Structured sheet-metal profile for a load-bearing structure, load-bearing structure, and method for production

Abstract

The invention relates to a structured sheet-metal profile (10) for a load-bearing structure, in particular for a boat hull, the structured sheet-metal profile comprising: - a profiled metal sheet (18), which is bent at bend lines (17) and can be inserted between two parallel adjacent framing regions of the load-bearing structure and can be fastened to the framing regions, wherein the profiled metal sheet (18) comprises on its upper face (21) an upper profile hole grid (110); and - an upper cover element, which comprises an upper cover element hole grid and is placed on the profiled metal sheet (18), wherein the upper profile hole grid (110) and the upper cover element hole grid are aligned with one another and connected via fastening means. Here, the upper cover element and / or the bent profiled metal sheet comprises support surfaces (19) to be placed on the two framing regions, - the upper cover element hole grid and / or the upper profile hole grid (110) are provided for alignment on framing region hole grids of the framing regions and for connection to the framing region hole grids of the framing regions via fastening means.

Description

[0001] Structural sheet profile for a supporting structure, supporting structure and method for manufacturing

[0002] The invention relates to a structural sheet metal profile for a supporting structure and to such a supporting structure. Furthermore, a boat hull with the supporting structure, a catamaran with the supporting structure, a method for producing a supporting structure, and a method for producing a catamaran are provided.

[0003] DE 10 2011 111 530 B3 shows such a structural sheet profile, which can be used particularly in the side hulls of a catamaran. The structural sheet profiles are each formed by a folded profiled sheet with recesses in their flanks. Parallel cross struts are subsequently inserted through the recesses, and then deck elements are placed and secured on the top and bottom sides. This already enables a lightweight yet rigid sandwich construction.

[0004] It turns out that such designs are relatively complex to withstand the high demands placed on the occurring loads and to enable a relatively low manufacturing effort, especially since it is difficult to precisely manufacture corresponding folded alignment elements, especially with high material thicknesses. DE 20 2009 011 263 U1 shows a device for protecting a ship's hull against the effects of shock waves, wherein a substantially flat element is provided on the outside of the ship's hull, which

[0005] 4609-3 PCT Bre / kl 17.05.2023 is designed to be flexible and has such deformability that it is capable of at least partially dissipating the energy transmitted by a shock wave before the shock wave reaches the ship's hull. The planar element can be elastic or plastic and can serve to form an outer skin.

[0006] The invention is based on the object of creating a structural sheet metal profile for a supporting structure, such a supporting structure, a boat hull and methods for manufacturing which enable fast and precise production with low weight.

[0007] This object is achieved by a structural sheet metal profile, a supporting structure, a boat hull, a catamaran with the boat hull, and methods for manufacturing the same according to the independent claims. The subclaims describe preferred developments.

[0008] The supporting structure according to the invention and / or the catamaran according to the invention can be manufactured in particular by a method according to the invention. The catamaran can in particular be a swath catamaran (small waterplane area twin hull catamaran) or a catamaran with a twin hull and a small waterline area.

[0009] Thus, a structural sheet profile is created which is particularly designed and intended to be placed between two frames. The structural sheet profile has a folded profiled sheet which is formed by bending a perforated starting sheet and preferably has parallel elevations and depressions formed between them, thus enabling high rigidity and flexural strength. Furthermore, an upper cover element is placed on the profiled sheet. The two frames and corresponding support surfaces of the profiled sheet for resting on the two spaced-apart frames run in a transverse direction, in particular parallel. In the case of a U-shaped or semi-open support structure, the transverse direction can also extend partially or entirely in a vertical direction, corresponding to the course of the frames, which can be angled, for example.

[0010] According to an advantageous embodiment, unlike, for example, in DE 10 2011 111 530 B3, no continuous struts are provided that extend continuously through the structural sheet metal profile in the transverse direction and reinforce the folded sheet metal profile. In particular, no struts extending at least partially in the transverse direction can be provided, preferably without any reinforcing struts at all. Advantageously, stiffening can be achieved by recesses in several raised areas without the complex insertion of continuous struts.

[0011] According to an alternative embodiment, recesses are formed in several, preferably all, elevations and struts are inserted through the recesses. In particular, diagonally sloping flanks in which the recesses are formed can run between the elevations (20) and the depressions, wherein the struts run at least partially in the transverse direction of the folded profiled sheet and are inserted through the recesses of several elevations. Advantageously, in this embodiment, the struts run diagonally to the elevations and depressions, in particular crossing one another or in an X-formation, and are fastened or can be fastened, e.g. welded, to the frames in their end regions. This achieves a high level of rigidity, since a direct connection between the frames is achieved by the diagonally running struts, in addition to the connection via the folded sheet.

[0012] By placing the structural sheet metal profiles between the frames, a stable and rigid structure can be created with high manufacturing precision, in which the structural sheet metal profiles ensure the connection between the frames. Furthermore, this creates a supporting structure that can advantageously be fully sealed on both the top and bottom sides.

[0013] Ribs are elongated load-bearing elements, such as square tubes. In the case of a catamaran's hull, ribs are the load-bearing, particularly U-shaped, crossbeams that run transversely through the hull, at least in some areas.

[0014] An upper cover element, which according to a preferred embodiment is made of metal, is placed on the upper side of the profiled sheet and in particular of the frames. An upper cover element hole pattern is formed in the upper cover element. Furthermore, an upper profile hole pattern is formed in the upper side of the profiled sheet, which preferably corresponds to the hole pattern of the upper cover element. These hole patterns serve for the mutual attachment and alignment of adjacent frames, each of which has at least one upper frame hole pattern.

[0015] Thus, according to the invention, the hole pattern can be aligned so that the upper deck elements and / or the profile elements with their hole pattern are placed on the two adjacent frames, and the frames and the upper deck element and / or the profile element are precisely and securely aligned with each other with little effort. For this purpose, the frames are preferably already in place, but are initially mounted in an adjustable manner and can thus be aligned or adapted to the upper hole pattern of the profile element and the upper deck element hole pattern by adjustment.

[0016] Aligning or adjusting two hole patterns is understood in particular to mean an arrangement of the two hole patterns that overlaps or is concentric, at least in some holes. Unlike in DE 10 2011 111 530 B3 mentioned at the beginning, the upper cover element hole pattern also has support surfaces for resting on the frames and fastening holes for fastening to the frames, i.e. the upper cover element is fastened with its fastening holes not only to the structural profile sheet, but also to the adjacent or opposite frames. This support can be achieved directly or with an intermediate element, in particular the profile sheet. The alignment and fastening of the upper cover element and / or the profile sheet to the frames also interacts in particular with the inventive manufacturing method for the supporting structure, as described further below.

[0017] According to a particularly preferred embodiment, the profiled sheets have support webs with which they are placed on the frames. The support webs can in particular delimit the depressions formed between the elevations of the structural profile towards the sides. The profiled sheets can thus be placed on the upper side of the frames with their lateral, preferably circumferential, support webs, which enables quick and secure formation, since the profiled sheets only have to be placed there from the upper side. In this case, the hole pattern on the upper side of the profiled sheets, in particular the holes in the support webs, is aligned with the hole pattern on the upper side of the frames. In this way, the frames in particular can be readjusted slightly in the longitudinal direction of the supporting structure in order to achieve a match, in particular a concentric match.The upper cover element is then placed on top and aligned with the hole pattern of the frames and the profiled sheet, allowing it to be securely fixed and fastened using the fasteners provided. Rivets, in particular, can be used as fasteners, but screws or, for example, plastic clips can also be used. This means that the profiled sheets and cover elements can be firmly connected to the frames, thus forming a unit. The upper cover element is advantageously made from metal, i.e. as a cover sheet that is connected to the top side of the profiled sheet and the top side of the frames using rivets that serve as fasteners. Accordingly, the lower cover element is advantageously made from metal, i.e. as a cover sheet that is fastened using rivets that serve as fasteners.

[0018] According to an alternative design, an insulating cover plate, e.g., made of a plastic such as fiberglass, or wood or plywood, can be attached as the upper and / or lower cover element. This allows areas not exposed to water to be covered with other materials. In such designs, the cover element can be attached and secured via the hole pattern, with plastic clips, for example, serving as fastening elements. Alternatively, the cover elements can also be added later, e.g., as sold by the meter.

[0019] The upper and / or lower cover elements can also be constructed in two parts, e.g., one layer of sheet metal and another layer of a different material. The two layers of the cover element preferably each have a hole pattern, in particular aligned or matching hole patterns, and can thus be connected to the profiled sheet and / or frames using common or separate fastening means. In the case of a wooden layer, for example, the respective hole may also be discontinuous.

