional view of a composite beam 1 according to a third embodiment is shown. The composite beam 1 is a mechanical engineering profile.

[0152] As described in detail in conjunction with the first embodiment, the composite beam 1 includes a hollow profile 2 and a core 3. However, in this third embodiment, the core 3 does not have a cavity 9.

[0153] The hollow profile is made of aluminum. The core 3 is made of wood.

[0154] Compared to conventional mechanical engineering profiles with the same external geometry, the design of composite profile 1 allows for a reduction in the amount of aluminum used (approximately 27%) while simultaneously improving mechanical properties and reducing weight (approximately 5%). For example, the deflection of this mechanical engineering profile can be reduced by approximately 7% compared to conventional mechanical engineering profiles.

[0155] As an alternative, a thinner hollow aluminum profile can be used. This results in a weight reduction of approximately 10%, a deflection reduction of approximately 2%, and a saving of approximately 40% of aluminum material.

[0156] Figure 4 A schematic diagram of the composite beam 1 according to the fourth embodiment is shown in three-dimensional view form. The composite beam also includes a hollow profile 2 and a core 3. The cross-section of the composite beam 1 is constant along the longitudinal extension direction 7 of the hollow profile 2.

[0157] Figure 5 A schematic cross-sectional view of the composite beam 1 according to the fifth embodiment is shown. Here, the core 3 is composed of a plurality of components 10 forming a cross profile. The cross profile is obtained by longitudinally sawing a log into four pieces, and then rotating each of the four pieces by 90° so that the cut surfaces face outward.

[0158] Figure 6 A schematic view of the composite beam 1 according to the sixth embodiment is shown. The construction of the composite beam 1 is similar to that of the fourth embodiment; however, it is shown here that sealing elements 6 are provided on both end faces of the composite beam 1.

[0159] The sealing element 6 here is exemplarily formed by direct injection molding capping. Polyurethane is used here, but thermoplastics and other reactive resins are equally applicable. In embodiments not described in detail, the sealing element 6 may also be formed in other ways, particularly as described in the general section.

[0160] The sealing element 6 shown here is formed as follows: a composite consisting of a hollow profile 2 and a core 3 is vertically positioned on a turntable and surrounded by an injection mold. For example, there may be eight loading stations on the turntable. Subsequently, polyurethane resin is injected, allowed to cure, and the sealed composite beam 1 is demolded. After applying a release agent to the injection mold, the second end face of the composite beam 1 is also fitted with the sealing element 6 as described above.

[0161] As an alternative, low-pressure equipment used in single-component polyurethane systems can be used to form the sealing element 6.

[0162] Alternatively, conventional injection molding equipment can be used to inject plastic or reactive resin onto a single composite beam 1, or to distribute it to multiple composite beams 1 through a central injection point and runner.

[0163] As an alternative sealing element 6, a cap can be placed on and bonded to one end face of the composite beam 1. A metal cap can also be welded or brazed to the hollow profile 2. Furthermore, it is particularly possible to fluidly seal the end face of the core 3 using a sealant.

[0164] Also disclosed are embodiments in which the hollow profile 2 is formed of other materials described herein, such as steel or plastic. Therefore, in Figure 1 , 4 In alternative embodiments, the hollow profile 2 in 5 and 6 can also be formed of steel or plastic.

[0165] In these embodiments, the core 3 may also be composed of or include other lignocellulose-containing materials. In the alternative embodiments disclosed herein, Figure 1 , 4 The cores in 5 and 6 are composed of pressed particleboard or wood-plastic composite material.

[0166] Figure 7 A schematic diagram of a device according to one embodiment is shown.

[0167] The equipment includes a storage area 11 from which raw materials for the core 3 of the composite beam 1 are supplied. Storage area 11 includes a drying chamber 23 equipped with air conditioning to adjust the raw materials to a predetermined moisture content. The raw materials can be placed in batches into the drying chamber 23 and dried there for up to 10 days. Storage area 11 also includes a buffer chamber 24 where the dried raw materials can be intermediately stored for further use. Air conditioning is also provided in this buffer chamber.

[0168] The raw materials are transferred from the storage area to the defect identification station 17, where wood defects are detected automatically or manually and removed with the help of a cut-off saw.

[0169] In the subsequent connecting station 18, the various parts of the raw materials are joined together (e.g., by finger jointing and gluing) to form a component that can then be used to manufacture the core 3.

