TUBE-SHAPED STRUCTURAL PROFILE AND CONSTRUCTION SYSTEM

Description

[0001] The technical problem that the present invention solves refers to achieving a structural profile and a composite structure or construction system using this profile, made of semi-rigid and foldable material, as is the particular case of cardboard, in order to create by means of folding of a sheet, a rigid and lightweight structure, usable in various fields of application, especially in the manufacture of composite structures for the industry of packaging, furniture, the display of consumer products for sale, for example.

[0002] The special case of the fields of application of structures with a short useful life, which are preferably made up of recyclable materials such as cardboard and some types of plastics, is becoming increasingly relevant. This is both due to regulatory restrictions for caring for the environment, as well as to the maximisation of the cost efficiency of the material recycling process, which makes it necessary to innovate in structural elements and composite structures which have a technical advantage in the conception thereof, thus making it possible to omit the incorporation of other materials different from the base material.

[0003] In the case of cardboard, a material especially suitable for being recycled after the use thereof, both in applications for packaging and furniture for displaying products for sale and other applications, it is usually necessary to incorporate elements for fastening and reinforcing the structures, made up of other materials, such as metal bolting and plastic and metal clips in cardboard furniture, and the case of reinforcing elements for packaging, such as polystyrene and polyethylene foams or rigid profiles containing binding resins with a difficult and expensive recycling process.

[0004] Another facet of the technical problem addressed by this innovation is the growing need, in the retail market of products sold to the public, to find an optimisation of operating costs and minimisation of environmental impacts from the transport of products from factories to retail at the point of sale by means of the use of furniture containing products, which has the structural strength to contain the products for transport to the point of sale, in addition to having design characteristics which permit retail buyers to easily see the displayed products and remove them from the furniture for the purchase thereof. In this particular application, due to existing technologies, several operational and environmental problems currently arise both at the place where the structure and the load of products thereof are created and at the point where the furniture is emptied and must be disposed of as waste. These problems arise firstly due to the fact that the structures of the furniture currently used do not permit the structural rigidities and strengths necessary to fulfil the multiple functions required in manufacturing starting from a folded cardboard sheet, for which reason they require the use of other elements and especially fastening elements additional to a cardboard sheet for the assembly thereof, and in most cases also specialised tools for inserting these elements. Another problem is related to the logistical difficulties within the factories, as it is necessary to transport furniture from an assembly area to a product loading area. Additionally, in places of sale, the application of specialised techniques and tools is necessary for dismantling the furniture already used, prior to the disposal thereof.

[0005] Faced with the needs related to the different facets of this technical problem, it is necessary to achieve a new structural profile and a composite structure or construction system based on this profile, which permits the different aspects of the need proposed to be solved.Brief description of the invention

[0006] A tubular structural profile is disclosed in accordance with claim 1, and a construction system or composite structure made of the aforementioned profile is disclosed in accordance with claim 3.Description of what is known in the art

[0007] Among the background of the prior art, there are numerous disclosures relating to the use of profiles for architectural construction, for securing prefabricated panels, however, most of them are oriented towards a different manner of operation and consequently with different shape features, the one corresponding to a product of plastic or metal profiles called a "Z perimeter profile" being a relevant disclosure, which is widely marketed and disseminated in catalogues, especially designed for the securing and perimeter trim of panels of dropped ceilings. This profile solves the securing of panels of dropped ceilings, but in order to achieve a recessed perimeter trim, it is necessary to perform a series of arduous jobs prior to the application thereof, increasing the risk of deformation, execution time and costs from labour and supplies.

[0008] The document US2011271623 (A1) discloses a construction element for buildings having a hollow body, which extends along a longitudinal axis and has a substantially rectangular transverse cross section, wherein the corners can be rounded, and at least one first and at least one second strut element extending between diagonally opposing borders in the hollow body. The strut elements can absorb compressive forces, but not tensile forces. Different prefabricated elements can be positioned in the place of the strut elements. The innovation, although it contains elements in common with the present invention, does not envisage the elements necessary for an assembly of the structural element starting from a sheet of material, but rather requires a closed tube as the base material, plus the strut elements.