[0020] Thus, the structural sheet profile according to the invention is formed, in particular, by the folded profile sheet and the upper, and optionally also lower, cover element, whereby the elements of the structural sheet profile are thus successively fastened to or on the frames, so that the structural sheet profile is completely formed on the frames. No struts are required here; according to a preferred embodiment, struts extending in the transverse direction, e.g., also in the transverse and longitudinal directions, i.e., an oblique direction, can be provided. However, structural sheet profiles without struts can also be provided.

[0021] A significant advantage of the invention is that the connection of two adjacent frames takes place in the unedged longitudinal direction of the profiled sheets; this means that the upper profile hole pattern in the profiled sheet connects two adjacent frames in the longitudinal direction of the supporting structure without the distance between the holes of the upper profile hole pattern in this longitudinal direction being influenced by bends.

[0022] This allows the high rigidity of a folded profiled sheet to be combined with a high degree of fit thanks to a prefabricated hole pattern that is unaffected by bending. This allows for precise, low-cost manufacturing and assembly by successively aligning and connecting the frames. The bends or folds of the profiled sheets thus advantageously do not affect the longitudinal direction of the supporting structure, e.g., the boat.

[0023] A further advantage of the supporting structure is its modular design and the fact that it can be extended using many identical parts to create hulls of different lengths or dimensions. Standardized frames and profiled sheets, as well as deck elements and, if necessary, insulating deck elements, can be used.

[0024] A further advantage is the high degree of automation achieved through computer-aided manufacturing. In particular, the prefabricated hole pattern in the original sheet prior to bending enables computer-aided manufacturing; this means that holes for the connections between the frames and other elements do not have to be drilled during assembly, i.e. when the profile elements are attached, as is the case with the prior art. A further advantage of using identical parts, and in particular computer-aided manufacturing, is that it enables easy adaptation to areas of the boat hull subject to different loads. The high degree of automation and computer-aided manufacturing enable topology optimization, for example by creating topology holes in areas of the folded profile sheets that are subject to less stress. This enables weight to be reduced and manufacturing and operating costs to be reduced.Advantageously, the topology optimization can be adapted to the loading at different points of the supporting structure. For example, in areas of a supporting structure exposed to greater wave action, a different topology optimization, e.g., with fewer recessed areas, can be used than in less stressed areas. Nevertheless, standardized folded profile elements can be used, which are optimized with different topologies depending on the load.

[0025] The topology holes can be formed by simple cutting; alternatively or additionally, the topology holes can also be flanged at their edges or reinforced by edging, which in turn achieves greater rigidity.

[0026] According to an advantageous further development, the transitions between the elevations and depressions in the folded profile sheets are formed by flanks, e.g. obliquely running flanks.

[0027] According to a preferred embodiment, reinforcing elements are inserted into the folded profiled sheets. The reinforcing elements can be inserted from the top side into the recesses of the folded profiled sheets and / or from the bottom side into the raised portions, e.g., as plug-in inserts that are inserted into suitable fastenings of the folded profiled sheet. The reinforcing elements can be designed, e.g., as reinforcing ribs, in particular trapezoidal sheets, or as wedge-shaped elements, preferably sheet metal elements, and are fastened to the profiled sheet. This allows a significant increase in rigidity to be achieved with minimal material and manufacturing expenditure. Reinforcing elements can, in particular, also be provided instead of the struts.

[0028] Due to the high prefabrication of the individual elements achieved according to the invention, and in particular the self-alignment of the elements, the construction time can be reduced while increasing the accuracy of fit.

[0029] In principle, the profiled sheets and / or the upper and lower profile elements can be placed between exactly two adjacent frames. Furthermore, the folded profiled sheet and / or the upper cover element and / or the lower cover element can extend over more than two, in particular over three, frames, i.e., overlap a central frame. This allows flat surface areas, in particular, to be covered with a smaller number of parts, reducing assembly time.

[0030] According to the invention, a high degree of accuracy of fit and rapid production are achieved, in particular, by the formation of hole patterns in the elements to be used, whereby the hole patterns can be formed with high precision, e.g., by lasering, using computer support.

[0031] In the manufacturing method according to the invention, the step of forming the profiled sheets can be carried out before or after the formation of the frames and before or after the erection of the frames and the connection of an upper and lower frame in a transverse plane.

[0032] The manufacturing method according to the invention enables fast and reliable production, in which the frames are first aligned parallel to one another and then the profiled sheets are inserted, in particular placed on top. This alone forms a secure, solid supporting structure. Subsequently, the upper cover elements, in particular cover elements, are placed on at least the top side and preferably connected to one another via the matched or aligned hole patterns, so that the structural sheet profiles formed in this way both securely fix the frames in their position and connect them. Preferably, further fixation is provided by the lower cover elements, which are attached to the folded profiled sheets and the frames and thus increase the strength as part of the structural sheet profiles.

[0033] In this way, tolerances in particular can be kept small or reduced, as tolerances are eliminated by aligning the hole patterns. The profile elements and cover elements can be placed on the frames, and these parts can be adjusted to one another by aligning the hole patterns, so that, for example, the frames can be aligned somewhat, particularly adjusted lengthwise, to correspond to the hole pattern of the profiled sheets and cover elements. This means that the adjacent elements are aligned to one another. The profiled sheets, and preferably also the cover elements, connect two adjacent frames to one another, with the hole patterns of the profiled sheets and the cover elements being placed on the hole patterns of both the left and right frames, thus connecting them. The hole patterns of adjacent frames thus overlap or overlap one another via the hole patterns of the profiled sheets and cover elements.enable secure, gradual alignment of the elements during production. The profiled sheets and deck elements can thus be successively placed, aligned, and fixed between two frames, allowing the subsequent structural profiles to be attached and aligned to the frames and the adjacent frames.

[0034] By fixing the cover elements with rivets, faulty tensions, which generally lead to the rivets coming loose, can be reliably detected. This also allows any structural weaknesses in the non-visible profiles to be detected from the outside.

[0035] Another advantage of modular production and external accessibility is that damaged segments can be easily replaced. If, for example, a deck element or a profiled sheet is damaged, these can be removed from above, replaced, and reattached between the frames. Accessibility from above is particularly advantageous here.

[0036] Advantageously, the underside of the frames and profiled sheets is also reinforced with lower deck elements. This provides a hole pattern on the underside of the profiled sheets and the underside of the frames, onto which the lower deck element, with its hole pattern, is placed and aligned. Fixing is advantageously achieved using fasteners, e.g., rivets.

[0037] This sandwich construction of profiled sheets with upper and lower cover elements and side frames allows closed air chambers to be formed in the individual structural sheet profiles, which thus also act as buoyancy bodies. Thermal insulation is also achieved through the air chamber of the structural sheet profile, i.e. between the sheets or the sheet and the cover elements. This can be further enhanced by the use of a separating layer. A plastic layer or plastic plate, for example, can be applied as a separating layer between the levels or sheet levels, in particular between the frames and the cover elements. Additionally or alternatively, the separating layer can also be achieved using an adhesive that connects the levels.

[0038] The resulting air volumes can, in principle, also be created using a vacuum and / or a protective gas. Alternatively, the air volumes or cavities in the structure, particularly between the deck elements and the frames, can be appropriately filled with foam, thus increasing rigidity and improving leak tightness. Sealed buoyancy bodies, especially with foam, can achieve a high degree of unsinkability.

[0039] The support structure or boat hull constructed in this way can, in particular, further comprise lower profile pieces for receiving the floats of a catamaran, in particular a swath catamaran. For this purpose, the lower ends of a bow-shaped support structure can be formed with, for example, vertically extending profile pieces that are inserted into suitable, matching receptacles of the floats.

[0040] Aluminum or an aluminum alloy, particularly a seawater-resistant aluminum alloy such as AlMg3 or AlMg4.5, is advantageously used as the material for the frames and profiled sheets, and possibly also for the deck elements. Such aluminum material is very lightweight and highly rigid, thus achieving low weight with high seawater resistance. The aluminum material also enables the cutting and edging processes with minimal technical effort. For example, the rivet holes in the flanks, as well as topology holes, can be created by laser cutting.

[0041] According to the invention, significant weight savings of, for example, more than 30% can be achieved compared to conventional support structures and manufacturing processes, so that the environmental balance is already improved during production and lower fuel consumption is also required for operation.