[0170] The raw material is then planed in planing station 19 and shaped into a rough beam. This rough beam has an interference fit compared to beam 3.

[0171] The coarse beams thus manufactured are stored intermediately in buffer station 22 and then transferred to post-drying station 13. Here, the wood is over-dried at elevated temperatures (e.g., about 80°C). The coarse beams may remain in post-drying station 13 for 1 to 2 days, depending on the requirements.

[0172] The post-dried core blank may be stored intermediately in another buffer (not shown), depending on the circumstances.

[0173] Subsequently, to form the core 3, the core blank is planed to its final dimensions in the finishing station 20. A groove is provided for the core blank, which forms a cavity 9 of the core 3 in the composite beam 1. In addition, the moisture content of the core is determined using a humidity measuring device. If the core 3 is composed of multiple parts 10, these parts can also be glued or bonded here.

[0174] In the bonding station 14, the core 3 is introduced into the internal space 4 of the hollow profile 2. The bonding station 14 may include rollers (e.g., rubber-coated rollers) to move the core 3 and / or the hollow profile 2.

[0175] The assembled beam is then sent to swelling station 15, where swelling fluid is enriched. An appropriate amount of swelling fluid is added to achieve the desired moisture content of beam 3. To determine this amount, measurements of the moisture content of beam 3 taken before the introduction of hollow profile 2 will be referenced.

[0176] The swelling station 15 is equipped with spray guns that are inserted into the cavity 9 of the core 3 and spray water into the cavity.

[0177] Subsequently, the end faces of the composite beam are fluid-tightly sealed in the sealing device 21. For this purpose, the sealing device 21 exemplarily includes an injection molding device for injection molding plastic caps, but may also include other suitable devices.

[0178] The composite beam 1 may be post-treated, for example, by coating, in the post-treatment station 25, as needed.

[0179] In an alternative equipment embodiment not described in detail, the core 3 may also be manufactured into a final product before entering the post-drying zone 13. In this case, the finishing station 20 can be omitted.

[0180] Figure 8 A schematic cross-sectional view of the composite beam 1 according to the seventh embodiment is shown, which is largely similar to the first embodiment. Unlike the first embodiment, the core 3 here is formed of four wooden boards 26, which are held together by mortise and tenon joints 16 to form a hollow box-shaped profile with cavities 9.

[0181] This design allows for the use of lower-cost side plates in the manufacture of core 3 and reduces waste of scrap material. This design is particularly suitable for sizes starting at 50x50 mm and above.

[0182] Figure 9 A schematic cross-sectional view of the composite beam 1 according to the eighth embodiment is shown, which is largely similar to the second embodiment. Unlike the second embodiment, here the core 3 is formed of eight wooden boards 26, which are held together by mortise and tenon joints 16 to form a hollow box-shaped profile with cavities 9.

[0183] Figure 10 A schematic cross-sectional view of the composite beam 1 according to the ninth embodiment is shown, which is largely similar to the third embodiment. Unlike the third embodiment, the core 3 here is formed of four wooden boards 26, which are held together by mortise and tenon joints 16 to form a hollow box-shaped profile with cavities 9.

[0184] Figure 11 A schematic cross-sectional view of the composite beam 1 according to the tenth embodiment is shown. Here, the hollow profile 2 is a round profile made of aluminum, while the core 3 is formed of wood. It has a cavity 9. This composite beam 1 can be used as a stage profile. This design allows for the saving of approximately 30% of aluminum while maintaining comparable mechanical properties. Alternatively, the core 3 can also be designed without the cavity 9, or the core 3 can be designed as a multi-piece structure.

[0185] The exemplary advantages of the composite beam embodiments described herein are as follows: - Vibration reduction provided by wood core: Wood composites have advantages over pure metal solutions.

[0186] - Fatigue characteristics: When using wood-metal hybrid materials, the structural components subjected to alternating loads require less cross-sectional area increase in the design compared to pure metal structures.

[0187] - Fracture Energy: Wood exhibits extremely high ductility under compression and absorbs a large amount of energy, but under tension, the material exhibits extremely brittle fracture. In the combination of wood and metal, the metal shell bears the ductile deformation under tension. Composite profiles do not buckle prematurely, thus absorbing additional energy under dynamic loads. The fracture energy can be doubled under visible conditions.

[0188] - Bending strength: By combining wood and metal, improvements in strength and deflection can be achieved in compression members and bending members while reducing weight.

