Multi-chamber structural element and method for manufacturing a multi-chamber structural element - Patents.com

Abstract

The object of the present invention is a method for manufacturing a multi-chamber structural element for forming a multi-chamber structural element, the chamber profile (1) extending radially from a center defined by the joining of chamber profiles (1), comprising the following steps: providing at least three chamber profile preforms (2), each chamber profile preform (2) made from a sheet of metal material and comprising two walls (3) arranged relative to each other in substantially parallel planes with a gap therebetween, the edges of the individual walls (3) coming together, and a valve element (6) being arranged on at least one wall (3); The edge of each unconnected wall (3) is sealed with a seal (5) to form a closed, sealed, empty interior space of the chamber profile preform (2), a fluid under pressure is introduced into the interior space of the chamber profile preform (2) through a valve element (6) to form a deformed chamber profile (1), and at least three chamber profile preforms (2) or chamber profiles (1) are connected along at least a part of their inner edges to corresponding inner edge areas of the chamber profile preforms (2) or chamber profiles (1) proximal to the connecting axis (4).

Description

[Technical Field]

[0001] The object of the invention is a multi-chamber structural element, in particular for use as a vertical column type load-bearing structure, and a method for manufacturing a multi-chamber structural element, which is applied in the construction, mining or energy industry for manufacturing vertical load-bearing structures.

[0002] One of the most important structural elements used in many technical fields is the pillar, a vertical free-standing structural support. As posts and columns, they are used to support and bear the weight of buildings, bridges, viaducts and other structures. Load-bearing structural elements are also used in mining, such as roof supports in caves, or in street furniture, for example in the construction of pergolas. [Background technology]

[0003] Polish Patent No. 224768B1 discloses a mining load-bearing support pillar comprising a vertical layer, each including a pair of substantially parallel outer beams defining two vertical support walls, and a horizontal layer, each including a pair of substantially parallel outer beams defining two horizontal support walls, the horizontal layers being arranged interchangeably with the vertical layers such that the outer beams of the horizontal layers intersect adjacent outer beams of the vertical layers at four intersections and are connected thereto via notches formed on the upper and lower surfaces of the vertical and horizontal beams. This type of structure is used in underground mining, such as for protection elements, roof support elements, or bracing elements between the floor and roof of mining caverns. The load-bearing capacity of the pillar can be increased by filling its internal space with a self-hardening composition, such as a cementitious mineral composition, to form a composite structure.

[0004] Polish Patent No. 171919B1 discloses a roof support for mining caverns, specifically coal mines, comprising a pile of wooden beams arranged in layers, the beams of one layer of the pile being arranged perpendicular to the beams of the adjacent layer, and sacks filled with cement mortar arranged on one side of the pile. The system shown comprises a core mounted on one side of the pile and made of wooden elements, the majority of which are arranged with their fibers vertically, the core having a vertical stiffness greater than the vertical stiffness of the pile, while the sacks contain cement mortar in an amount that applies a desired stress between the pile with the core and the roof of the cavern.

[0005] Polish Utility Model No. 67807Y1 discloses a structural element, specifically a sheet metal part for use in a sheet metal structure. The structural element has inner walls with longitudinal edges that are bent inward, preferably at the center of the base. The inner walls are folded and deviate from each other at their edge walls, preferably perpendicular to the side walls. Preferably, the edges are near the side wall surfaces. At the transition curve from the base surface, the inner walls are additionally joined at weld points. Summary of the Invention [Problem to be solved by the invention]

[0006] The technical problem of the present invention is to provide a method for manufacturing such a multi-chamber structural element, which allows the production of a multi-chamber structural element having the desired characteristics for use as a support column, specifically with respect to load-bearing performance in terms of strength-to-weight ratio, while maintaining the desired dimensional accuracy. It is desirable that the method for manufacturing a multi-chamber structural element be realized in a way that involves a limited number of technical steps, does not require the use of specialists and complex equipment, and directly provides the economic benefit of a simplified and less time-consuming process for manufacturing multi-chamber structural elements, thus making the process cheaper. It is also desirable that the method for manufacturing a multi-chamber structural element be characterized by low material consumption and be capable of manufacturing multi-chamber structural elements with a wide range of geometric parameters, specifically various heights, spacings, and both symmetrical and asymmetrical characteristics. It is also important to provide a method for manufacturing a multi-chamber structural element, the shape of which can be easily modified within a wide range of geometric parameters, and which should not require the reconfiguration of the equipment used in the manufacturing process. Importantly, it is also desirable to provide a multi-chamber structural element that is easily transported and installed at its destination. Another technical problem of the present invention is to also provide a multi-chamber component having the above-listed characteristics and desired technical parameters. [Means for solving the problem]