[0042] The deck elements can also extend over several frames if necessary, thus requiring fewer joints. In principle, the modular design allows for identical parts and specially adapted parts in particularly shaped areas of the hull. For example, curved areas in the bow area of ​​the ship can be achieved through special designs, e.g., of the folded profiled sheet and the deck elements. Curves or radii can be appropriately formed, for example, by forming the profiled sheet with a curve, or even in two parts, e.g., by two attached parts.

[0043] Furthermore, in some areas the profiled sheet can also be formed by folded support webs instead of support webs, ie in particular with a 90° fold compared to the profiled sheet, so that the folded support web is placed on the front side against a side surface of a frame and fastened via a hole pattern.

[0044] To create corresponding radii, e.g., in the bow or stern, the profiled sheets can be folded on several sides, creating raised edges. Two opposing raised edges can, in turn, have a hole pattern that continues into the frames and on the inside and / or outside of the frames. For example, at a point where the deck elements rest, radii can be divided into different segments, which can be folded to support the deck element. Furthermore, notches can be created here, which are reflected on the deck elements of both levels.

[0045] Alternatively or in addition to this, the desired radii can also be achieved by flanging around an upturned edge in order to continue a hole circle in the sheet metal. Furthermore, by simply welding the deck element to the flat profile folded up at the ends, a design can be achieved which serves to position the corresponding hole pattern towards the frames. The supporting structure can thus be provided in particular in the boat hull. Furthermore, the superstructure provided above the boat hull can also have a supporting structure according to an embodiment of the invention. For example, windows can also be provided between the frames.

[0046] Furthermore, the described elements can be constructed in multiple parts, designed to be pluggable along the radii for positioning. The vertically inserted sheet metal strips can be inserted into the hole pattern of the cover elements, so that the attached sheet metal parts achieve a high level of rigidity.

[0047] The production of a ship's hull is carried out according to one aspect of the invention with the steps

[0048] - Production of the floats

[0049] - Production of the frames

[0050] - Forming the profiled sheets, whereby these three first steps can be carried out in any order,

[0051] - Inserting the frames into the floats, initially without precise fixation of the frames in the longitudinal direction

[0052] - Attaching the profiled sheets to the frames, aligning and fixing the frames in the longitudinal direction and attaching at least the upper deck elements, preferably also the lower deck elements, and if necessary further elements

[0053] - if necessary, further training, e.g. sealing foils, covers.

[0054] The invention is explained in more detail below with reference to some embodiments in the accompanying drawings. They show:

[0055] Fig. 1 a structural sheet profile as a folded profiled sheet, before an upper cover element is attached;

[0056] Fig. 2 shows a structural sheet profile with additional lugs on the underside; Fig. 3 shows a detailed view of the fastening of the profile sheets and deck elements to the frames;

[0057] Fig. 4 shows a further illustration of the fastening of the profiled sheets and the upper deck element to the frames;

[0058] Fig. 5 Top views of areas of a boat hull with and without deck element;

[0059] Fig. 6 a perforated sheet as starting sheet before bending;

[0060] Fig. 7 another perforated sheet as starting sheet, for forming a folded profile sheet with lugs on the underside;

[0061] Fig. 8 is a bottom view of a structural sheet profile with lugs on the underside;

[0062] Fig. 9 a bottom view of a folded profiled sheet with lugs on the underside, before inserting the struts;

[0063] Fig. 10 a reinforcing element as a wedge-shaped sheet metal insert;

[0064] Fig. 11 shows a profile element with the reinforcement element from Fig. 25.

[0065] Fig. 12 shows the alignment of the hole pattern of the profiled sheet and cover element on the frames, forming a structural profiled sheet;

[0066] Fig. 13 an angled frame;

[0067] Fig. 14 the design of the angled frame and the attachment of a profiled sheet;

[0068] Fig. 15 the subsequent attachment of reinforcement plates to the angled frame,

[0069] Fig. 16 a section of the bow area of ​​a boat hull;

[0070] Fig. 17 shows the illustration from Fig. 16 with a longer cover element;

[0071] Fig. 18 an embodiment with three struts in the profile sheets

[0072] 1 ig. 19 a two-part profiled sheet for attachment in curved areas of the boat hull, in an exploded view;

[0073] Fig. 20 a bottom view of a folded profiled sheet with lateral folded tabs, for frontal attachment to a frame;

[0074] Fig. 21 shows the structural design of the catamaran's superstructure; Fig. 22 shows the design of a structural sheet profile with inserted reinforcement plates, before inserting the struts and attaching the deck elements.

[0075] Fig. 23 the first arrangement of the frames of Fig. 21 , before fitting the structural sheet profiles,

[0076] Fig. 24 a section of the boat hull with floats;

[0077] Fig. 25 shows a catamaran according to an embodiment of the invention;

[0078] Fig. 26 is a flow chart of a manufacturing method according to the invention;

[0079] Fig. 27 a reinforcing intermediate plate

[0080] Fig. 28 a design of the supporting structure with the reinforcement intermediate sheet: Fig. 29 an embodiment of the folded profile sheet without recesses and struts:

[0081] Fig. 30 an embodiment of the folded profile sheet with reinforcing T-profiles inserted into the recesses

[0082] Fig. 31 is a rear view of Fig. 30,

[0083] Fig. 32 a design of the folded profile sheet with diagonally running elevations, without struts,

[0084] Fig. 33 to 36 embodiments in which the folded profile sheet extends over three frames,

[0085] Fig. 37 another embodiment of a structural profile sheet,

[0086] Fig. 38 a folded profile sheet according to an embodiment;

[0087] Fig. 39 an embodiment of a folded profile sheet with folded webs

[0088] Fig. 40 an embodiment of a folded profile sheet with laterally folded webs on the recesses, for frontal attachment.

[0089] In the embodiments, particularly in Figures 1 and 2, the structural sheet profiles 10 shown are essentially formed by a folded profiled sheet 18, struts 26, 27 inserted through the profiled sheet 18, and an upper cover element 36, preferably also a lower cover element 38. To form a profiled sheet 18, according to a method step A), a starting sheet 12 made of aluminum from a coil or as a sheet metal strip is first provided, in which a hole pattern 16 is formed in a method step B), for example, by cutting or punching the starting sheet 12, wherein the hole pattern 16 has rivet holes 28, recesses 14, 14a, and topology holes 15. Figures 6 and 7 show starting sheets 12 formed in this way.

[0090] Subsequently, in method step C), the starting sheet 12 is bent or folded along bending lines 17 to produce the folded profiled sheet 18 shown in Figure 6. The profiled sheet 18 has a parallel, regular arrangement of parallel elevations 20 extending in a longitudinal direction x and depressions 22 formed between the elevations 20. On both sides of the elevations 20, flanks 24 run downwards, wherein they can run obliquely or, for example, vertically downwards, so that the depressions 22 are trapezoidal or rectangular. The elevations thus form a flat upper side 21 interrupted by the depressions 22. Accordingly, the depressions 22 preferably also form a flat underside 23. The elevations 20 are designed to be larger than the depressions 22.After folding, the rivet holes 28 form an upper profile hole pattern 110 provided on the upper side 21 and a lower profile hole pattern 112 provided on the underside 23. Figs. 9 and 22 show an embodiment of the folded profile sheet 18, wherein in Fig. 9 additional lugs 9 are formed on the underside 23 and on the recesses 22, respectively, which extend in the longitudinal direction x and here enable further engagement, in particular engagement with frames 8 and for receiving a lower cover element 36.

[0091] The recesses 14, 14a run in the flanks 24, through which obliquely running struts 26, 27 are subsequently placed as shown in Figures 1 and 2. The struts 26, 27 cross each other or are arranged in an X-shape; they therefore do not run exactly in the transverse direction y, but in the XY plane, but diagonally or obliquely to the longitudinal direction x and transverse direction y. Figures 1, 2 and 8 show the design with the struts 26 and 27 used. Here, for example, two long struts 26 can be used which cross each other or are inserted through each other; furthermore, as shown in Figure 2, two short struts 27 can be attached at an angle to a long strut 26 in order to form the X-shape. Furthermore, for example, four short struts 27 can be connected to one another in the middle.

[0092] The struts 26, 27 thus intersect in a central region of the profiled sheet 18, wherein this region has a central recess 14a that is somewhat wider than the other recesses 14. Furthermore, topology holes 15 are formed in the starting sheet 12 such that the folded profiled sheet 18 shown in Figures 6, 7 is weight-optimized, with areas not subject to such stress being left out by the topology holes 15.

