Longitudinal cavity profile prefabricated part and longitudinal cavity profile manufacturing method

Abstract

The invention relates to a longitudinal chamber profile preform (1) comprising an inner wall (2) and an outer wall (3) which are made of sheet metal and which are arranged relative to one another so as to maintain a gap therebetween, a valve (5) being arranged on at least one of the walls (2, 3), the valve (5) being arranged between the inner wall (2) and the outer wall (3), the valve (5) being arranged between the inner wall (2) and the outer wall (3), and the valve (5) being arranged between the inner wall (2) and the outer wall (3). The edges of these walls (2, 3) are sealed with seals (6) and define a pressure-tight airtight interior space (4), the longitudinal chamber profile preform (1) being wound in the shape of a substantially Archimedes spiral. The invention also relates to a method for producing a longitudinal chamber profile (7).

Description

[0001] This invention relates to a prefabricated longitudinal cavity profile and a method for manufacturing a longitudinal cavity profile. The invention is intended for application in construction, in the manufacture of vehicle parts for the automotive industry, or as structural and decorative elements in the furniture industry. It can also be applied in aerospace for the construction and deployment of structural elements for spacecraft such as solar sails.

[0002] Longitudinal chamber profiles, made of sheet metal and containing cavities that can be filled with functional materials, are widely used in various technical fields. For example, in construction, they are used as structural components for panels of walls, ceilings, doors, and other structural elements. Longitudinal chamber profiles can also be used to manufacture various vehicle parts (such as body panels, doors, or covers), or in the furniture industry as components for manufacturing furniture of various shapes or as decorative elements.

[0003] Known methods for manufacturing longitudinal chamber profiles in the art are based on providing components having a length corresponding to the final desired length of the longitudinal chamber profile, and on subsequently joining these components, for example, by longitudinal welding, to obtain the final desired longitudinal chamber profile. This method of manufacturing longitudinal chamber profiles requires providing components of the final desired length to an assembly or manufacturing location, which presents logistical challenges when the profile has a large length. A solution of this type is disclosed in US 2021301530 A1.

[0004] Document US 2021301530 A1 discloses a modular, integrated structural reinforcement component comprising a plurality of elongated metal members having: a planar base extending between adjacent longitudinal edges and having a pattern of smaller orifices; larger material inlet / outlet openings extending their length on the planar base; and a pair of planar legs extending from the longitudinal edges of the planar base to form leg base structural bends of 45° to 135°. The planar legs have a pattern of smaller orifices extending their length on the planar legs. A pair of flange sections extend from the longitudinal edge of the planar leg and have a first flat planar portion and a second curved planar portion; the first flat planar portion extends from the longitudinal edge of the planar leg to form a flange-leg structure bend of 90 to 135 degrees; the second curved planar portion extends from the longitudinal edge of the adjacent first flat planar portion to form a helical, circular, or curved planar reinforcement portion. Due to this structure, metal fasteners securely connect two or more consecutive structural members to assemble various types of modular, integrated structural components.

[0005] Alternative methods for manufacturing longitudinal chamber profiles are based on providing components with a length less than the final desired length of the longitudinal chamber profile, and then joining these components in series, for example, by circumferential welding, to obtain the final desired longitudinal chamber profile. This method of manufacturing longitudinal chamber profiles with significant lengths requires numerous alignment and joining operations, complicating the manufacturing process. Furthermore, the resulting longitudinal chamber profile has many connection areas, which may reduce its strength and the final desired load-bearing capacity.

[0006] A further alternative to the above solution is to provide a telescopic structure. Document WO 2006021085 A2 discloses a support column, particularly a telescopic support column used in building systems. The telescopic column includes an outer tube, a plurality of slots arranged longitudinally along the outer tube, an inner tube, and at least one tongue-shaped member attached to and projecting from the inner tube. The at least one tongue-shaped member is configured to be received by the plurality of slots; wherein the dimensions of the inner tube and the at least one tongue-shaped member are determined to slide within the outer and inner tubes, and the at least one tongue-shaped member can rotate within the outer tube to engage with at least one of the plurality of slots.