[0009] The document FR2951705 (A1) discloses a pallet spar which is made starting from folding a rectangular sheet of cardboard which comprises parallel fold lines which divide the sheet into 8 rectangular sectors, in order to obtain a solid part. The innovation comprises elements in common with the present invention, such as a diagonal section and faces and 4 substantially orthogonal layers, but the manner of folding thereof is different and does not envisage other elements necessary for closing the profile, such as the tongues and slots wherein these are inserted.

[0010] The document US4563377 (A) discloses a high-strength tubular beam of corrugated cardboard, for example, for constructing disposable load-carrying platforms, comprising a single cardboard sheet folded back several times on itself to form a rectangular or isosceles trapezium external cross section, divided into two adjacent rectangular or trapezium cross sections, each comprising two mutually inverted triangular cross sections having a diagonal in common. The innovation has elements in common with the present invention, however, it differs in the form of folding and layout of the sheet thereof, in addition to envisaging diagonal segments which are simple and not formed by two layers as in the present invention, and additionally, it does not envisage closing means for the profile, which can only achieve closing and structural strength by being adhered to an external element by the open face thereof.

[0011] The document US4333622 (A) discloses a knockdown spacer for bookshelves and the like which is made from a rectangular sheet of material, folded at spaced intervals to fold into an open ended box-like shape with internal diagonal walls, wherein the external walls of the box wrap around the diagonal walls and one end of the sheet has a flap which overlaps one of the walls and is secured by means of releasable fastening elements. The innovation has elements in common with the present invention, however, it differs in the form of folding and layout of the sheet thereof, in addition to envisaging, and in an additional manner, it does not envisage closing means created in the sheet of material, but rather requires external elements.

[0012] The document DE202008011113 (U1) discloses a shelf with at least four vertical, prism-shaped columns to which floor supports are detachably attached.

[0013] The document GB957762 (A) discloses a foot secured to a platform of a stillage by fitting bent-out tongues integral with the platform into a cavity or cavities in the foot, each tongue being in contact with a wall of the foot.

[0014] The document ES2281244 (A1) discloses a modular bookshelf having a supported frame which includes one or multiple superimposed modular bodies.

[0015] The document US3877396 (A) discloses a knockdown display rack including a plurality of horizontal shelves, preferably of Masonite, a plurality of vertical support columns, preferably of folded fibrous or plastic sheet material, each being slotted in the interior at the same heights to slidably receive and support the corresponding peripheries of the shelves.Detailed description of the invention

[0016] The present invention is applied in various fields of application, especially in the manufacture of composite structures for the industry of packaging, furniture, the display of consumer products for sale, for example.

[0017] A tubular structural profile for a construction system is disclosed, manufactured starting from the folding and cutting of a sheet of semi-rigid and foldable material, with high rigidity against bending, compression and torsion, the tubular structural profile comprising an external contour which comprises 4 substantially orthogonal sections joined at fold lines, and the tubular structural profile comprising an internal section located diagonally joining two opposing fold lines in a folded position. The sheet of semi-rigid material has 6 rectangular, adjacent and parallel sections (1-6), separated from each other by fold lines (10-14), wherein the two central sections (1, 2) correspond to two first external sections (1, 2) of the external contour, separated by a first fold line (10), followed by two sections corresponding to two second external sections (3, 4) of the external contour, separated from the respective first external sections (1, 2) by two second fold lines (11, 12), and followed, in a symmetrical manner, by two sections corresponding to two internal diagonal sections (5, 6) of the tubular structural profile, separated from the respective second external sections (3, 4) by two third fold lines (13, 14). The sheet of semi-rigid material is configured to be folded in a single rotation direction in each fold line (10-14), with the diagonal sections (5, 6) forming an angle greater than 90° in the third fold lines (13, 14) in the folded position, and the second fold lines (11, 12) and the first fold line (10) forming a substantially right angle. The tubular structural profile comprises at least one tongue (7) in one of the third fold lines (13, 14) inserted in at least one slot (8) located on the corresponding opposing third fold line (13, 14) in the folded position to close the tubular structural profile, preventing the profile from opening during the structural performance thereof. The width of the two internal diagonal sections (5, 6) of the tubular structural profile is less than the internal diagonal distance between the opposing first and third fold lines in the folded position to create a fitted space, such that when the tubular structural profile is folded around an angle profile (9) of the construction system having two wings positionable against the respective two first external sections (1, 2), the angle profile (9) fits into the fitted space, thus permitting the structural solidarity of structural profiles collinear with each other.