[0093] In the folded profiled sheet 18, support webs 32 run along the sides in the transverse direction y, which thus delimit the recesses 22 at their ends, i.e. in the longitudinal direction x. Preferably, the support webs 32 run at the height of the upper side 21, i.e. in the upper plane, with rivet holes 28 being formed in the support webs, which thus form part of the upper profile hole pattern 110. In the embodiments, in particular in Figs. 2, 7, 8, 9, the lugs 9 on the underside 23 additionally extend outwards in the longitudinal direction x in order to form a further, lower support surface, so that the folded profiled sheet 18 can be placed into the frames 8 from the side.

[0094] In the flat starting sheet 12, the support webs 32 are advantageously separated from the material areas of the flanks 24 by cuts or cutting lines 33, so that during bending the tool bends the flanks 24 inwards along the bend lines or downwards in the Z direction, but does not bend the support webs 32, so that they remain in the plane of the upper side 20. By bending, the starting sheet 12 is shortened in the transverse direction Y, so that the support webs 32 of adjacent elevations 20 can, for example, come into contact with one another, for example in a suitable end-face contact of the support webs 32, so that continuous support webs 32 are formed on the sides. In this way, for example, a circumferential upper side 21 is formed.Alternatively, the support webs 32 can also be spaced apart from one another in the transverse direction y after folding, and intermediate sheets can be placed, e.g. welded, in the spaces between the support webs 32 on the upper side of the frame 8 and / or the folded profiled sheet 18, so that the support webs 32 together with the intermediate pieces cover the upper side in the edge region of the folded profiled sheet 18.

[0095] The support webs 32 can be joined together in a materially bonded manner, e.g., by gluing or welding; however, it is generally sufficient if they are subsequently riveted to the frame 8 and / or the upper deck element 36.

[0096] In addition, in a subsequent processing step D) of the manufacturing process, reinforcing elements 34, 35 are inserted from the top side 21 into the recesses 22 and / or from the bottom side 23 into the elevations 20, which rest against the flanks 24, and are fastened in a materially bonded manner, e.g. by welding and / or gluing, and / or by form-fitting. According to Fig. 8, the reinforcing elements are designed as trapezoidal sheets 34, which thus rest against the flanks 24 and in the recesses 22. Fig. 22 shows, for illustration, a folded profile sheet 18 with inserted trapezoidal sheets 34 without struts 26, 27. According to the embodiment of Figs. 10 and 11, the reinforcing elements are designed as wedge-shaped sheet inserts 35. The reinforcing elements 34, 35 can themselves have a topology hole 41 for weight optimization.Subsequently, in a process step E), the struts 26, 27 are placed through the recesses 14, 14a and connected to them by welding and / or gluing, so that the configuration shown, for example, in Fig. 1, 2, 8 and 11 results.

[0097] The frames 8 are manufactured according to process step G) and erected according to process step F), initially without fixing in the X-direction.

[0098] The bent profiled sheets 18, reinforced by struts 26, 27, are then placed in a process step I) with their support surfaces 19 on the two adjacent frames 8, as can be seen, for example, in Fig. 12. In the embodiments with nose 9, the reinforced, bent profiled sheets

[0099] 18 are mounted from the side or in the x-direction. The support surfaces

[0100] 19 extend in particular over the support webs 32 and the ends of the elevations 20. An upper frame hole pattern 81 is formed on the upper side 80 of each frame 8. As explained above, additional intermediate plates can be placed between the support webs 32. This aligns the upper frame hole pattern 81 of the two adjacent frames 8 with the upper profile hole pattern 110. Accordingly, a lower frame hole pattern 83 is formed on the underside 82 of the frames 8, which in the above-mentioned embodiments is aligned with the holes in the lugs 9.

[0101] Subsequently, in a method step K), upper cover elements 36 and preferably lower cover elements 38 are placed on or under the frames 8 and fastened to the frames and the profiled sheets 18, so that the structural sheet profiles 10 are formed, as can be seen, for example, from Fig. 12. The cover elements 36 and 38 have, in particular, cover element hole patterns 30, 31 of rivet holes 128 corresponding to the hole pattern of the rivet holes 28 of the folded profiled sheet 18, wherein an upper cover element hole pattern 30 is preferably formed on the upper cover element 36 and a lower cover element hole pattern 31 is formed on the lower cover element 38. The rivet holes 28 and 128 are thus aligned or flush with one another, so that rivets 40 can be used for connection. The rivets 40 can, for example, only be inserted from the top side.The rivet holes 28 are advantageously provided both in the elevations 20 and in the depressions 22, as well as in the support webs 32, and thus enable a full-surface attachment and fixing of the cover elements 36, 38. In this case, plastic layers can be placed between the profiled sheet 18 and the cover elements 36, 38.

[0102] Here, an upper cover element 36 is placed on the upper side 21, i.e., on the elevations 20 and support webs 32 of the profiled sheet 18, and optionally also on the intermediate sheets, and the hole patterns 30 and 110 are connected to one another. Furthermore, a lower cover element 38 is placed on the underside 23, i.e., below the recesses 22, and the hole patterns 31 and 112 are connected to one another.

[0103] Thus, the upper deck element is also placed with support surfaces 119 provided on the edge on the support surfaces 19 of the profiled sheets 19, if necessary also on intermediate sheets, and on the frames 8, ie in this area the support surfaces 19 and 119 lie on the frames.

[0104] The upper cover element 36 thus rests on the upper side 21 of the structural sheet profile 10 and on the frame upper sides 80. Thus, the support web 32 is received between the upper cover element 36 and the frame upper side 80, whereby fixation can also be achieved with the continuous rivets 40, which are thus placed through the upper cover element hole pattern 30, the upper profile hole pattern 110, and the upper frame hole pattern 81.

[0105] The lower cover elements 38 are added from the underside 23 of the profiled sheets 18 and placed on the undersides of the frames 82, and are aligned and fastened via the lower cover element hole grid 31 as well as the lower hole grid of the structural sheet profiles and the lower frame hole grid.

[0106] The base sheet 12 and the reinforcing ribs 34 are advantageously made of aluminum, so that no electrical stresses or corrosion occur in the contact areas, and the expansion behavior of the material remains consistent. The cover elements 36, 38 can also be made of aluminum, so that no electrical stresses or corrosion occur, and the expansion behavior of the material remains consistent. If necessary, the cover elements can also be made of plastic or coated wood, for example. The structured sheet profile 10 can form a closed volume.

[0107] Tolerances arise due to the edging, ie the dimensions of the profiled sheets 18 in the y-direction change due to the tolerances, but not the dimension in the x-direction in which the profiled sheets 18 connect the frames 8.

[0108] Process steps I) and K) position and fix the position of the frames 8. To form the boat hull 4, the frames 8 are first placed next to one another, i.e., essentially parallel to one another. In this case, the frames 8 are not permanently fixed in position, but are initially placed next to one another in an adjustable manner. Their position relative to one another is determined by placing profiled sheets 18 and upper deck elements 36, as well as, if applicable, the lower deck elements 38, i.e., in process steps I) and K). In this case, the frames and profiled sheets 18, as well as the upper deck elements 36, are aligned using the hole pattern. The individual frames 8 are thus spaced apart in the longitudinal direction x of the boat and are not connected in this longitudinal direction by, for example, profiles or other structural parts. Fixing in the longitudinal direction is only subsequently achieved by the attached profiled sheets 18 and the deck elements 36 and 38.However, the cover elements 36 and 38 can also be added subsequently, e.g. as meter goods.

[0109] For assembly, as can be seen in particular from Figs. 21 to 24, two frames 8 are first placed upright next to one another, i.e. spaced apart in the longitudinal direction x, and profiled sheets 18 and upper deck elements 36 are successively placed between the two frames 8 in such a way that the upper profile hole pattern 110 and upper deck element hole pattern 30 are aligned with the upper frame hole pattern 81 of both frames 8. The frames run in the transverse direction y and, on the sides, also in the vertical direction z, as can be seen from Figs. 21 to 24. Accordingly, the transverse direction y, which is shown in the figures for the structural profiled sheets 10, also extends partially in Figs. 21 to 24 in the Z direction of the supporting structure 6 or of the catamaran 1.

[0110] Thus, for precise alignment and adjustment, the frames 8 are adjusted accordingly in the longitudinal direction of the boat hull 4 so that they are aligned with the upper profile hole pattern 110. Thus, alignment of the frames 8 and profile sheets 18 is achieved solely based on the hole pattern of the two elements. After alignment, the elements 8, 18 can first be fixed to one another using rivet holders so that rivets 40 can subsequently be inserted. Thus, the frames 8 can already be aligned and fixed to one another using a few profile sheets 18. In this step, all of the profile sheets 18 can be placed between the frames 8, or a sufficient number so that the frames 8 are fixed in their position relative to one another.