[0007] Furthermore, US 8114524 B2 discloses a precision-folded, high-strength, fatigue-resistant structure and the resulting sheet material. The object of this invention is its application to the production of three-dimensional load-bearing structures from two-dimensional sheets (such as straight and curved beams, chassis, or exoskeletons). This invention can be applied to the fabrication of three-dimensional structures in outer space, where high-strength power tools are not readily available. In one of these embodiments, a roll of sheet material is shown with slits or grooves along two curved lines. The sheet material also includes openings and tabs periodically positioned near opposite sheet edges. This roll has a highly compact configuration, advantageous for transporting the sheet material. Therefore, the thus formed and coiled sheet can be transported by spacecraft to an outer space location where the sheet is unrolled from the roll, and during or after unrolling, the sheet can be fabricated into a three-dimensional structure using hand tools or medium-power tools. The fabrication of a three-dimensional structure involves the following steps: bending a sheet along a curve and bending tabs into openings to lock the sheet within the three-dimensional structure (such as a triangular beam). The result is a long beam with a triangular cross-section, which can be connected to other structures to create complex three-dimensional spatial structures.

[0008] Document EP 2110189 A1 discloses a method for manufacturing a chamber element, which includes forming two sheet metal parts with desired profiles, and subsequently joining the corresponding profiles by welding to form a pressure-sealed chamber, wherein a valve is disposed on one of the sheet metal parts for supplying pressurized air. In a next step, high-pressure air is introduced into this chamber element preform through the valve, causing the sheet metal parts to deform within their plastic limits, and thus forming a deformed chamber element.

[0009] The technical problem of this invention is to provide a method for manufacturing longitudinal chamber profiles that allows for the manufacture of longitudinal chamber profiles with desired characteristics and defined geometries while maintaining high dimensional accuracy. It is desirable that the longitudinal chamber 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 economical manufacturing process for longitudinal chamber profiles. It is also desirable that the longitudinal chamber profile manufacturing method is characterized by low material consumption and allows for the manufacture of longitudinal chamber profiles with a wide range of geometric parameters, particularly different heights, spatial forms, and both symmetrical and asymmetrical characteristics. It is also important to provide a method for manufacturing longitudinal chamber profiles that allows for easy modification of the shape of the longitudinal chamber profile within a wide range of geometric parameters without rearranging the equipment used in the manufacturing process. It is also anticipated that a method for manufacturing longitudinal chamber profiles with straight-line characteristics will be provided.

[0010] A further technical problem of the present invention is to provide a longitudinal chamber profile preform, which will be an intermediate element in the manufacture of longitudinal chamber profiles and will require a limited number of operations to produce the longitudinal chamber profiles. It is also anticipated that the longitudinal chamber profile preform is easy to store and transport, and has a compact structure that occupies a limited volume of space when stored.

[0011] According to a first aspect of the invention, a longitudinal chamber profile preform is provided, the longitudinal chamber profile preform comprising an inner wall and an outer wall made of sheet metal and arranged relative to each other to maintain a gap between the inner wall and the outer wall, wherein a valve is arranged on at least one of the walls, wherein the edge of each of the walls is sealed with a seal and defines a pressure-sealed, airtight internal space, characterized in that the longitudinal chamber profile preform is coiled into a substantially Archimedean spiral shape.

[0012] Preferably, the valve is a check valve.

[0013] Preferably, the seal is a welded component, a pressure welded component, an adhesive layer, or an overlap joint.

[0014] Preferably, the valve is arranged close to the outer end of the longitudinal chamber profile preform.

[0015] Preferably, the longitudinal cavity profile preform is coiled from the inner end of the longitudinal cavity profile preform opposite to the outer end of the longitudinal cavity profile preform.

[0016] Preferably, a valve is arranged on the outer wall.