[0007] A first object of the present invention is to form a multi-chamber structural element with chamber profiles extending radially from a center defined by the concatenation of the chamber profiles, comprising the following steps: a) providing at least three chamber profile preforms, each chamber profile preform being made from a sheet of metal material and including two walls arranged relative to one another in substantially parallel planes with a gap maintained between the planes, edges of the individual walls meeting, and a valve element being disposed on at least one of the walls; b) sealing the edges of each free wall of the chamber profile preform with a seal to form a closed, sealed, empty interior space of the chamber profile preform; c) introducing a fluid under pressure into the interior space of the chamber profile preform through the valve element to form a deformed chamber profile; d) at least three chamber profile preforms or chamber profiles are coupled along at least a portion of their inner edges to corresponding inner edge areas of the chamber profile preforms or chamber profiles proximal to the coupling axis; A method for manufacturing a multi-chamber structural element, characterized in that steps c) and d) may be performed in reverse order.

[0008] In a preferred embodiment of the present invention, the chamber profile preform is made from a single sheet of metal material that is bent along one edge to form two walls positioned relative to each other in substantially parallel planes.

[0009] In another preferred embodiment of the invention, step c) is performed after the chamber profile preform has been introduced between the pressure plates in such a way that the pressure plates are in contact with the walls of the chamber profile preform.

[0010] In another preferred embodiment of the invention, during step c), a force is applied to the pressure plate in the direction of the chamber profile preform.

[0011] Preferably, step c) is carried out by connecting the valve element to a source of fluid under pressure.

[0012] It is also preferred that step c) is performed simultaneously on all of the chamber profile preforms corresponding to the chamber profiles in the multi-chamber structural element.

[0013] More preferably, in step d), the chamber profiles are joined while keeping their symmetrical configuration with respect to the joining axis.

[0014] In a preferred embodiment of the invention, step b) and / or step d) is realized by fusion welding, crimping, gluing or crimping.

[0015] In another preferred embodiment of the invention, the fluid is air, water, oil, fluid concrete or fluid plastic.

[0016] In a further preferred embodiment of the invention, step c) is carried out at room temperature or at elevated temperature.

[0017] Preferably, the pressure of the fluid introduced into the chamber profile preform is 5 bar.

[0018] Also preferably, in step c), the fluid under pressure is introduced into the interior space of the chamber profile preform for 1 minute, after which a constant pressure is maintained within the chamber profile preform for 30 seconds.

[0019] In a preferred embodiment of the present invention, steps b) and d) are performed simultaneously.

[0020] In another preferred embodiment of the invention, the simultaneous sealing and joining of at least three chamber profile preforms along at least a portion of their inner edges to corresponding inner edge areas of chamber profile preforms proximal to the joining axis is achieved by laser welding.

[0021] A second object of the present invention is a multi-chamber structural element comprising at least three chamber profiles deformed by a fluid under pressure introduced into their sealed empty spaces, the chamber profiles being connected to one another with corresponding seals along at least a portion of the seals to form a multi-chamber structural element with chamber profiles extending radially from a center defined by a connecting axis.

[0022] In a preferred embodiment of the invention, the chamber profiles are arranged axially symmetrically with respect to the connecting axis.

[0023] In a further preferred embodiment of the invention, the chamber profile has an inner edge which is oriented towards the connection axis of the multi-chamber structural element and which extends in a straight line or at least partially in a curve.

[0024] In another preferred embodiment of the invention, the chamber profile has an outer edge that extends in a straight line parallel to the connecting axis of the multi-chamber structural element, in a curve that is opposite to the connecting axis, in a concave curve away from the connecting axis, or in a convex curve away from the connecting axis.

[0025] Advantageously, the chamber profiles extend at different radial lengths relative to the connecting axis.

[0026] Also advantageously, the fluid is air, water, oil, fluid concrete or fluid plastic.