[0111] Subsequently, the adjacent frames 8 are attached, and profiled sheets 18 are again placed between them, whereby alignment again takes place via their hole patterns 81, 110, and the frames 8 are thus fixed relative to one another. Thus, in general, intermediate placement is initially provided; with a double tab at the top and bottom, the frames are threaded through or inserted between them and then riveted. In this way, the structure of the boat hull 4 can be successively aligned and fixed, whereby the CN C prefabricated hole patterns, ie in particular the upper frame hole pattern 81 and the upper profile hole pattern 110, are aligned with one another. Thus, no rivet holes need to be drilled on site.

[0112] 21 and 22, 24 show the design of the ship's hull 4, Fig. 25 the catamaran 1 produced in this way, in particular a Swath (Small Waterplane Area Twin Hull) catamaran or catamaran with a double hull with a small waterline area. The catamaran 1 has, according to Figure 25, a hull 4 on which a superstructure 5 is formed, e.g. with cabins for the passengers and steering devices. The hull 4 in turn has two lateral floating bodies 2, 3 and a supporting structure 6 connecting the floating bodies 2, 3, which is formed with a plurality of mutually parallel, each bow-shaped or half-open frames 8. Between the frames 8, structural sheet profiles 10 are provided, which thus serve on the one hand to connect the frames 8 and furthermore form a flat finish with the frames 8.

[0113] According to Fig. 24, the supporting structure 6 can have upper and lower frames 8, which define a transverse plane or YZ plane. Between the upper and lower frames 8, a lattice structure 130, in particular a tubular spacer structure 130, is provided, e.g., by a framework structure made of connecting profiles 131, e.g., square tubes 131, which, however, does not connect the frames 8 in the longitudinal direction x. Thus, in the X direction, the upper frames 8 can be connected to one another via structural profile sheets 10, in particular to cover elements 36, 38, and correspondingly, the lower frames 8 can be connected to one another via structural profile sheets 10, in particular to cover elements 36, 38. The tubular spacer structure 130 can be inserted into the lower frames and / or upper frames 8, preferably in finger joint engagements and / or inserted laterally. In the method shown in Fig. 26, the profile sheets are first

[0114] 18 trained by

[0115] - Process step A) Provision of the starting sheet 12 and, if necessary, further materials

[0116] - Process step B) - Punching the starting sheet 12, ie forming a hole pattern 16 with recesses 14, 14a, topology holes 15 and rivet holes 28

[0117] - Process step C) Bending the perforated starting sheet 12 along bending lines 17;

[0118] - Process steps D), E) - in any order - Process step D) Inserting the reinforcing ribs 34 or trapezoidal sheets into the recesses 22, in particular connecting them by means of a material bond, ie in particular welding and / or gluing, Process step E) Inserting the long oblique strut 26 and the two short struts 27, which together form an X-shape or cross-shape, and connecting them by means of a material bond, ie in particular welding and / or gluing,

[0119] - Process step G) Manufacturing the frames 8 with formation of the frame hole grids 81, 83

[0120] - Process step H) Erecting the frames 8 and

[0121] - Process step I) successive alignment of two adjacent frames 8 on the profiled sheet(s) 18 placed between them and fastening of the profiled sheets 18 between the frames 8,

[0122] - Process step K) the upper cover elements 36 and preferably lower cover elements 38 are fastened to the frames 8 and the profiled sheets 18, so that the structural sheet profiles 10 are formed. As described above, the profiled sheets 18 are formed with lateral support webs 32, which thus form part of the upper side 21. The upper profile hole grid 110 thus extends over the upper side 21, including the support webs 32. The support webs 32 are thus provided in the non-folded part of the starting sheet 12. The upper profile hole grid 110 also extends over the support webs 32. When the starting sheet 12 is folded, the length of the starting sheet 12 is reduced in the transverse direction y, i.e. the folded profiled sheet 18 is shorter. Accordingly, no change occurs in the longitudinal direction X. Thus, the upper profile hole pattern 110 in the longitudinal direction x is not affected by the bending process.

[0123] By subsequently placing the profiled sheets 18 with the support webs 32 onto the upper sides 80 of the frames 8, and aligning the upper profile hole pattern 110 in the support webs 32 with the upper frame hole pattern 81, the two hole patterns 81 and 110 are aligned with one another solely in this longitudinal direction x, i.e. perpendicular to the bending line or folding direction y of the structural sheet profiles. This ensures a high degree of accuracy of fit of the CN C prefabricated hole patterns 81 and 110, which is not impaired by the folding process. The entire structure of the boat hull 4 is thus predetermined by the CN C prefabricated hole patterns 81, 110, with the profiled sheets 18 being successively placed between the frames 8 and aligned or fixed. The same preferably occurs in the embodiments with lower noses 9, which extend in the longitudinal direction x and rest on the underside of the frame.

[0124] In the embodiment shown here, in which the upper frame hole patterns 81 are formed on the frame upper sides 80, fixing and alignment are thus also carried out independently of tolerances in the frames 8. If the frames 8, for example, form a 10O square tube which, due to manufacturing tolerances, has tolerances of, for example, 1 mm, the width of the frames can also be 99 mm or 101 mm. However, this is not relevant for the alignment and design of the boat hull 4; the upper frame hole patterns 81 are formed on the frames 8 from the upper side, wherein, according to Fig. 3, they are related to a center line 85 of the frame upper sides 80.By subsequently placing a structural sheet profile 10 on the two adjacent frames 8 and aligning the hole patterns 81, 110 with one another, a relative displacement of the upper frame hole pattern 81 on the frame upper side 80 is not relevant, since the upper frame hole pattern 81 is aligned with the center line 85.

[0125] Since the upper frame hole patterns 81 are thus aligned with the center lines 85, and the profile sheets 18 are also mounted on the frame hole patterns 82, the manufacturing tolerances, ie the width of the individual frames 8, are not taken into account in the further alignment and assembly.

[0126] Since the upper (and lower) frame hole pattern 81 is formed from the centerline 85, systematic tolerances cannot accumulate: For each frame 8, the upper frame hole pattern 81 is again formed from the centerline 85, so that the profile hole patterns 110 are each fixed to this frame hole pattern. These tolerances do not accumulate. Only the CNC-machined hole patterns, i.e., the upper and lower frame hole patterns 81, as well as the upper profile hole patterns 110 and lower profile hole patterns 112, define the distances.

[0127] In a modified embodiment, the structural sheet profiles do not form support webs 32 on the sides, but the profiled sheet 18 is folded downwards in the lateral area and attached to the end faces of the sides of the frames 8. Thus, a corresponding tolerance of the frames 8 is translated into a shift in the hole pattern. However, this design is preferably only used as a supplement in specific areas of the boat hull. In the modified design for special areas, for example, the upper frame hole patterns 81 are formed from the side surface. Thus, system-related tolerances, in which, for example, the profiles each form a width of 101 mm (millimeters), can add up successively, which, however, is not possible with alignment on the center line 85.

[0128] The prefabricated hole patterns in all elements therefore enable secure fastening without the need to compensate for tolerances on site.

[0129] The profiled sheets 18, frames 8, and deck elements 36, 38 can be further secured by adhesive and / or welding. In particular, an adhesive can be applied between the frame top surface 80 and the support webs 32, as well as between the frame top surface 80 and the underside of the upper deck elements, which provides a cohesive bond and also enables sealing.

[0130] According to a further embodiment, plastic layers can also be placed between the frame tops 80 and the support webs 32 as well as the upper deck element 36 to achieve a seal. This allows closed, sealed volumes to be created in the individual structural sheet profiles 10, thus improving buoyancy and ensuring unsinkability.

[0131] Furthermore, a waterproof outer shell is advantageously applied to the upper side of the upper cover elements 36, and preferably a waterproof underlayer is applied to the outside of the lower cover elements 38.

[0132] As can be seen from Figure 12, a common upper cover element 36 can also be placed, for example, on two profiled sheets 18, ie on three frames 8, wherein the upper cover element 36 has an upper cover element hole pattern 30 which enables attachment to both profiled sheets 18 and the three frames 8.

[0133] Furthermore, special components can be used in the curved areas, especially the bow of the boat hull 4. These special elements allow the inventive design with frames and structural sheet profiles as well as deck elements to be implemented consistently even in these curved areas.