[0017] According to a second aspect of the present invention, a method for manufacturing a longitudinal cavity profile is provided, characterized in that the method includes the following steps: a) Provide a longitudinal chamber profile preform as defined in the first aspect of the invention. b) The pressurized fluid is introduced through a valve into the pressure-sealed, airtight internal space to deform and unwind the longitudinal chamber profile preform.

[0018] Preferably, between steps a) and b), the inner end of the longitudinal cavity profile preform is introduced into the roller system.

[0019] Preferably, the valve is arranged on the opposite side of the roller system relative to the rest of the longitudinal chamber profile preform.

[0020] Preferably, the fluid is air, water, oil, fluid concrete, or fluid plastic.

[0021] Preferably, step b) is performed at room temperature, elevated temperature, or below zero degrees Celsius.

[0022] Preferably, the pressure of the fluid introduced into the longitudinal chamber profile preform is at least 5 bar.

[0023] The longitudinal chamber profile preform of the present invention is an intermediate element in the manufacture of longitudinal chamber profiles, which can be straight or arched profiles used in the manufacture of three-dimensional truss structures. The longitudinal chamber profile preform is a structurally simple element comprising a limited number of component parts, which is economically advantageous and improves technical reliability. The formation of the longitudinal chamber profile requires only the step of introducing pressurized fluid into the hermetically sealed internal space of the longitudinal chamber profile preform, demonstrating a simple and therefore more reliable manufacturing technique. Furthermore, due to the use of a roller system, the longitudinal chamber profile preform is introduced into the roller system during the manufacturing process, and the resulting longitudinal chamber profile can have straight characteristics. Moreover, in such a system, the valve is arranged on the opposite side of the roller system relative to the rest of the longitudinal chamber profile preform, which ensures that the longitudinal chamber profile preform is automatically moved by the roller system when pressurized fluid is introduced into the pressure-sealed hermetically sealed internal space of the preform, and therefore, such a system does not require an additional drive mechanism to unwind the preform. Furthermore, since the structure of the longitudinal chamber profile preform is coiled into a shape that is essentially an Archimedean spiral, the longitudinal chamber profile preform occupies a limited volume of space and can be easily transported to the intended installation location, where, upon introduction of pressurized fluid, the longitudinal chamber profile preform will unwind into the final desired longitudinal chamber profile.

[0024] Using a valve in the form of a check valve allows pressurized fluid to be introduced into the longitudinal chamber profile preform and prevents fluid from escaping to the outside.

[0025] The solution according to the invention has been shown in the following embodiments and illustrated in the accompanying drawings, in which: Figure 1 This is an isometric view of an embodiment of the longitudinal cavity profile preform according to the present invention. Figure 2 It is by Figure 1 A side view of an embodiment of a longitudinal cavity profile formed from prefabricated longitudinal cavity profile components. Figure 3 It is by Figure 1 A top view of an embodiment of a longitudinal cavity profile formed from prefabricated longitudinal cavity profile components. Figure 4 This is a cross-sectional view of an embodiment of the longitudinal cavity profile preform according to the present invention. Figure 5 It is by Figure 4 Cross-sectional views and partial enlarged views of an embodiment of a longitudinal cavity profile formed from prefabricated longitudinal cavity profile components. Figure 6 A) to Figure 6 E) is a side view of a subsequent step in the first embodiment of the longitudinal chamber profile manufacturing method according to the present invention, in which the longitudinal chamber profile is deformed from the longitudinal chamber profile preform. Figure 7 A) to Figure 7 D) is a side view of a subsequent step in the process of deforming the longitudinal chamber profile from a longitudinal chamber profile preform according to a second embodiment of the longitudinal chamber profile manufacturing method of the present invention.

