Support element and method for manufacturing the same

Abstract

The invention relates to a support element, having an upper belt (1), a lower belt (2) and an intermediate element (3) connecting the upper belt (1) to the lower belt (2), wherein the intermediate element (3) is formed by a metal sheet, in particular a trapezoidal metal sheet, having elevations (4) and depressions (5). To achieve simple and at the same time process-safe production, according to the invention it is provided that the intermediate element (3) rests at least in some areas against the upper belt (1) and lower belt (2) and the metal sheet is connected to the upper belt (1) and lower belt (2) by means of screws, wherein screw heads (6) of the screws are arranged on the outside of the upper belt (1) or lower belt (2) and the screws are screwed into press nuts (7) attached to the intermediate element (3). In addition, the invention relates to a method for producing a support element, wherein an upper belt (1) and a lower belt (2) are provided, after which an intermediate element (3) having elevations (4) and depressions (5) is connected to the upper belt (1) and lower belt (2) by means of screws.

Description

[0001] The invention relates to a support element comprising an upper chord, a lower chord and an intermediate element connecting the upper chord to the lower chord, wherein the intermediate element is formed by a sheet metal having protrusions and depressions, in particular a trapezoidal sheet metal.

[0002] Furthermore, the invention relates to a method for manufacturing a support element, wherein an upper chord and a lower chord are provided, after which an intermediate element having protrusions and depressions is connected to the upper chord and lower chord by screws.

[0003] Support elements of the type mentioned above, in particular beams, are known from the prior art, wherein an upper chord and a lower chord are connected by a corrugated base body (for example, from document DE 1 994 487 U).

[0004] With such a beam, high stiffness in different directions normal to a longitudinal axis of the top chord or bottom chord can be achieved with a particularly simple construction and low weight.

[0005] A disadvantage has been found to be that the production of such carriers is very costly.

[0006] Document US 1 975 228 A discloses a support element according to the preamble of claim 1 and a method for manufacturing a support element according to the preamble of claim 11.

[0007] This is where the invention comes in. The object of the invention is to provide a support element of the type mentioned above, which is particularly easy and inexpensive to manufacture. Furthermore, a method for the simple and inexpensive manufacture of such a support element is to be provided.

[0008] The first problem is solved according to the invention by a support element of the type mentioned at the outset, in which the intermediate element rests at least partially on the upper chord and lower chord and the sheet metal is connected to the upper chord and lower chord by screws, wherein the screw heads of the screws are arranged on the outside of the upper chord or lower chord and the screws are screwed into press-fit nuts attached to the intermediate element.

[0009] Within the scope of the invention, it was recognized that this design of the support element allows for simple and cost-effective manufacturing, especially since the press-fit nuts can be pre-arranged in screw holes of the intermediate element. This means that for on-site assembly of the support element, for example at a construction site, it is sufficient to position the top chord, bottom chord, and intermediate element next to each other and connect them by screwing in the screws. In particular, it is not necessary to hold nuts and, if applicable, washers or the like separately while a screw is being inserted from another side, as is common in prior art designs. Assembly can therefore be carried out easily with minimal personnel, for example, using a cordless screwdriver or a torque wrench.

[0010] The elevations and depressions of the intermediate element usually extend at least partially in a plane that is normal to a direct connection between the upper chord and the lower chord, i.e., generally transverse to a longitudinal axis of the upper chord and the lower chord, so that a high section modulus and thus a high stiffness are also achieved in a direction transverse to the longitudinal axis.

[0011] It is advantageous if the top chord and / or the bottom chord are formed by hollow profiles, in particular square profiles, preferably square tubes, which have openings for the tabs of the intermediate element. This allows for particularly simple assembly. Furthermore, such a support element ensures high stiffness in different spatial directions. The openings for the tabs generally have dimensions corresponding to those of the tabs and are preferably arranged on a top surface of the hollow profiles, particularly adjacent to a side surface.

[0012] The intermediate element therefore preferably has tabs whose tab height corresponds approximately to the profile height of the hollow profiles. For square tubes, the profile height corresponds approximately to the length of the side faces of the hollow profiles.

[0013] The tabs can then lie flat against the inside of the side surfaces of the hollow profiles to ensure a good friction-fit connection.