[0018] The first fold line (10) of the tubular profile can be divided into two parallel rectilinear trajectories, separated from each other by a distance similar to twice the thickness of the material of the sheet.

[0019] The tubular structural profile of the construction system has at least one break (15) of continuity of the sheet of semi-rigid material in the second external sections (3 and 4) and in the two internal diagonal sections (5 and 6), in a symmetrical manner, which permits the creation of an engaging area for transverse structural profiles which make up a set of elements of a composite structure.

[0020] The angle profile (9) can contain extensions transverse to the longitudinal axis thereof, formed by the two wings wedged against the respective two first external sections (1 and 2), wherein the extensions are adapted to join to at least one other angle profile substantially parallel to the first one, and wherein the breaks (15) in the second external sections (3 and 4) and in the two internal diagonal sections (5 and 6) coincide with the extensions.Examples of application

[0021] A first preferred application of the tubular structural profile of the present invention corresponds to the creation of linear reinforcements, resistant to external bending and compression forces, for the reinforcement of packaging, preferably closed or semi-closed cardboard boxes, to be installed inside of them and preferably along the edges thereof, thus preventing the collapse thereof due to loads from stacking and impacts. Additionally, the profile can be installed in the form of an array with a parallel arrangement, for the reinforcement of container bases, in order to increase the weight-bearing capacity thereof, creating a base with a high strength against compressive and shearing loads without needing to incorporate other materials in the packaging.

[0022] A second preferred application of the tubular structural profile and of the composite structure of the profile corresponds to the manufacture of pallets for the stacking, transport and storage of products, wherein a resistant frame, created from a contour of profiles in a horizontal parallelepiped arrangement is reinforced by means of the insertion of horizontal tubular profiles, with the application of at least 4 short segments of tubular profiles under the resistant frame for the creation of supports towards the floor.

[0023] A third preferred application consists in the manufacture of furniture for displaying and selling products in the retail business, which have structural strength and external dimensions suitable for the transport and storage on pallets, display of products, assembly and disassembly in the place of use, without needing specialised tools or additional materials, comprising the creation of composite structures, starting from sheets of plastic or cardboard material, of at least 3 pillars formed with the tubular structural profile, assembled together by means of the folding of a sheet around another, wherein the internal diagonal layers (5 and 6) of the profiles have breaks at the same height between the pillars, for the insertion of transverse profiles which are conveniently integral to horizontal surfaces contained between the pillars, which permit the support of the products in storage, transport, display and sale.Description of the figures