[0026] Example 1 An embodiment of the longitudinal cavity profile preform 1 of the present invention is shown in Figure 1 Chinese and Israeli axonometric views and Figure 4 The cross-sectional view is shown schematically. In this embodiment, the longitudinal chamber profile preform 1 has an approximately Archimedean spiral shape, and after being manufactured using the method of the present invention, the longitudinal chamber profile is as follows: Figure 2 Side view, Figure 3 Top view and Figure 5 The cross-sectional view shows a longitudinal chamber profile 7 with an arched shape. The longitudinal chamber profile 7 formed using the method of the present invention can be a component that forms a three-dimensional truss structure by joining multiple longitudinal chamber profiles 7 thus formed.

[0027] This embodiment of the longitudinal chamber profile prefabricated component 1 is manufactured using a method comprising the following steps, in which both the inner wall 2 and the outer wall 3 are made of sheet metal and are arranged relative to each other in substantially parallel planes, with a gap maintained between the inner and outer walls. The edges of the respective walls 2 and 3 converge, and a valve 5 is arranged on one wall. In this embodiment, for example, as... Figure 1 and Figure 4 As shown, valve 5 is arranged on the outer wall 3, but its position within the longitudinal chamber profile preform 1 is unrestricted as long as fluid communication with the interior of the longitudinal chamber profile preform 1 is permitted. In this embodiment, valve 5 is arranged near the outer end of the longitudinal chamber profile preform 1 to facilitate access to valve 5 during the fabrication of the longitudinal chamber profile 7. The outer end of the longitudinal chamber profile preform 1 is the end located in the outer region of the structure within the final intended (Archimedean) spiral of the longitudinal chamber profile preform 1.

[0028] In the next step, the edges of the unconnected walls 2 and 3 are sealed with sealant 6 to form a pressure-sealed, airtight, empty internal space 4 between the inner wall 2 and outer wall 3 of the longitudinal chamber profile preform 1. After the walls 2 and 3 of the longitudinal chamber profile preform 1 have been matched with each other, the edges of the metal sheets forming these walls are sealed. In this embodiment, therefore, all circumferential edges of the matched walls 2 and 3 of the longitudinal chamber profile preform 1 are sealed. In this embodiment, the sealing is performed by welding the corresponding edges together to form a circumferential weld. By sealing all the above-mentioned edges, a pressure-sealed, airtight internal space 4 is formed in the longitudinal chamber profile preform 1, such as... Figure 4The cross-section is shown (see the space between the inner wall 2 and the outer wall 3). In this case, the type of seal 6 is not a limitation of the scope of the invention, and any type of seal 6 can be used in alternative embodiments, provided that a pressure-sealed, airtight internal space 4 is formed in the longitudinal chamber profile preform 1 by means of, for example, pressure welding, soldering, gluing, bending, or pressing.

[0029] In the final step of manufacturing the longitudinal chamber profile preform 1, the resulting structure is coiled from the inner end of the longitudinal chamber profile preform 1 into an approximate Archimedean spiral shape, with the inner end positioned opposite to the outer end where the valve 5 is located. After the coiling step, the desired result is... Figure 1 and Figure 4 The final desired longitudinal chamber profile prefabricated component 1 is shown.

[0030] In one embodiment of these embodiments, the longitudinal chamber profile preform 1 may be coiled onto a roller or column to facilitate the formation of the final desired spiral shape and for transport and / or storage.

[0031] The valve 5 of the longitudinal chamber profile preform 1 is an inlet element for introducing pressurized fluid into the pressure-sealed, airtight internal space 4 of the longitudinal chamber profile preform 1. In this embodiment, the valve 5 is a check valve that ensures one-way fluid communication with the pressure-sealed, airtight internal space 4.

[0032] After performing the above steps, a longitudinal chamber profile preform 1 is formed, which includes an inner wall 2 and an outer wall 3, the inner wall and the outer wall being made of metal sheets and arranged relative to each other to maintain a gap between the inner wall and the outer wall, wherein a valve 5 is arranged on the outer wall 3, wherein the edge of each of the walls 2 and 3 is sealed with a seal 6 and defines a pressure-sealed airtight internal space 4, wherein the longitudinal chamber profile preform 1 is coiled into a substantially Archimedean spiral shape.