[0014] Preferably, the tabs have bores or approximately circular screw holes in which the press-fit nuts are arranged. These nuts connect the tabs, located on the inside of the hollow profiles, to the hollow profiles or the top and bottom flanges by means of screws. These screws are inserted from the outside through the side surfaces of the top and bottom flanges and screwed into the press-fit nuts located on the tabs. The tabs are thus positioned between the press-fit nuts on one side and the side surfaces of the hollow profiles on the other, resulting in particularly good contact pressure of the tabs against the inner surfaces of the hollow profiles.

[0015] Particularly high stiffness of the supporting element is achieved when the tabs in the hollow profiles abut the inner surfaces of the hollow profiles, preferably opposite inner surfaces. This allows, for example, both the raised and recessed areas of the intermediate element to be connected to the top and bottom chords. The tabs of the intermediate element thus preferably project through tab openings located on the upper surfaces of the top and bottom chords and abut the inner surfaces of the side faces of the top and bottom chords, which are typically formed by hollow profiles. In a preferred embodiment of the hollow profiles as square profiles or square tubes, the side faces connect the upper surfaces of the hollow profiles to their lower surfaces.

[0016] It is particularly preferred that the distance between the raised and recessed areas of the sheet metal, or, in the case of a trapezoidal sheet metal intermediate element, the height of the trapezoid, corresponds to the distance between the side surfaces of the hollow profiles forming the top and / or bottom flanges. This allows for a surface connection of the intermediate element to the hollow profiles on opposite side surfaces, preferably on the inside, to achieve particularly simple manufacturability.

[0017] If the intermediate element is designed with tabs, a tab spacing in the transverse direction usually corresponds to a distance between protrusions and depressions, or, if the intermediate element is designed as a trapezoidal sheet, to a height of the trapezoid.

[0018] It is advantageous if screw holes are provided on the tabs, through which the press-fit nuts are located, specifically on the side opposite a contact surface of the intermediate element with the top or bottom flange. The screw holes, which can also be designed as bores, are usually through holes, allowing the tabs arranged in the hollow profile to be clamped between the press-fit nuts and the side surfaces of the hollow profiles by screws that are inserted from the outside of the hollow profiles through corresponding bores or screw holes in the hollow profiles and in the tabs, and then screwed into the press-fit nuts. This clamping action ensures good force transmission.

[0019] The screw holes are preferably created by laser cutting into the sheet metal that forms the intermediate element, thus ensuring simple and reliable manufacturing.

[0020] The thickness of the sheet metal of the intermediate element and / or the hollow profiles can be, for example, 1 mm to 30 mm, preferably 5 mm to 15 mm. It is understood that this thickness is selected depending on the expected load, which, in the case of a beam, can also be determined by its length, span, or cantilever. Typically, the sheet metal or intermediate element has approximately the same thickness throughout, which consequently usually corresponds to the flange width.

[0021] The screws and nuts are usually also dimensioned according to an expected load and can be designed with a nominal size of M10, M14 or M16 to achieve good pressure of the tabs against the hollow profiles.

[0022] Preferably, the intermediate element has tabs spaced apart along a transverse direction, which are connected to opposite side faces of the hollow profile, preferably over a surface. This achieves particularly high stiffness even in a transverse direction. Typically, the tabs are thus spaced apart both along a longitudinal axis of the top and bottom chords and along a transverse direction perpendicular to the longitudinal axis.

[0023] A particularly simple yet highly precise manufacturing method is achieved when the tab openings and / or screw holes are formed by laser cutting. This allows the tab openings in the top and bottom chords to be easily adapted to the dimensions of the tabs, ensuring a highly precise connection of the intermediate element's tabs to the top and bottom chords with minimal weakening of the chords.

[0024] The screw openings, which correspond to the dimensions of screws through which the top chord or bottom chord is connected to the intermediate element, are also preferably created by laser cutting in the top chord, bottom chord and / or intermediate element.

[0025] It is particularly preferred that the tab openings extend to a side surface of the hollow profile and have an opening width that corresponds at least to one tab width plus one height of the part of the press-fit nut projecting from the intermediate element, wherein the width is preferably less than one tab width plus twice the height of the part of the press-fit nut projecting from the intermediate element. In other words, the tab openings are preferably designed to be just large enough to allow the tabs, including the press-fit nuts usually already attached to them, to be inserted into the tab openings, but not much larger, in order to minimize material weakening of the top and bottom flanges.