[0134] Figures 16, 17 show the use of a curved cover element, which thus describes a radius on its upper side, whereby a profiled sheet 18 according to Fig. 19 and 22 can be used.

[0135] Figures 19 and 22 show the design of modified structural sheet profiles 10, wherein, according to Fig. 19, a radius is formed on the upper side of the bent profiled sheet 18 and a front-end connection is made possible by lugs 98 of a superimposed connecting sheet 97 being inserted from above onto the bent profiled sheet 18, in particular in recesses on the upper side of the bent profiled sheet 18, wherein the superimposed connecting sheet 97 in turn forms a hole pattern which can thus be placed, aligned and fastened on the front side to the side surface of a frame 8. In particular, no support webs 32 are provided here, but the starting sheet 12 is preferably folded in such a way that it is subsequently placed on the front side to the inside of the frames 8 and is fastened there, for example, via hole patterns formed on the side surfaces of the frames 8.

[0136] By using such specially modified elements, the formation in the curved areas of the boat hull 4 is also possible.

[0137] Figures 13, 14, 15 show the design of angled frames 8, which is intended to form the bow shape or U-shape of the frames 8. To create the bend, a frame 8 is first milled out on three sides, i.e. a wedge-shaped recess 90 is formed in the frame 8 by cutting out three of the four sides of the frame 8 designed as a square tube, and the fourth side remains to form a bending line 91. Furthermore, the top side of the frame 8 is designed for a finger joint engagement 92. The frame 8 thus formed is subsequently bent along the bending line 81 so that the finger joint engagement 92 is formed, the frame 8 being additionally welded here so that the angled frame 8 shown in Figure 13 is formed. In addition, as shown in Fig. 15, reinforcement is provided by laterally attached reinforcing plates 95, which are attached to the side surfaces of the frame 8.A lateral hole pattern 93 is provided on the side surfaces of the frame 8, and a corresponding reinforcement plate hole pattern 86 is formed on the reinforcement plates or side plates 95, so that the reinforcement plates 95 are attached directly to the frames 8 and reinforce them. The formation of the reinforcement plate hole pattern 86 in the reinforcement plates 85 precisely defines the shape of the frames or the angle, so that tolerances can be avoided.

[0138] Fig. 27 shows a reinforcement intermediate plate 140 or stiffening plate used for reinforcement or stiffening, which is formed from a sheet metal strip with rivet holes 218 and edge lines 217 and, for example, support surfaces 232. According to Fig. 28, it is placed between two structural sheet profiles 10 for reinforcement or stiffening in the vertical direction z, for example riveted by means of rivet holes 218 to the rivet holes of the cover elements 36, 38, and / or glued or welded, for example with folded support surfaces 232 for resting on the cover elements 36, 38. This reinforcement is particularly helpful in an upper region of the supporting structure 6 or the superstructure 4 of the catamaran 1, in which a larger vertical distance is formed between the levels, as can be seen in particular from Figs. 23 and 24. Fig. 29 shows an embodiment of the folded profile sheet 18 without recesses 14, 14a and without struts. In particular, additional reinforcing elements, e.g.the wedge-shaped sheet metal elements 35 from Fig. 10 and 11 are inserted. The upper and lower cover plates 36, 38 are attached as in the previous embodiments.

[0139] Fig. 30, 31 shows an embodiment of the folded profiled sheet 18, in particular a folded profiled sheet without struts, with reinforcing T-profiles 141 inserted into the recesses 22.

[0140] In the embodiment of Fig. 30, the elevations and depressions do not run exactly in the transverse direction y, but obliquely, which can increase the rigidity - especially in designs without struts.

[0141] Fig. 31 shows a rear view of Fig. 30.

[0142] Fig. 32 shows another embodiment in which no strut is provided. It corresponds to Fig. 30 without the T-profiles. Here, the elevations 20 and depressions 22 run diagonally to the struts 8.

[0143] Fig. 33 to 37 show embodiments in which the folded profiled sheet 10 extends over three frames 8. Just as in Fig. 12 the upper cover sheet 36, the folded profiled sheet 10 can also extend over more than two frames 8. For this purpose, according to Fig. 34, the struts are formed with recesses for receiving the middle frame 8, and furthermore, a continuous recess is formed in the depressions 22, for example.

[0144] Fig. 33 shows the reinforcement with a cross; for attachment, the folded profile sheet 18 rests with its central recess on the central frame 8. According to one embodiment, a strut with a recess can extend in the transverse direction, thus receiving the frame and forming a cross with the frame. In Fig. 34, the struts 26, 27 are additionally inserted. In Fig. 35, the central frame 8 is accommodated accordingly. In the top view of Fig. 37, the fastening holes 28 are shown on the top side.

[0145] In principle, the profiled sheets and / or the upper and lower profile elements can be placed between exactly two adjacent frames. Furthermore, the folded profiled sheet and / or the upper cover element and / or the lower cover element can extend over more than two, in particular over three, frames, i.e., overlap a central frame. This allows flat surface areas, in particular, to be covered with a smaller number of parts, reducing assembly time.

[0146] Figures 38 to 40 show further embodiments of a folded profiled sheet 18, which in particular serves entirely or partially for the frontal contact with the frames 8. In this case, areas of the webs, the elevations and / or the depressions on the sides can thus be folded over for the frontal contact with the frames.

[0147] The process steps for forming the supporting structure 6 and / or the ship's hull 4 are as shown in Fig. 26:

[0148] After starting in step StO, first

[0149] A) to E) as described above, the formation of the profile sheets 18 with struts 26, 27 and reinforcing ribs 34

[0150] F) Production of floats 2, 3

[0151] G) Manufacturing of frames 8

[0152] - in a variable order of steps A) to G), then the supporting structure 6 or the boat hull 4 is manufactured by

[0153] H) Erecting the frames 8, by inserting the frames 8 into the floats 2, 3, initially without precise fixation of the frames in the longitudinal direction x

[0154] I) successively aligning two adjacent frames 8 on the profiled sheet(s) 18 placed between them, and attaching the profiled sheets 18 to the frames 8, while aligning and fixing the frames 8 in the longitudinal direction x

[0155] K) Attaching at least the upper cover elements 36, preferably also the lower cover elements 38, and

[0156] L) Attaching additional elements such as sealing foils.

[0157] List of reference symbols Catamaran , 3 Floating body Hull Structure on hull 4 Supporting structure Frames a Frame ends Noses on underside 0 Structural sheet profile 2 Starting sheet 4 Recess 4a Recess in the middle area 5 Topology holes 6 Hole pattern in starting sheet 12, contains the rivet holes 28 of the profile grid 110, 112, the recesses 14, 14a and the topology holes 157 Edge lines 8 Folded profile sheet 9 Support surfaces of the folded profile sheet 18 for support on the

[0158] Ribs 8 0 Raised surface 1 Top side of the folded profiled sheet 18 2 Recess 3 Bottom side of the folded profiled sheet 18 4 Flanks 6, 27 Oblique struts 8 Fastening holes, in particular rivet holes, in the folded profiled sheet 18 0 Upper deck element hole pattern, ie hole pattern of the upper deck element 36 31 Lower deck element hole pattern, ie hole pattern of the lower deck element 38

[0159] 32 support bars, bars

[0160] 33 cuts or incisions between the webs 32 and the flanks 24

[0161] 34 Reinforcing element as reinforcing rib, in particular trapezoidal sheet

[0162] 35 Reinforcing element as wedge-shaped sheet metal element

[0163] 36 upper deck element

[0164] 38 lower deck element

[0165] 40 rivets

[0166] 41 Topology hole in reinforcement element

[0167] 80 Frame top

[0168] 81 upper frame hole pattern

[0169] 82 Underside of frames

[0170] 83 lower frame hole pattern

[0171] 85 Centerline of the frame top 80

[0172] 86 reinforcement plate hole grid

[0173] 90 three-sided recess in the frame 8

[0174] 91 Bending line in frame 8

[0175] 92 Toothing, e.g. finger joint

[0176] 93 side hole pattern

[0177] 95 reinforcement plates

[0178] 97 attached connecting plate

[0179] 98 Noses of the connecting plate 97

[0180] 110 upper profile hole pattern

[0181] 112 lower profile hole pattern

[0182] 119 Support surfaces of the upper deck element 36 for resting on the frames 8 128 Fastening holes, in particular rivet holes in deck elements 36, 38

[0183] 130 Lattice structure, e.g. tubular lattice structure

[0184] 140 Reinforcing intermediate plate

[0185] 141 reinforcing T-profile

[0186] 218 Rivet holes in the reinforcement intermediate plate 140 217 Edge lines in the reinforcement intermediate plate 140