[0189] - Alternating climate stress: Wood has a relatively high heat capacity, along with high thermal conductivity and a low coefficient of thermal expansion. By combining wood with metal, heat absorption and loss are significantly mitigated under alternating temperature stress. This minimizes the adverse effects of thermal expansion under visible conditions.

[0190] - Manufacturing technology: The simplification of profile geometry (especially the elimination of reinforcing ribs) enables higher throughput when manufacturing hollow profiles (e.g., when they are manufactured by extrusion processes).

[0191] -Fire resistance: The fire resistance (e.g., ignition point, pyrolysis) of wood can be greatly improved by using fluid-sealed sealing components.

Claims

1. A composite beam having a hollow profile (2), said hollow profile (2) comprising or composed of aluminum or an aluminum alloy, wherein, The hollow profile (2) has an internal space (4) and a core (3) arranged in the internal space, wherein the core (3) comprises wood or is formed of wood, characterized in that the core (3) is arranged in the internal space (4) without gaps and presses against the inner wall (8) of the hollow profile (2) from each side in the cross-sectional direction.

2. The composite beam according to claim 1, characterized in that, More than 60%, preferably more than 80%, more preferably more than 95% of the cross-sectional periphery of the core (3) is supported on the inner wall (8) of the hollow profile (2) via surface contact or segmented contact.

3. The composite beam according to claim 1 or 2, characterized in that, The cross-sectional area of ​​the hollow profile (2) is less than 50% of the cross-sectional area of ​​the composite beam (1), preferably less than 30%, and more preferably less than 25%.

4. The composite beam according to any one of claims 1 to 3, characterized in that, The density of the composite beam (1) is less than 1000 kg / m3, preferably less than 500 kg / m3, and more preferably less than 300 kg / m3.

5. The composite beam according to any one of claims 1 to 4, characterized in that, The inner wall (8) of the hollow profile (2) has no web, that is, in particular, there is no reinforcing web extending along the longitudinal extension direction (7) of the hollow profile (2).

6. The composite beam according to any one of claims 1 to 5, characterized in that, The hollow profile (2) has a substantially constant cross-section along its entire longitudinal extension direction (7), that is, in particular, a constant cross-sectional geometry and a constant cross-sectional area.

7. The composite beam according to any one of claims 1 to 6, characterized in that, The hollow profile (2) has a plurality of internal spaces (4) extending in the longitudinal extension direction (7) of the hollow profile (2) and separated from each other, wherein a core (3) is arranged in each of the internal spaces (4).

8. The composite beam according to any one of claims 1 to 7, characterized in that, The hollow profile (2) is an extruded profile.

9. The composite beam according to any one of claims 1 to 8, characterized in that, - The core (3) has a compression zone (5) along its outer cross-sectional periphery, in which the core (3) is compacted due to the pressure acting between the inner wall (8) of the hollow profile (2) and the outer surface of the core (3), and / or -The hollow profile (2) is integrally formed in cross-section and completely surrounds the core (3), and / or - The hollow profile (2) is a closed profile.

10. The composite beam according to any one of claims 1 to 9, characterized in that, The longitudinal extension direction of the wood fibers of the core (3) is substantially parallel to the longitudinal extension direction (7) of the hollow profile (2).

11. The composite beam according to any one of claims 1 to 10, characterized in that, The core (3) is constructed as a hollow body, wherein the core (3) is formed, if necessary, by a plurality of components (10) that together form the hollow body, wherein the core (3) is particularly a hollow box-shaped profile formed by a plurality of wooden boards, the plurality of wooden boards preferably being mortised and tenoned together.

12. The composite beam according to claim 11, characterized in that, The core occupies up to 70% of the cross-sectional area of ​​the internal space (4) of the hollow profile (2).

13. The composite beam according to claim 11 or 12, characterized in that, -The core (3) is constructed as a box-shaped profile, particularly a two-piece or four-piece box-shaped profile, especially a hollow box-shaped profile, or - The core (3) is constructed as a cross beam.

14. The composite beam according to any one of claims 1 to 13, characterized in that, A sealing element (6) is provided so that the core (3) is fluid-tight, especially water vapor-tight, enclosed in the internal space (4).

15. The composite beam according to claim 14, characterized in that, The sealing element (6) is formed by one or more of the following means: - A cap, wherein the cap is bonded to at least one end face of the composite (1); - A sealing layer, said sealing layer being coated on at least one end face of the composite (1); - The carbonized zone of the core (3) is located on at least one end face of the composite (1).