[0027] The method for manufacturing a multi-chamber structural element according to the present invention allows for the production of structural elements with desired characteristics, particularly with respect to the structural element's strength and stiffness coefficients, as well as its load-bearing capacity to weight ratio. In particular, due to the extensive use of relatively thin metal sheets in the production of multi-chamber structural elements, multi-chamber structural elements manufactured by the method according to the present invention can have a significantly increased load-bearing capacity to weight ratio compared to conventional solutions known in the art. Furthermore, the method for manufacturing a multi-chamber structural element according to the present invention allows for the use of less complex machine equipment, which translates into economic benefits and a significantly simplified manufacturing process for multi-chamber structural elements. The reduced number of seals increases the speed and reduces the labor intensity of the process for manufacturing multi-chamber structural elements. Additionally, the production of chamber profiles, which are the basic elements of multi-chamber structural elements, based on the introduction of a fluid under pressure into the hermetically closed internal space of a chamber profile preform allows for a wide range of parameter modifications of the manufactured chamber profiles, and thus of the final multi-chamber structural element, particularly its final geometry. Importantly, due to the use of relatively thin chamber profile preforms manufactured from sheets of metal material, and due to the use of uncomplicated machine tools, the multi-chamber structural elements allow the components to be easily introduced into hard-to-reach places, for example excavated caverns, where they can be manufactured and erected in a simple operation to form the load-bearing elements for the roof structure.

[0028] The solution according to the invention is shown in the following embodiments and illustrated in the drawings. [Brief explanation of the drawings]

[0029] [Figure 1A] 5 illustrates steps in a method for manufacturing a multi-chamber structural element according to an embodiment of the present invention. [Figure 1B] 5 illustrates steps in a method for manufacturing a multi-chamber structural element according to an embodiment of the present invention. [Figure 2A] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 2B] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 3A] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 3B] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 4A] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 4B] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 5A] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 5B] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 5C] 5A-5C show steps of a method for manufacturing a multi-chamber structural element according to a further embodiment of the invention; [Figure 6A] 1 shows a cross section of a multi-chamber structural element according to different embodiments of the present invention; [Figure 6B] 1 shows a cross section of a multi-chamber structural element according to different embodiments of the present invention; [Figure 6C] 1 shows a cross section of a multi-chamber structural element according to different embodiments of the present invention; [Figure 6D] 1 shows a cross section of a multi-chamber structural element according to different embodiments of the present invention; [Figure 6E] 1 shows a cross section of a multi-chamber structural element according to different embodiments of the present invention; [Figure 7A] 1A-1D show front views of chamber profiles for use in multi-chamber structural elements according to different embodiments of the present invention. [Figure 7B] 1A-1D show front views of chamber profiles for use in multi-chamber structural elements according to different embodiments of the present invention. [Figure 7C] 1A-1D show front views of chamber profiles for use in multi-chamber structural elements according to different embodiments of the present invention. [Figure 7D] 1A-1D show front views of chamber profiles for use in multi-chamber structural elements according to different embodiments of the present invention. [Figure 7E] 1A-1D show front views of chamber profiles for use in multi-chamber structural elements according to different embodiments of the present invention. [Figure 7F] 1A-1D show front views of chamber profiles for use in multi-chamber structural elements according to different embodiments of the present invention. [Figure 8A] 1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 8B] 1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 8C] 1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 8D] 1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 8E] 1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 9A] FIG. 8A shows a cross section of a multi-chamber structural element along the intersecting plane indicated. [Figure 9B] FIG. 8B shows a cross section of the multi-chamber structural element along the indicated intersecting plane. [Figure 9C] FIG. 8C shows a cross section of the multi-chamber structural element along the indicated intersecting plane. [Figure 9D] FIG. 8D shows a cross section of the multi-chamber structural element along the indicated intersecting plane. [Figure 9E] FIG. 8E shows a cross section of the multi-chamber structural element along the indicated intersecting plane. [Figure 10A] 1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 10B]1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 10C] 1A-1C show front views of a multi-chamber structural element according to different embodiments of the present invention; [Figure 11A] FIG. 10A shows a cross section of a multi-chamber structural element along the intersecting plane indicated. [Figure 11B] FIG. 10B shows a cross section of the multi-chamber structural element along the indicated intersecting plane. [Figure 11C] FIG. 10C shows a cross section of the multi-chamber structural element along the indicated intersecting plane. DETAILED DESCRIPTION OF THE INVENTION