[0187] 232 Support surfaces of the reinforcement intermediate plate 140

[0188] X Longitudinal direction

[0189] Y transverse direction

[0190] Z vertical direction

Claims

Patent claims Structural sheet profile (10) for a supporting structure (6), in particular for a boat hull, comprising: - a profiled sheet (18) folded along edge lines (17), which can be inserted between two parallel, adjacent frames (8) of the supporting structure (6) and fastened to the frames (8), wherein the profiled sheet (18) has an upper profile hole pattern (110) on its upper side (21), - an upper cover element (36) which has an upper cover element hole pattern (30) and is placed on the profiled sheet (18), wherein the upper profile hole pattern (110) and the upper cover element hole pattern (30) are aligned with one another and connected via fastening means (40), characterized in that - the upper cover element (36) and / or the folded profiled sheet (18) has support surfaces (19, 119) for resting on the two frames (8), - the upper cover element hole pattern (30) and / or the upper profile hole pattern (110) is provided for alignment with the frame hole pattern (81) of the frames (8) and for connection to the frame hole pattern (81) of the frames (8) via fastening means (40). Structural sheet profile (10) according to claim 1, characterized in that - the folded profiled sheet (18) has support webs (32) on the sides, - the upper profile hole pattern (110) extends over the support webs (32) and fastening holes (28) of the upper profile hole pattern (110) are formed in the support webs (32), - each support web (32) is designed as part of the support surface (19) of the profiled sheet (18) for resting on a frame upper side (80) of one of the frames (8) and for positioning between the frame top side (80) and the upper cover element (36), - the holes of the support webs (32) can be aligned with the upper frame hole pattern (81) and can be fastened using fastening means (40).

3. Structural sheet profile (10) according to one of the preceding claims, characterized in that the profiled sheet (18) has: a folded transverse direction (y), the dimension of which is determined by the folds, and an unbent longitudinal direction (x), wherein the dimension of the profiled sheet (18) in the unbent longitudinal direction (x) and the distances of the holes of the profile hole pattern in the unbent longitudinal direction (x) are not determined by the folds, wherein the frames (8) are formed by the profiled sheets (18) of the structural sheet profiles (10) can be connected to one another in the unfolded longitudinal direction (x).

4. Structural sheet profile (10) according to one of the preceding claims, characterized in that the profiled sheet is formed from a perforated starting sheet (12) by edges in such a way that it has - several parallel, spaced elevations (20) extending in an upper plane and - depressions (22) formed between the elevations (20) and extending in a lower plane, with obliquely sloping flanks (24) extending between the elevations (20) and the depressions (22), .

5. Structural sheet profile (10) according to claim 4, characterized in that - from the top side (21) into the recesses (22) and / or - from the bottom into the elevations (20) Reinforcing elements (34, 35) for stiffening the structural sheet profile (10) are inserted and fastened, in particular on sloping flanks, e.g. as reinforcing ribs (34) and / or wedge-shaped elements (35).

6. Structural sheet profile (10) according to one of claims 4 to 5, characterized in that the elevations are folded downwards in lateral regions to form a frontal contact with the adjacent frame, wherein a hole pattern is formed on the folded regions of the elevations, which hole pattern can be aligned and fastened in a hole pattern on side surfaces of the frames (8).

7. Structural sheet profile (10) according to one of the preceding claims, characterized in that it further comprises a lower cover element (38) with a lower cover element hole grid (31) which is placed and fastened to the underside (23) of the folded profiled sheet (18), wherein its lower cover element hole grid (31) is aligned with a lower profile hole grid (112) of the folded profiled sheet (18) and / or is connected via fastening means (40).

8. Structural sheet profile (10) according to claim 7, characterized in that, apart from the folded profile sheet (18), the upper cover element (36) and the lower cover element (38), it has no further elements extending over at least two frames (8).

9. Structural sheet profile (10) according to one of the preceding claims, characterized in that the profiled sheet (18) is designed without struts extending at least partially in the transverse direction (y), preferably entirely without reinforcing struts. Structural sheet metal profile (10) according to one of claims 1 to 7, characterized in that the profiled sheet (18) has recesses (14, 14a), wherein reinforcing struts (26, 27) of the folded profiled sheet (18) are set through the recesses (14, 14a), in particular in one of the following orientations of the struts (26, 27) - at least partially extending in the transverse direction (y) of the profiled sheet (18), - crossing or X-shaped, - Can be fastened, e.g., welded, to the frames (8) in the end regions of the struts (26, 27). Structural sheet metal profile (10) according to one of the preceding claims, characterized in that, in addition to the holes of the hole pattern, topology holes (15) are formed in the folded profile sheets (18) for weight optimization.Supporting structure (6), in particular for a boat hull (4), wherein the supporting structure (6) comprises: a plurality of frames (8) arranged parallel to one another, each running in a transverse direction (y) and being spaced apart in a longitudinal direction (x), wherein the frames (8) have support surfaces (80, 82) with at least one frame hole pattern (81, 83), a plurality of structural sheet profiles (10) according to one or more of the preceding claims, each of which is placed between two adjacent frames (8), wherein the upper deck element hole patterns (30) of the upper deck elements (36) are each placed on two adjacent frames (8) and the folded profiled sheet (18) placed between the frames (8b), wherein the frame hole patterns (81, 83) of the two frames (8) and the. upper cover element hole patterns (30) are aligned with one another and connected via fastening means (40). Supporting structure (6) according to claim 12, characterized in that the bearing surfaces of the frames (8) are frame upper sides (80) on which upper frame hole patterns (81) are formed, wherein the upper cover element (36) rests, is aligned, and is fastened with its upper cover element hole pattern (30) on the upper frame hole patterns (81) of the two adjacent frames (8).Supporting structure (6) according to one of claims 12 to 13, characterized in that the frames (8) each have a lower frame hole grid (83) on their frame undersides (82), a lower cover element (38) with a lower cover element hole grid (31) is placed on the underside (23) of the folded profiled sheet (18) and on the frame undersides (82) of the two adjacent frames (8), the lower frame hole grid (83) being aligned and fastened via fastening means (40). - the lower cover element hole pattern (31) and / or - a lower profile hole pattern (112) formed on the underside (23) of the folded profile sheet (18). Supporting structure (6) according to one of claims 12 to 14, characterized in that a distance between the two adjacent, parallel frames (8) in the longitudinal direction (X) is determined, in particular is determined exclusively, by - the profile hole pattern (110) of the profile sheet (18) placed between the adjacent frames (8), and / or - the upper deck element hole pattern (30) of the two frames (8) set upper cover element (36), and / or - the lower deck element hole pattern (31 ) of the two frames (8) set lower cover element (38).

16. Supporting structure (6) according to one of claims 12 to 15, characterized in that the frames (8) are connected and / or fixed in the longitudinal direction exclusively by the structural sheet profiles (10).

17. Supporting structure (6) according to one of claims 12 to 16, characterized in that in partial regions of the supporting structure (6), e.g. a front curved region of the supporting structure (6), further structured structural sheet profiles are provided, which have a flat perforated sheet.

18. Support structure (6) according to one of claims 12 to 17, characterized in that a thermal insulation layer, e.g. plastic, is provided between - the upper deck element (36) and the structural sheet profile (10) and / or the frames (8), and / or - the lower deck element (38) and the structural sheet profile (10) and / or the frames (8).