16. A fence profile comprising a composite beam according to any one of claims 1 to 15.

17. A fence comprising a plurality of fence profiles as described in claim 16.

18. A window frame profile comprising a composite beam according to any one of claims 1 to 15.

19. A window frame comprising a plurality of window frame profiles according to claim 18 that are interconnected with each other.

20. A stage profile comprising a composite beam according to any one of claims 1 to 15.

21. A mechanical engineering profile, comprising a composite beam according to any one of claims 1 to 15.

22. A method for manufacturing a composite beam (1), comprising the following steps: a. Provide a hollow profile (2), the hollow profile (2) comprising or composed of aluminum or aluminum alloy; b. Provide a core (3) comprising or composed of wood, wherein the core (3) has a sub-dimension compared to the internal space (4) of the hollow profile (2); c. Introduce the core (3) into the internal space (4) of the hollow profile (2); and d. By means of a swelling fluid, particularly water, the core (3) is swollen in the internal space (4) of the hollow profile (2), thereby the core is arranged without gaps in the internal space (4) and presses against the inner wall (8) of the hollow profile (2) from each side in the cross-sectional direction.

23. The method according to claim 22, characterized in that, The core (3) has a cavity (9) and the swelling fluid is introduced into the cavity (9).

24. The method according to claim 23, characterized in that, The swelling fluid is introduced via a spray gun inserted into the cavity (9).

25. The method according to claim 23 or 24, characterized in that, The water content of the core (3) is measured before the core (3) is introduced into the internal space (4), and the amount of the swelling fluid is controlled to accommodate the predetermined target water content of the core (3).

26. The method according to any one of claims 22 to 25, characterized in that, The core (3) is sharpened at its end face and introduced into the internal space (4) with the sharpened end face facing forward.

27. The method according to any one of claims 22 to 26, characterized in that, The core (3) is pre-treated, particularly planed, milled and / or cut, before being introduced into the interior space (4).

28. The method according to any one of claims 22 to 27, characterized in that, The core (3) is formed by joining multiple components (10).

29. The method according to any one of claims 22 to 28, characterized in that, The core (3) has a water content between 0% by weight and 10% by weight when introduced into the internal space (4), particularly between 3.0% by weight and 6.0% by weight, and / or the core (3) has a water content between 6.0% by weight and 17% by weight after swelling, particularly between 8.0% by weight and 14% by weight.

30. An apparatus for manufacturing a composite beam (1), comprising the following equipment parts: - Storage area (11), for storing raw materials for the core (3) of the composite beam (1), wherein, The storage area (11) specifically includes air conditioning equipment for setting a predetermined temperature and / or humidity. -Preparation area (12) for forming a core blank from the raw materials, wherein the core blank may optionally have an interference fit compared to the core (3). - Post-drying zone (13) is used to reduce the moisture content of the core blank and form the core (3). - A joint station (14) for introducing the core (3) into the internal space (4) of the hollow profile (2), and - Swelling station (15) for bringing the core (3) into contact with a swelling fluid, particularly water.

31. The device according to claim 30, characterized in that, The preparation area includes one or more of the following devices: - A defect identification station (17) for identifying defects in the raw material for the core, and a defect removal station, such as a cutting station, optionally assigned to the defect identification station (17); - Connecting station (18), for joining multiple components of the raw material; - Planing station (19); - Cutting station.

32. The device according to claim 30 or 31, characterized in that, The post-drying zone (13) includes an air conditioning device for setting a predetermined temperature and / or air humidity, wherein the air conditioning device includes a heating device.

33. The device according to any one of claims 30 to 32, characterized in that, A finishing station (20) is arranged after the post-drying zone (13), wherein the finishing station (20) includes one or more of the following devices: - A humidity measuring device for measuring the moisture content of the core blank or the core (3) before introducing the core (3) into the internal space (4) of the hollow profile (2); -Planking device; - Milling device.

34. The device according to any one of claims 30 to 33, characterized in that, The swelling station (15) includes a spray gun for contacting the core (3) with the swelling fluid, wherein the spray gun is specifically configured to be inserted into the cavity (9) of the core (3).

35. The device according to any one of claims 30 to 34, characterized in that, The device also includes a sealing device (21) for fluid sealing of the end face of the composite beam (1).

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