[0026] It is particularly preferred that the opening length of the tab openings is less than 30 mm, preferably less than 15 mm, and in particular less than 5 mm, greater than the tab length of the tabs.

[0027] Furthermore, it is advantageous if the opening width of the openings is less than 30 mm, in particular less than 15 mm, preferably less than 5 mm, greater than the tab width plus the height of the press-fit nut protruding from the tab.

[0028] As a rule, the tab width corresponds to the thickness of the sheet metal from which the intermediate element is formed.

[0029] If the tab openings are created in the hollow profiles by laser cutting, a corresponding dimension can be achieved in a particularly simple, process-reliable and precise manner.

[0030] The tab openings can therefore have an opening width of, for example, 15 mm to 30 mm. The opening length of the tab openings typically corresponds to approximately the length of the tabs themselves and can, for example, range from 20 mm to 200 mm.

[0031] It is particularly advantageous if the intermediate element between the plates, which are positioned in the top or bottom chord, rests at least partially against an outer surface of the top or bottom chord. This allows force transmission not only at the plates but also along the area between them, with contact typically occurring via an end face of the intermediate element to the upper surface of the top or bottom chord.

[0032] The intermediate element can be formed in a variety of ways, for example, as a welded structure with raised and recessed areas. A particularly simple manufacturing method is achieved when the intermediate element is formed from a bent sheet of metal. For example, the intermediate element can consist of a sheet of metal bent into a trapezoidal shape or be formed entirely from such a sheet. The intermediate element is typically connected to the upper or lower flange by press-fit nuts and bolts that protrude through the upper or lower flange and bolt holes in the intermediate element.

[0033] A load-bearing element according to the invention is easy to manufacture and simultaneously exhibits high stiffness and strength in different spatial directions. Accordingly, the load-bearing element can be used for a wide variety of purposes. It is particularly advantageous if a structure, especially a carport or a building, which has a beam, incorporates a beam formed by a load-bearing element according to the invention. This allows the structure to be manufactured simply and cost-effectively, while simultaneously achieving high stiffness and strength.

[0034] The further problem is solved according to the invention by a method of the type mentioned at the outset, in which the screws are guided through side surfaces of the upper chord or lower chord and screwed into press-fit nuts arranged on the intermediate element in order to press the intermediate element onto the upper chord or lower chord in certain areas.

[0035] This enables a particularly simple and simultaneously reliable manufacturing process for a load-bearing element with high stiffness in multiple spatial directions. The intermediate element, with its integrated press-fit nuts, can be prefabricated, making assembly on-site very easy.

[0036] It is advantageous if the contour of the intermediate element is formed at least partially, and preferably entirely, by laser cutting. The contour of the intermediate element can be produced, for example, by laser cutting a substantially rectangular sheet metal part with optionally arranged tabs on the top and bottom surfaces. The tabs are designed to be inserted into corresponding openings in the top or bottom flange and screwed to the top or bottom flange, which are preferably hollow profiles. The term "contour" is thus understood to refer in particular to a contour in a side view, i.e., with a projection direction along the transverse direction.

[0037] The contour of the intermediate element is typically formed by laser cutting before the element is bent. During laser cutting, the intermediate element is therefore usually still a flat sheet of metal.

[0038] The raised and recessed areas of the intermediate element can be formed in a variety of ways, for example by welding individual sheets together. Particularly simple manufacturing is achieved if the raised and recessed areas of the intermediate element are at least partially formed into a flat sheet by forming, especially bending, preferably after the sheet has been cut.

[0039] The sheet metal is usually made of steel, especially structural steel.

[0040] To avoid corrosion, it is preferably provided that the sheet metal of the intermediate element is galvanized, preferably after the sheet metal has been bent.

[0041] To achieve particularly easy manufacturing, it is preferably provided that the press-fit nuts are pressed into the intermediate element after the sheet metal has been galvanized.