[0030] Embodiment 1 A method for manufacturing a multi-chamber structural element according to one embodiment of the present invention is partially illustrated schematically in FIGS. 1A-B. The illustrated embodiment of the method for manufacturing a multi-chamber structural element includes providing a chamber profile preform 2 made from a metal sheet and including two walls 3 arranged relative to each other in substantially parallel planes with a gap therebetween, where the edges of the individual walls 3 meet. A valve element 6 is disposed on at least one of the walls 3. The valve element 6 is a pneumatic or hydraulic coupling that can provide a leak-tight connection to a supply duct 7 from an external source of pressurized fluid. In some embodiments of the present invention, the valve element 6 may be a valve, specifically a check valve. The location of the valve element 6 is not limited within the scope of the present invention; therefore, the valve element 6 may be disposed anywhere on the metal sheet, provided that it can couple with the interior space of the chamber profile preform 2.

[0031] In this embodiment, the chamber profile preform 2 is formed from two walls 3, each of the walls 3 being made from a separate metal sheet. In an alternative embodiment, a single sheet of metal material can be provided which is bent along one edge using a cold bending operation known in the art to form two walls 3 arranged relative to each other in substantially parallel planes. This embodiment advantageously has one edge of the produced chamber profile preform 2 already sealed in the step of providing the metal sheet (where the metal sheet is bent), thus reducing the number of successive sealing operations.

[0032] In the next step of the method for manufacturing a multi-chamber structural element, the chamber profile preform 2 is sealed to create a sealed, airtight interior space. Sealing is performed on the edges of the metal sheets that form the walls 3 of the chamber profile preform 2 after they have been mated together. In this embodiment, sealing is thus performed on the entire peripheral edge of the mated walls 3 of the chamber profile preform 2, and FIG. 1A shows only the vertical seal 5. In this embodiment, sealing is performed by welding corresponding edges together, forming, among other things, a vertical weld. Sealing is also performed on the edges of the mated walls 3 located on the front and back sides of the chamber profile preform 2. By sealing all of the above-mentioned edges, a leak-proof, airtight interior space is formed in the chamber profile preform 2, as schematically shown in the cross section of FIG. 1A. The type of seal 5 is not limited to the scope of the present invention in this case; in alternative embodiments, any type of seal 5 can be used, such as crimping, soldering, gluing, bending, or pressing, as long as a leak-proof interior space is formed in the chamber profile preform 2.

[0033] In a next step, an external source of fluid under pressure is connected to the valve element 6 through a supply duct 7. In this embodiment, the fluid is air, the source of fluid under pressure is a compressor, and the supply duct 7 together with the valve element 6 forms a pneumatic connection. The type of external source of fluid under pressure and the connector is not limited to the scope of the present invention; in alternative embodiments, fluids in the form of water, fluid cement, machine oil, fluid plastics such as type 1, type 2, or type 3 foam materials (e.g., Flex 140 type), etc. can be used with connectors and a source of fluid under pressure appropriate for those fluids. The less compressible the fluid, the more control there is over the deformation state of the chamber profile preform 2.

[0034] In the next step of the method for manufacturing a multi-chamber structural element according to the present invention, a fluid under a defined pressure is delivered into the sealed interior space of the chamber profile preform 2. The technique of introducing a fluid under pressure into closed, sealed chamber elements made from sheet metal to deform them and provide them in their final form is known, inter alia, from EP 2 110 189 A1. As a result of delivering the fluid under pressure into the interior space of the chamber profile preform 2, the walls 3 of the chamber profile preform 2 are deformed, with the greatest deformation level being located in the center of the chamber profile 1, as best shown in FIG. 1B, which shows a cross-section of a chamber profile 1 manufactured from the chamber profile preform 2. As can be seen, the walls 3 of the chamber profile preform 2 are highly deformed. The next two chamber profiles 1 are manufactured by the same method to obtain three chamber profiles 1.

[0035] It should be noted that although the introduction of the fluid under pressure into the interior space of the chamber profile preform 2 is carried out using a cold technique (i.e. at room temperature), this is not limiting to the scope of the present invention and in alternative embodiments the process may be carried out at elevated or high temperatures.

[0036] In one embodiment of the present invention, the step of introducing a fluid under pressure is performed under the following process parameters: Process temperature: 20℃, Operating pressure: 5 bar, Deformation time: 1 minute until the pressure is equalized in the chamber, profile and preform. Pressure holding time: 30 seconds Total transformation time: performed in 1.5 minutes.