19. Supporting structure (6) according to one of claims 12 to 18, characterized in that in each case an upper frame (8) and a lower frame (8) run in a common transverse plane (YZ), are spaced apart in the vertical direction (Z) and are connected to one another via a lattice structure (130), wherein the lattice structure (130) connects the two frames (8) to one another in the transverse plane (XY), wherein - two upper frames (8) adjacent in the longitudinal direction (X) and / or - two lower frames (8) adjacent in the longitudinal direction (X) are connected to one another only by the structural sheet metal profiles (10), so that the distance between the two adjacent upper frames (8) in the longitudinal direction (X) and / or the distance between the two adjacent lower frames (8) in the longitudinal direction (X) is determined only by the structural sheet metal profiles (10). Supporting structure (6) according to claim 19, characterized in that the tubular space structure (130) has connecting profiles (131) which are interlocked with the lower frame (8) and the upper frame (8), preferably in finger-jointed engagements and / or inserted laterally. Supporting structure (6) according to one of claims 12 to 20, characterized in that in angled regions (8b) of the supporting structure (6), the frames (8) are recessed on three sides and bent in a bending line (91) in such a way that an angle, in particular an obtuse angle, is formed in the frame (8).Supporting structure (6) according to claim 21, characterized in that in the angled region (8b) of the frame (8), on the side opposite the bending line (91), a toothing (92) is formed, e.g., by projections projecting from one side and receptacles formed on the other side, for redirecting any cracks that may occur. Supporting structure (6) according to one of claims 21 to 22, characterized in that lateral reinforcing plates (95) with hole patterns (94) are attached to the angled region of the frame (8) and are fastened to hole patterns (93) of the frame (8), wherein the hole patterns (94) of the reinforcing plates (95) determine the angling of the frame (8). Supporting structure (6) according to one of claims 12 to 23, characterized in that, to form a curved region of the supporting structure (6), a structural sheet profile (10) is designed such that, at its longitudinal end, a connecting sheet (97) is placed perpendicularly through the profiled sheet (18), wherein a radius at the longitudinal end of the profiled sheet (18) and a bending radius of the attached connecting sheet (97) are coordinated with one another to form a curved longitudinal end of the structural sheet profile (10). Supporting structure (6) according to one of claims 12 to 24, characterized in that the structural sheet profiles (10), the frames (8), and the cover elements (36, 38) are made of aluminum or an aluminum alloy, in particular a seawater-resistant aluminum alloy.Supporting structure (6) according to one of claims 12 to 25, characterized in that at least one intermediate reinforcing sheet (140) is placed and fastened between two structural sheet profiles (10) in a vertical direction (z), in particular as a sheet folded along edge lines (217), e.g. with folded support surfaces (232) and / or rivet holes (218) for fastening to cover elements (36, 38) of the two structural sheet profiles (10). Supporting structure (6) according to one of claims 12 to 26, characterized in that at least one structural profile sheet and / or a folded profile sheet and / or an upper cover element (36) and / or a lower cover element (38) extends over more than two, in particular over three, frames (8) and thus covers a central frame (8). A boat hull (4), in particular of a catamaran (1), having a supporting structure (6) according to one of claims 12 to 27, wherein a circumferential, sealed outer shell is formed on an upper side of the boat hull (4), and a continuous inner coating is formed on an inner side of the boat hull such that the frames (8), the structural profile elements (10), and cover elements (36, 38) are accommodated between the outer shell and the inner coating. A boat hull (4) according to claim 28, characterized in that the cover elements (36, 38) and the frames (8) each form a closed, sealed volume in which the structural sheet metal profile (10) is accommodated, so that the boat hull (4) has a plurality of closed, separate volumes.Boat hull (4) according to claim 28 or 29, characterized in that the frames (8) are each bow-shaped or U-shaped and open downwards, and have downwardly extending profile pieces at their lower ends, with which the frames (8) are inserted into lower receiving bodies, in particular floating bodies (2, 3). Catamaran (1) comprising: two lower, parallel floating bodies (2, 3), a boat hull (4) according to claim 30, which is inserted into the floating bodies (2, 3) with its downwardly extending profile pieces and fastened therein, and a structure (5) provided on an upper side of the boat hull (4), in particular for accommodating passengers. Method for producing a supporting structure, in particular for a boat hull (4) of a catamaran (1), the method comprising at least the following steps: - Edging a perforated starting sheet (12) to a folded profiled sheet (18), wherein the fastening holes (28) are on the upper side of the profiled sheet (18) form an upper profile hole pattern (110), and - Forming frames (8) with an upper frame hole pattern (81) on the upper side of the frames (8), - Arranging or setting up the frames (8) parallel to each other, - Inserting the profiled sheets (18) between at least two adjacent frames (8) and fastening them to the frames (8), - placing an upper cover element (36), which has an upper cover element hole pattern (30), on two adjacent frames (8) and the profiled sheet (18) accommodated therebetween in such a way that the upper cover element hole pattern (30) is aligned on the one hand with the upper frame hole pattern (81) and on the other hand with the upper profile hole pattern (110), thereby determining the distance between the two adjacent frames (8), and Connecting the hole patterns (30, 81, 110) by fastening elements (40). Method according to claim 32, characterized in that recesses (14, 14a) are formed in flanks (24) of the profiled sheet (18) and / or the starting sheet (12), and - reinforcing struts (26, 27) are inserted through the recesses (14, 14a) of the folded profiled sheet (18) and fastened to the folded profiled sheet (18) or several folded profiled sheets (18). Method according to claim 32 or 33, characterized in that - a lower frame hole pattern (83) is formed on an underside of the frames (8), - by edging some of the fastening holes (28) on the underside of the profile sheet (18) form a lower profile hole pattern (112), - a lower cover element (38) is placed on the underside of the profiled sheet (18) and the underside of the frames (8), which lower cover element has a lower cover element hole pattern (31), - wherein the lower deck element hole pattern (31) is aligned with or on the lower frame hole pattern (83) and / or with the lower profile hole pattern (112), and - wherein the lower deck element (38) is fastened to the underside of the frames (8) and to the underside of the structural sheet metal profile (10) by means of fastening means (40) in the hole patterns (83, 112). Method according to one of claims 32 to 34, characterized in that, to prevent mechanical stresses in the formed boat hull (4), the frames (8) are successively positioned in a longitudinal direction (x) and aligned, connected to one another, and fixed via the hole patterns (30, 31, 81, 83, 110, 112) of the structural sheet metal profiles (10) and / or deck elements (36, 38) placed therebetween.Method according to claim 35, characterized in that a distance between two adjacent frames (8) is set by aligning the hole patterns (81, 83) of the adjacent frames (8) with the hole patterns (30, 31) of the cover elements (30, 38) and / or the structural sheet profiles (10) placed between them, whereupon a subsequent frame adjacent in the longitudinal direction is again aligned and fixed in this way. (8) is aligned and connected by interposing the cover elements (30, 38) and / or the structural sheet profiles (10). Method according to claim 36, characterized in that the two adjacent frames (8) are initially not fixed or adjustable relative to one another in the longitudinal direction (x), and their spacing from one another in the longitudinal direction (x) is only determined by the cover elements (36, 38) and / or the structural sheet profiles (10).Method according to one of claims 32 to 37, characterized in that, when the profiled sheets are edged, an upper side (21) is formed from parallel elevations (20) and a lower side (23) is formed from depressions (22) running between the elevations (20), wherein the flanks (24) are formed between the elevations (20) and the depressions (22), wherein support webs (32) are formed on the upper side, which delimit the depressions (22) in the longitudinal direction (x) and in particular run flush with the elevations (20), wherein holes are formed in the support webs (32) which form part of the upper profile hole pattern, and wherein the support webs (32) are placed on the upper side of the frames (8) and the upper hole pattern of the frames (8) and the holes in the support webs (32) are aligned with one another. Method according to one of claims 32 to 38, characterized in that an adhesive is applied:. - between the folded profiled sheet and the frames (8), and / or between the upper cover element (36) and the structural sheet profile (10), for the material-locking connection and formation of a tight seal. Method according to one of claims 32 to 39, characterized in that, to form angled regions of a frame (8), a three-sided recess is formed in the frame (8), and subsequently, the frame (8) is bent along a bending line in the remaining surface, and subsequently, reinforcing plates are laterally fastened, preferably riveted, to the angled region of the frame (8), in particular with a suitable hole pattern in the reinforcing plates and the sides of the frame (8). Method according to one of claims 32 to 40, characterized in that an alignment of the upper frame hole pattern along its center line and / or a center line of the frame (8) is carried out in particular in such a way that systematic tolerances do not add up.Method according to one of claims 32 to 41, characterized in that in the starting sheet (12) support webs (32) are separated by cutting lines (33), in particular from the material regions of the flanks (24), without splitting the starting sheet (12), and folding in such a way that the flanks (24) are folded downwards, but the webs 32 are not folded, so that they remain in the plane of the upper side (20). Method according to claim 42, characterized in that during the folding, the starting sheet (12) is shortened in the transverse direction (Y) so that the support webs (32) of adjacent elevations (20) are brought closer to one another, in particular come into contact with one another, and completely or largely continuous webs (32) are formed at edge regions, in particular as an upper side (21) running around the edge region. Method for producing a catamaran (1), in which a boat hull (4) is formed using a method according to one of claims 32 to 43, two floating bodies (2, 3) are arranged parallel and spaced apart from one another, wherein the frames (8) are each formed in a bow-shaped or U-shaped manner and are open at the bottom and are inserted with their lower frame ends (8a) into the floating bodies (2, 3) from above.

Images