[0042] After the intermediate element is completed, the top chord, bottom chord, and intermediate element are typically connected and bolted together. For this purpose, preferably, tabs of the intermediate element are first inserted into tab openings on the top surfaces of the top chord and bottom chord, respectively, and screws are inserted from the outside through screw holes on the top chord and bottom chord and the intermediate element, and screwed into press-fit nuts located on the inside of the intermediate element adjacent to the screw holes.

[0043] The intermediate element is thus usually formed by first cutting the sheet metal by laser cutting, whereby the sheet metal is usually still flat, after which the sheet metal is bent, preferably into a trapezoidal sheet, after which the sheet metal is galvanized, after which the nuts are pressed into the area of ​​screw openings or holes, which were usually also introduced into the sheet metal by laser cutting during the cutting process, after which the intermediate element is screwed to the upper chord and lower chord.

[0044] A corresponding beam can thus be assembled on a construction site in a particularly simple manner. The top chord, bottom chord, and intermediate element are typically manufactured in a single production run, preferably using an automated laser cutting device. This device creates openings for tabs in the top and bottom chords, as well as screw holes in the intermediate element, top chord, and bottom chord, and cuts the contour of the intermediate element from a flat sheet of metal.

[0045] Further features, advantages, and effects of the invention will become apparent from the exemplary embodiments described below. The drawings referenced therein show: Fig. 1 bis 3 a first embodiment of a support element according to the invention; Fig. 4 a further embodiment of a support element according to the invention; Fig. 5 a flowchart of a method according to the invention for manufacturing a support element.

[0046] Fig. 1 Figure 1 shows the upper chord 1, lower chord 2, and intermediate element 3 of a support element according to the invention in a partially assembled state. The upper chord 1 and lower chord 2 are each formed by a square tube and have laser-cut tab openings 8 into which tabs 9 of the intermediate element 3 can be inserted.

[0047] In the Fig. 1 In the depicted state, the tabs 9 are already inserted into the tab openings 8 of the lower chord 2, and the upper chord 1 lies in the unassembled state next to the lower chord 2 and intermediate element 3, so that the tab openings 8 of the upper chord 1 and the tabs 9 are clearly visible.

[0048] As can be seen, the intermediate element 3 is formed by a trapezoidal sheet metal sheet bent into a profile with protrusions 4 and depressions 5, which has tabs 9 that can be inserted into the tab openings 8 on the top chord 1 and bottom chord 2. The tabs 9 each have a tab height 23, which is approximately equal to the profile height 24 of the top chord 1 and bottom chord 2, i.e., a length equal to the side surfaces 14 of the top chord 1 and bottom chord 2, which are formed here by square tubes. This ensures particularly good force transmission between the tabs 9 and the top chord 1 or bottom chord 2.

[0049] Circular bores or screw holes 10 are arranged on each of the tabs 9, with press-fit nuts 7 positioned on their inner sides. As can be seen, the press-fit nuts 7 are arranged on one side of the tabs 9, opposite a contact surface 11 of the tabs 9. The contact surface 11 is understood to be the surface on which the tabs 9, in the assembled state, bear against the inner side surfaces 14 of the upper chord 1 or lower chord 2.

[0050] Furthermore, in Fig. 1 It is evident that tabs 9 are arranged on both the raised sections 4 and the recesses 5 of the intermediate element 3, and are thus spaced apart in the transverse direction 13. A tab spacing 25 of the tabs 9 in the transverse direction 13 corresponds approximately to a side surface spacing 26 of the side surfaces 14 of the hollow profile, so that the tabs 9 can be connected alternately over their entire surface to the opposite side surfaces 14. In this way, a particularly high stiffness is achieved even in the transverse direction 13.

[0051] The top chord 1 and bottom chord 2 can thus be easily connected to the tabs 9 of the intermediate element 3 by means of screws (not shown). These tabs project through the tab openings 8 into the interior of the top chord 1 and bottom chord 2, respectively. The screws are inserted through corresponding circular screw holes 10 or bores on the side surfaces 14 of the top chord 1 and bottom chord 2 and the tabs 9, after which the screws are screwed into the press-fit nuts 7 located on the inside. This creates a full-surface friction-fit connection between the tabs 9 of the intermediate element 3 and the inner surfaces of the top chords 1 and bottom chords 2, which are formed by hollow profiles.