[0037] In an alternative implementation of the method for manufacturing a multi-chamber structural element, the step of introducing a fluid under pressure into the interior space of the chamber profile preform 2 may be preceded by placing the chamber profile preform 2 between pressure plates 8 so that the pressure plates 8 are in contact with the walls 3 of the chamber profile preform 2, as shown in FIG. 5B. The pressure plates 8 may be working elements of a mechanical press. In this case, a controlled force may be applied to the pressure plates 8, specifically in a direction towards the chamber profile preform 2. During the step of delivering a fluid under pressure into the sealed interior space of the chamber profile preform 2, the chamber profile preform 2 is held between the pressure plates 8. As a result, the chamber profile 1 formed after this method has a flat surface in the central area of ​​the walls 3, as best shown in the cross-section of the multi-chamber structural element shown in FIG. 5C.

[0038] In a subsequent step, the three chamber profiles 1 are connected to one another by connecting corresponding inner edges of the chamber profiles 1 proximal to the connecting axis 4 along at least a portion of their inner edges. In this embodiment, this is achieved by connecting corresponding seals 5. The connecting area of ​​the chamber profiles 1 includes the three edges (seals 5) of the chamber profiles 1, which together form the connecting axis 4 with a connecting weld. In this embodiment, the chamber profiles 1 are connected to one another by welding, but this is not limiting to the scope of the invention and in alternative embodiments, other connecting techniques such as crimping, soldering, gluing, bending or pressing can be used.

[0039] The connection of the chamber profiles 1 is realized in an axially symmetrical configuration of the chamber profiles 1 with respect to the connecting axis 4, i.e. in a cross-sectional view as shown in Figure 6A, where each of the chamber profiles 1 extends radially outward from the connecting axis 4 and the chamber profiles 1 are arranged at equal angles around the connecting axis 4, in this embodiment at an angle of 120°.

[0040] Embodiment 2 A method for manufacturing a multi-chamber structural element according to a second embodiment of the present invention is shown schematically in Figures 2A-B. The depicted embodiment of the method for manufacturing a multi-chamber structural element is substantially similar to the method for manufacturing a multi-chamber structural element shown in embodiment 1, and therefore similar steps will not be discussed in detail for the sake of clarity of the present disclosure.

[0041] In a second embodiment of the method for manufacturing a multi-chamber structural element, in a first step, two metal sheets are provided, which are the two walls 3 of the chamber profile preform 2. The walls 3 of the chamber profile preform 2, which are brought together, are then sealed on their free edges to form a sealed, closed interior space. Following this method, three chamber profile preforms 2 are manufactured.

[0042] Unlike the method for manufacturing a structural element shown in embodiment 1, the method for manufacturing a structural element according to the second embodiment comprises connecting the thus formed chamber profile preforms 2 to one another by connecting corresponding seals 5 along at least a portion of the seals 5 (as shown in FIG. 2A). The connecting area of ​​the chamber profile preforms 2 comprises three edges (seals 5) of the chamber profile preforms 2, which are joined together by connecting welds to form a connecting axis 4 in the final multi-chamber structural element. In this embodiment, the chamber profile preforms 2 are connected to one another by welding, and the connected chamber profile preforms 2 are shown in FIG. 2A.

[0043] In a subsequent step of the method for manufacturing a multi-chamber structural element according to the second embodiment of the present invention, a fluid under a defined pressure is delivered to the sealed internal space of the chamber profile preform 2, which delivery is achieved by connecting an external source of fluid under pressure to the valve element 6 through a supply duct 7 (see FIG. 2B). The introduction of the fluid under pressure into the internal space of the chamber profile preform 2 may be achieved separately for each chamber profile preform 2 as a series of operations (i.e., one after the other) or simultaneously for all chamber profile preforms 2, as shown in FIG. 2B. However, the simultaneous introduction of the fluid under pressure into the internal spaces of the chamber profile preforms 2 requires the use of a larger number of supply ducts 7, and a suitable source of fluid under pressure ensures the possibility of simultaneously connecting the same number of supply ducts 7.

[0044] As a result, a multi-chamber structural element is obtained with a cross section shown in Figure 6A, which has three chamber profiles 1 extending radially and arranged symmetrically with respect to a connecting axis 4, which are deformed by a fluid under pressure introduced into the hermetically sealed internal space.