[0033] The longitudinal chamber profile preform 1 thus prepared is used to form the longitudinal chamber profile 7. In order to form the longitudinal chamber profile 7 from the longitudinal chamber profile preform 1, in a next step of the method for manufacturing the longitudinal chamber profile 7, an external pressurized fluid source is connected to valve 5 via a supply pipe. In this embodiment, the fluid is air, the pressurized fluid source is a compressor, and the supply pipe forms a pneumatic connection with valve 5. The type of external pressurized fluid source and connecting equipment is not a limitation of the scope of the invention, and in alternative embodiments, the fluid can be used with suitable connecting equipment and pressurized fluid sources, in the form of water, fluid cement, machine oil, fluid plastics such as single-component, two-component, or three-component foams (e.g., Flex 140 type), etc. The lower the compressibility of the fluid, the more controlled the deformation conditions of the longitudinal chamber profile preform 1.

[0034] In the next step of the longitudinal chamber profile manufacturing method according to the invention, a fluid under a defined pressure is delivered to the pressure-sealed, airtight internal space 4 of the longitudinal chamber profile preform 1. The technique of introducing pressurized fluid into closed, sealed chamber elements made of sheet metal to deform them and provide them with a final form is known in particular from document EP 2110189 A1. Thus, by delivering pressurized fluid to the pressure-sealed, airtight internal space 4 of the longitudinal chamber profile preform 1, the walls 2, 3 of the longitudinal chamber profile preform 1 deform, and the longitudinal chamber profile preform 1, coiled in an approximate Archimedean spiral shape, simultaneously unwinds. Figure 6 A) to Figure 6 E) shows the steps of unwinding the longitudinal cavity profile preform 1 to obtain the longitudinal cavity profile 7, wherein the unwinding of the longitudinal cavity profile preform 1 and the deformation of the walls 2 and 3 of the longitudinal cavity profile preform 1 are performed simultaneously.

[0035] It should be noted that although the introduction of pressurized fluid into the pressure-sealed, airtight internal space 4 of the longitudinal chamber profile preform 1 is performed at a cold technology (i.e., room temperature), this is not a limitation of the scope of the invention, and in alternative embodiments, the method can be performed at elevated, high, or sub-zero temperatures, such as those found in outer space.

[0036] In one embodiment of the invention, the step of introducing pressurized fluid is performed under the following process parameters: Process temperature: 20°C - Work pressure: 5 bar - Deformation time: 1 minute, until the pressure in the longitudinal chamber profile preform 1 is balanced. - Pressure holding time: 30 seconds - Total deformation time: 1.5 minutes.

[0037] Example 2 Another embodiment of the manufacturing method of the longitudinal chamber profile 7 of the present invention is as follows: Figure 7 A) to Figure 7 It is schematically shown in the side view of E).

[0038] The embodiments of the manufacturing method of the longitudinal chamber profile 7 and the manufacturing method of the longitudinal chamber profile preform 1 are substantially similar to the method shown in Example 1, and therefore, for the clarity of this disclosure, similar techniques and structural characteristics of the longitudinal chamber profile preform 1 and the steps of the manufacturing method of the longitudinal chamber profile 7 will not be discussed in detail.

[0039] Unlike the longitudinal chamber profile 7 manufacturing method shown in Example 1, in this embodiment, an intermediate step is provided between the step of providing the longitudinal chamber profile preform 1 and the step of introducing pressurized fluid through valve 5 into the pressure-sealed airtight internal space 4. This intermediate step includes introducing the outer end of the longitudinal chamber profile preform 1 into the roller system 8. Figure 7 A) to Figure 7 The side view in E) illustrates further steps in manufacturing the longitudinal chamber profile 7 using the roller system 8. As can be seen, the valve 5 is arranged on the opposite side of the roller system 8 relative to the rest of the longitudinal chamber profile preform 1. Therefore, when pressurized fluid is introduced into the longitudinal chamber profile preform 1, the deformation of the walls 2, 3 applies pressure to the rollers in the roller system 8, causing the longitudinal chamber profile preform 1 to move automatically through the roller system 8. Thus, the proposed technique for manufacturing the longitudinal chamber profile 7 eliminates the need for an additional drive system to move the longitudinal chamber profile preform 1 through the roller system 8, significantly simplifying the process and impacting improved reliability.