[0052] Fig. 2 Figure 1 shows a process step in the assembly of the supporting element, in which the tabs 9 of the intermediate element 3 are inserted into the tab openings 8 of the top chord 1. It is particularly evident here that bores or circular screw holes 10 in the tabs 9 correspond to bores or circular screw holes 10 in the side surfaces 14 of the top chord 1, so that screws can be inserted from the outside through these screw holes 10 and screwed into the press-fit nuts 7 located on the inside.

[0053] Both the circular screw openings 10 for inserting screws, and the approximately rectangular tab openings 8 for receiving the tabs 9 on the upper chord 1 and lower chord 2 are usually formed by laser cutting, as is the contour of the intermediate element 3 and the circular screw openings 10 on the intermediate element 3.

[0054] Fig. 3 Figure 1 shows in detail a process step in which the tabs 9 of the intermediate element 3 are inserted into the tab openings 8 on a top surface 21 of the upper chord 1. As can be seen, the tab openings 8 on the top surface 21 of the upper chord 1 extend to the side surfaces 14 of the upper chord 1 and are approximately rectangular in shape, with an opening width 15 of the tab openings 8 being slightly larger than a tab width 16, or the thickness of the sheet metal of the intermediate element 3 plus a height 20 of the part of the press-fit nut 7 protruding from the sheet metal. An opening length 17 of the tab openings 8 is also only a few millimeters larger than a corresponding tab length 18 of the tab 9, so that the tab 9 can be easily inserted into the tab opening 8, while at the same time the insertion of the tab opening 8 causes only a slight weakening of the material of the upper chord 1 and lower chord 2.

[0055] Fig. 4 Figure 1 shows a support 22, which can be used, for example, for a carport, formed by a support element according to the invention. Here, the upper chord 1 and lower chord 2 are each screwed to intermediate elements 3, which are also formed by trapezoidal sheets. The screw heads 6 of the screws connecting the upper chord 1 and lower chord 2 to the intermediate element 3 are located on the outside. The screwing is therefore done from the outside, which simplifies assembly.

[0056] The construction with a trapezoidal sheet between the top chord 1 and bottom chord 2 achieves high stiffness in all directions perpendicular to the longitudinal direction 12. At the same time, the supporting element is easy to assemble, especially since the top chord 1 and bottom chord 2, already with appropriate dimensions and corresponding tab openings 8 and screw holes 10, as well as the intermediate element 3, can be delivered to the construction site pre-cut, bent, and fitted with screw holes 10 and press-fit nuts 7, where these elements simply need to be positioned and bolted together.

[0057] Fig. 5 shows a flowchart of a method according to the invention for manufacturing a support element.

[0058] According to this method, in a first process step Z1 a sheet is provided, after which the sheet is cut to size by laser cutting in a second process step Z2, whereby tabs 9 are also formed and screw openings 10 are made in tabs 9.

[0059] In a subsequent, third process step Z3, the sheet metal is bent, whereby raised areas 4 and indentations 5 are introduced into the previously flat sheet metal. For example, a trapezoidal sheet metal can be bent as shown in Fig. 1 bis 4 can be represented and formed.

[0060] In a further, fourth process step, the sheet metal can be galvanized, after which in a fifth process step the press-fit nuts 7 are pressed into the area of ​​the screw openings 10, so that screws protruding through the screw openings 10 can be screwed into the press-fit nuts 7.

[0061] The process steps one to five are therefore sufficient to form the intermediate element 3.

[0062] In a parallel process step, the upper chord 1 and lower chord 2 are formed, which can, for example, be designed as hollow profiles. For this purpose, corresponding profile tubes are cut and preferably also provided with tab openings 8 on the top surfaces 21 and screw openings 10 on the side surfaces 14 by laser welding.

[0063] It goes without saying that the top chord 1 and bottom chord 2 can also be galvanized.

[0064] Subsequently, the top chord 1 and bottom chord 2 are connected by the intermediate element 3 in an assembly step M. For this purpose, screws are inserted through corresponding screw holes 10 on the side surfaces 14 of the top chord 1 and bottom chord 2, as well as on the tabs 9 of the intermediate element 3, and screwed into the press-fit nuts 7 to press the tabs 9 against the side surfaces 14 of the top chord 1 and bottom chord 2. On-site at a construction site, after delivery of the prefabricated elements top chord 1, bottom chord 2, and intermediate element 3, only assembly by inserting the tabs 9 into the tab holes 8 and screwing them in place is required, thus enabling simple, reliable assembly with minimal personnel.