[0024] The symbology used is the following: (1, 2)First external sections (3, 4)Second external sections (5, 6)Internal diagonal sections (7)Tongue (8)Slot (9)Angle profile (10)First fold line (11, 12)Second fold lines (13, 14)Third fold lines (15)Engaging area Figure 1 shows a layout of the sheet starting from which the tubular structural profile is created, indicating the fold lines (10, 11, 12, 13, 14) thereof and also the first external sections (1 and 2), second external sections (3 and 4), internal diagonal sections (5 and 6), at least one tongue (7) and in a corresponding manner at least one slot (8) thereof. Figure 2 shows a first step of folding the tubular structural profile, wherein the internal diagonal sections (5 and 6) are folded symmetrically at an angle greater than 90°. Figure 3 shows a second step of folding the tubular structural profile, wherein the second external sections (3 and 4) are folded symmetrically at a right angle. Figure 4 shows a third step of folding the tubular structural profile, wherein the first external sections (1 and 2) are folded on the first fold line and wherein at least one tongue (7) is folded and inserted inside of at least one slot (8), permitting the final closing of the profile. Figure 5 shows a tubular structural profile which, however, does not form part of the present invention. The profile is in a folded and closed state, indicating the position corresponding to the different elements thereof, such as the first external sections (1 and 2), the second external layers (3 and 4) and the internal diagonal layers (5 and 6), with said internal diagonal layers (5 and 6) located joining diagonally opposing fold lines in the profile, and the tongue (7) inserted inside the slot (8). Figure 6 shows a detail of the structural assembly of the tubular structural profile on an angle profile (9), for the solidarity of the structure formed starting from the profile, permitting a firm joining of profiles collinear with each other, wherein the internal diagonal sections (5 and 6) are shorter, in order to create the space required for the angle profile (9). Figure 7 shows a layout of the sheet starting from which the tubular structural profile is created, wherein the first fold line (10) thereof is formed by two parallel trajectories, separated from each other by a distance similar to twice the thickness of the material of the sheet. Figure 8 shows an example of a break (15) in the second external sections (3 and 4) and in the two internal diagonal sections (5 and 6), in a symmetrical manner, in order to create an engaging area (15) for transverse structural profiles which make up a set of elements of a composite structure and / or to permit a collinear assembly of the tubular structural profile with an angle profile which has transverse extensions. Figures 9, 10, 11, 12 and 13 show a sequence of execution of one of the manners of application of the composite structure using the tubular structural profile and the engaging thereof, corresponding to a piece of furniture, wherein Figure 9 shows two structural frames formed starting from folded sheets, which end on the sides thereof in angle profiles, both frames being parallel to each other, and wherein furthermore there is a first sheet with cuts and layouts of folds of the structural profile, with allowances for engaging transverse profiles, which are located behind the two frames. Figure 10 shows a first wedging between both frames, wherein one of the first external sections of each tubular structural profile is positioned wedged against one of the wings of the angle profile of one of the sides of each frame. Figure 11 shows a next step of execution, wherein a second sheet has been added with cuts and layouts of folds of the structural profile, with allowances for engaging transverse profiles, similar to the first one, both wedged with the two frames, wherein furthermore a first structural tray has also been installed in the area of the base of the composite structure, which in at least two of the opposing edges thereof contains folds which form tubular profiles, after which the lower portions of the sheets with cuts and layouts of folds of the structural profile have been folded and closed around the wings with the angle profile of the frames, creating a locking of the first tray and creating an engaging area in 4 corners for a second tray. Figure 12 shows the entry of the second structural tray to rest on the engaging of 4 corners, after which tubular structural profiles will be folded and closed around the wings with the angle profile of the frames on a second level. Figure 13 shows the final step of the execution, wherein the different levels of structural profiles have been folded and closed around the frames and the trays have been installed, remaining locked, culminating in the installation of one last tray on the upper portion.