[0040] It is worth noting that the roller system 8 used in the manufacturing method of the longitudinal chamber profile 7 in this embodiment is a roller system 8 known in the field of rolled metal sheets, and is not intended to limit the scope of the invention. Importantly, the function of the roller system 8 is to roll and straighten the longitudinal chamber profile preform 1 so that the longitudinal chamber profile 7 obtained in the final step is straight, as... Figure 7 As shown in D).

[0041] List of reference numerals in the attached diagram: 1-Longitudinal cavity profile prefabricated component 2-Inner wall 3-Outer wall 4-Pressure-sealed airtight internal space 5-valve 6-Seals 7-Longitudinal chamber profile 8-roller system.

Claims

1. A longitudinal chamber profile preform (1), the longitudinal chamber profile preform comprising an inner wall (2) and an outer wall (3), the inner wall and the outer wall being made of metal sheets and arranged relative to each other to maintain a gap between the inner wall and the outer wall, wherein, A valve (5) is arranged on at least one of these walls (2, 3), wherein the edges of these walls (2, 3) are sealed with a seal (6) and define a pressure-sealed airtight internal space (4), characterized in that the longitudinal chamber profile preform (1) is coiled into a substantially Archimedean spiral shape.

2. The longitudinal chamber profile prefabricated component (1) according to claim 1, characterized in that, The valve (5) is a check valve.

3. The longitudinal cavity profile prefabricated component (1) according to claim 1 or 2, characterized in that, The seal (6) is a weldment, a pressure weldment, an adhesive layer, or a lap joint.

4. The longitudinal chamber profile prefabricated component (1) according to any one of claims 1 to 3, characterized in that, The valve (5) is positioned close to the outer end of the longitudinal chamber profile preform (1).

5. The longitudinal chamber profile prefabricated component (1) according to claim 4, characterized in that, The longitudinal cavity profile preform is coiled from the inner end of the longitudinal cavity profile preform (1) opposite to the outer end of the longitudinal cavity profile preform (1).

6. The longitudinal cavity profile prefabricated component (1) according to any one of claims 1 to 5, characterized in that, The valve (5) is located on the outer wall (3).

7. A method for manufacturing a longitudinal cavity profile (7), characterized in that, The method includes the following steps: a) Provide the longitudinal chamber profile preform (1) as defined in any one of claims 1 to 6. b) The pressurized fluid is introduced through the valve (5) into the pressure-sealed airtight internal space (4) to deform and unwind the longitudinal chamber profile preform (1).

8. The method for manufacturing the longitudinal chamber profile (7) according to claim 7, characterized in that, Between step a) and step b), the outer end of the longitudinal cavity profile preform (1) is introduced into the roller system (8).

9. The method for manufacturing the longitudinal chamber profile (7) according to claim 8, characterized in that, The valve (5) is arranged on the opposite side of the roller system (8) relative to the rest of the longitudinal chamber profile preform (1).

10. The method for manufacturing the longitudinal chamber profile (7) according to any one of claims 7 to 9, characterized in that, The fluid is air, water, oil, fluid concrete, or fluid plastic.

11. The method for manufacturing the longitudinal chamber profile (7) according to any one of claims 7 to 10, characterized in that, Step b) is performed at room temperature, elevated temperature, or below zero degrees Celsius.

12. The method for manufacturing the longitudinal chamber profile (7) according to any one of claims 7 to 11, characterized in that, The pressure of the fluid introduced into the longitudinal chamber profile preform (1) is at least 5 bar.

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