[0065] A load-bearing element according to the invention can thus be manufactured in a simple, process-reliable and cost-effective manner and exhibits high stiffness and strength in several spatial directions.

Claims

1. A bearing element having an upper belt (1), a lower belt (2), as well as an intermediate element (3) connecting the upper belt (1) with the lower belt (2), wherein the intermediate element (3) is formed by a sheet with elevations (4) and depressions (5), in particular a trapezoidal sheet, characterized in that the intermediate element (3) at least regionally abuts against the upper belt (1) and lower belt (2), and the sheet is connected with the upper belt (1) and lower belt (2) by screws, wherein screwheads (6) of the screws are arranged externally on the upper belt (1) and lower belt (2), and the screws are screwed into press-fit nuts (7) secured to the intermediate element (3).

2. The bearing element according to claim 1, characterized in that the upper belt (1) and / or the lower belt (2) is formed by hollow profiles, in particular square profiles, which have tab openings (8) in which tabs (9) of the intermediate element (3) are positioned.

3. The bearing element according to claim 2, characterized in that the tabs (9) in the hollow profiles abut against internal sides of the hollow profiles, preferably against opposing internal sides.

4. The bearing element according to claim 2 or 3, characterized in that the tabs (9) have arranged on them screw openings (10), on which the press-fit nuts (7) area arranged, specifically on a side lying opposite a contact surface (11) of the intermediate element (3) with the upper belt (1) or the lower belt (2).

5. The bearing element according to one of claims 2 to 4, characterized in that the intermediate element (3) has tabs (9) spaced apart along a transverse direction (13), which are connected with opposing lateral surfaces (14) of the hollow profile, preferably over a large area.

6. The bearing element according to one of claims 2 to 5, characterized in that the tab openings (8) and / or the screw openings are formed via laser cutting.

7. The bearing element according to one of claims 2 to 6, characterized in that the tab openings (8) extend up to a lateral surface (14) of the hollow profile and have an opening width (15) that corresponds at least to a tab width (16) plus a height (20) of the part of the press-fit nut (7) protruding from the intermediate element, wherein the width preferably corresponds to less than the tab width (16) plus double a height (20) of the part of the press-fit nut (7) protruding from the intermediate element.

8. The bearing element according to one of claims 2 to 7, characterized in that the intermediate element (3) between the tabs (9), which are positioned in the upper belt (1) or in the lower belt (2), at least regionally abuts against an external side of the upper belt (1) or the lower belt (2).

9. The bearing element according to one of claims 1 to 8, characterized in that the intermediate element (3) is formed by a bent sheet.

10. A structure, in particular a carport or building, having a carrier (22), characterized in that the carrier (22) is formed by a carrier element according to one of claims 1 to 9.

11. A method for manufacturing a bearing element, in particular a bearing element according to one of claims 1 to 9, wherein an upper belt (1) and a lower belt (2) are provided, based on which an intermediate element (3) having elevations (4) and depressions (5) is connected with the upper belt (1) and lower belt (2) by screws, characterized in that the screws are guided by lateral surfaces (14) of the upper belt (1) or lower belt (2), and are screwed into press-fit nuts (7) arranged on the intermediate element (3), so as to regionally press the intermediate element (3) against the upper belt (1) or lower belt (2).

12. The method according to claim 11, characterized in that a contour of the intermediate element (3) is at least partially, preferably entirely, formed via laser cutting.

13. The method according to claim 11 or 12, characterized in that the elevations (4) and depressions (5) of the intermediate element (3) are introduced into a flat sheet at least partially via molding, in particular bending, preferably after the sheet was cut.

14. The method according to one of claims 11 to 13, characterized in that the sheet of the intermediate element (3) is galvanized, preferably after the sheet was bent.

15. The method according to one of claims 11 to 14, characterized in that the press-fit nuts (7) are pressed into the intermediate element after the sheet was galvanized.

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