Claims

1. A tubular structural profile for a construction system, manufactured starting from the folding and cutting of a sheet of semi-rigid and foldable material, with high rigidity against bending, compression and torsion, the tubular structural profile comprising an external contour which comprises 4 substantially orthogonal sections joined at fold lines, and the tubular structural profile comprising an internal section located diagonally joining two opposing fold lines in a folded position, wherein: a) the sheet of semi-rigid material has 6 rectangular, adjacent and parallel sections (1-6), separated from each other by fold lines (10-14), wherein the two central sections (1, 2) correspond to two first external sections (1, 2) of the external contour, separated by a first fold line (10), followed by two sections (3, 4) corresponding to two second external sections (3, 4) of the external contour, separated from the respective first external sections (1, 2) by two second fold lines (11, 12), and followed, in a symmetrical manner, by two sections (5, 6) corresponding to two internal diagonal sections (5, 6) of the tubular structural profile, separated from the respective second external sections (3, 4) by two third fold lines (13, 14); b) the sheet of semi-rigid material is configured to be folded in a single rotation direction in each fold line (10-14), with the diagonal sections (5, 6) forming an angle greater than 90° in the third fold lines (13, 14) in the folded position, and the second fold lines (11, 12) and the first fold line (10) forming a substantially right angle; characterized in that c) the tubular structural profile comprises at least one tongue (7) in one of the third fold lines inserted in at least one slot (8) located on the corresponding opposing third fold line (13, 14) in the folded position to close the tubular structural profile, preventing the profile from opening during the structural performance thereof; wherein the width of the two internal diagonal sections (5, 6) of the tubular structural profile is less than the internal diagonal distance between the opposing first and third fold lines in the folded position to create a fitted space, such that when the tubular structural profile is folded around an angle profile (9) of the construction system having two wings positionable against the respective two first external sections (1, 2), the angle profile (9) fits into the fitted space.

2. The tubular structural profile of claim 1, wherein the first fold line (10) is divided into two parallel rectilinear trajectories, separated from each other by a distance similar to twice the thickness of the material of the sheet.

3. A construction system, based on a tubular structural profile which is manufactured starting from the folding and cutting of a sheet of semi-rigid and foldable material, with high rigidity against bending, compression and torsion, the tubular structural profile comprising an external contour which comprises 4 substantially orthogonal sections joined at fold lines, and the tubular structural profile comprising an internal section located diagonally joining two opposing fold lines in a folded position, wherein: a) the sheet of semi-rigid material has 6 rectangular, adjacent and parallel sections (1-6), separated from each other by fold lines (10-14), wherein the two central sections (1, 2) correspond to two first external sections (1, 2) of the external contour, separated by a first fold line (10), followed by two sections (3, 4) corresponding to two second external sections (3, 4) of the external contour, separated from the respective first external sections (1, 2) by two second fold lines (11, 12), and followed, in a symmetrical manner, by two sections (5, 6) corresponding to two internal diagonal sections (5, 6) of the tubular structural profile, separated from the respective second external sections (3, 4) by two third fold lines (13, 14); b) the sheet of semi-rigid material is configured to be folded in a single rotation direction in each fold line (10-14), with the diagonal sections (5, 6) forming an angle greater than 90° in the third fold lines (13, 14) in the folded position, and the second fold lines (11, 12) and the first fold line (10) forming a substantially right angle; characterized in that c) the tubular structural profile comprises at least one tongue (7) in one of the third fold lines (13, 14) inserted in at least one slot (8) located on the corresponding opposing third fold line (13, 14) in the folded position to close the tubular structural profile, preventing the profile from opening during the structural performance thereof; d) the tubular structural profile has at least one break (15) of continuity of the sheet of semi-rigid material in the second external sections (3, 4) and in the two internal diagonal sections (5, 6), in a symmetrical manner, which permits the creation of an engaging area for transverse structural profiles which make up a set of elements of a composite structure; wherein the width of the two internal diagonal sections (5, 6) of the tubular structural profile is less than the internal diagonal distance between the opposing first and third fold lines in the folded position, to create a fitted space for folding the profile around an angle profile (9) having two wings positioned against the respective two first external sections (1, 2), thus permitting the structural solidarity of structural profiles collinear with each other.

4. The construction system of claim 3, wherein the first fold line (10) is divided into two parallel rectilinear trajectories, separated from each other by a distance similar to twice the thickness of the material of the sheet.

5. The construction system of claims 3 to 4, wherein the angle profile (9) contains extensions transverse to the longitudinal axis thereof formed by the two wings wedged against the respective two first external sections (1, 2), wherein the extensions are adapted to join to at least one other angle profile substantially parallel to the first one, and wherein the breaks (15) in the second external sections (3, 4) and in the two internal diagonal sections (5, 6) coincide with the extensions.