[0045] Embodiment 3 A method for manufacturing a multi-chamber structural element according to the next embodiment of the present invention is shown schematically in Figures 3A-B. The depicted embodiment of the method for manufacturing a multi-chamber structural element is substantially similar to the method for manufacturing a multi-chamber structural element shown in embodiment 2, and therefore similar steps will not be discussed in detail for the sake of clarity of the present disclosure.

[0046] In a third embodiment of the method for manufacturing a multi-chamber structural element, in a first step, three metal sheets are provided, each forming one wall 3 of an adjacent chamber profile preform 2. The V-shaped profiles are mated to one another in such a way that the arms of the V-shaped profiles extend in a plane parallel to the arms of the adjacent V-shaped profiles, forming three chamber profile preforms 2, respectively. A sealing step is then performed on the free edges (outer edges) of the thus formed chamber profile preforms 2 to form a sealed, closed internal space. In a next step (or simultaneously), a seal 5 is created in the central area of ​​the joined chamber profile preforms 2. The step of sealing the inner edges of the chamber profile preforms 2 is realized using a sealing technique through the gaps maintained between the corresponding walls 3 of the chamber profile preforms 2, forming the seal 5 that hermetically closes the internal space of the chamber profile preforms 2. In this case, the sealing technique preferably comprises laser welding, which can connect the walls 3 of the chamber profile preforms 2 to one another by forming a weld seam (weld) through the gap and sealing the space formed between the walls 3 of the chamber profile preforms 2. Following this method, three chamber profile preforms 2 are simultaneously manufactured as shown in Figure 3A.

[0047] In a subsequent step of the method for manufacturing a multi-chamber structural element according to the third embodiment of the present invention, a fluid under a defined pressure is delivered to the sealed internal spaces of the chamber profile preforms 2, which delivery is achieved by connecting an external source of fluid under pressure to the valve element 6 through a supply duct 7 (see Fig. 3B). The introduction of the fluid under pressure into the internal spaces of the chamber profile preforms 2 is achieved simultaneously for all chamber profile preforms 2, as shown in Fig. 3B.

[0048] As a result, a multi-chamber structural element is obtained with a cross section shown in Figure 6A, which has three chamber profiles 1 extending radially and arranged symmetrically with respect to a connecting axis 4, which are deformed by a fluid under pressure introduced into the hermetically sealed internal space.

[0049] Embodiment 4 A method for manufacturing a multi-chamber structural element according to the next embodiment of the present invention is shown schematically in Figures 4A-B. The depicted embodiment of the method for manufacturing a multi-chamber structural element is substantially similar to the method for manufacturing a multi-chamber structural element shown in embodiment 2, and therefore similar steps will not be discussed in detail for the sake of clarity of the present disclosure.

[0050] In a fourth embodiment of the method for manufacturing a multi-chamber structural element, six correspondingly aligned metal sheets are provided in a first step to form chamber profile preforms 2. Each chamber profile preform 2 is sealed on its outer edge, similar to the previous embodiment. Unlike the previous embodiment, the inner edges of the chamber profile preforms 2 remain unsealed, and in a subsequent step, the inner edges of the chamber profile preforms 2 are positioned relative to each other by bringing the corresponding chamber profile preforms 2 toward each other with their inner edges aligned. The aligned inner edges of the chamber profile preforms 2 are then sealed and joined together in one operation to form a connecting shaft 4 and a sealed, hermetically sealed closure of the interior spaces of all the chamber profile preforms 2, as shown in FIG. 4A.

[0051] In a subsequent step of the method for manufacturing a multi-chamber structural element according to the fourth embodiment of the present invention, a fluid under a defined pressure is delivered to the sealed internal spaces of the chamber profile preforms 2, which delivery is achieved by connecting an external source of fluid under pressure to the valve element 6 through a supply duct 7 (see Fig. 4B). The introduction of the fluid under pressure into the internal spaces of the chamber profile preforms 2 is achieved simultaneously for all chamber profile preforms 2, as shown in Fig. 4B.

[0052] As a result, a multi-chamber structural element is obtained with a cross section shown in Figure 6A, which has three chamber profiles 1 extending radially and arranged symmetrically with respect to a connecting axis 4, which are deformed by a fluid under pressure introduced into the hermetically sealed internal space.

[0053] Embodiment 5 Further non-limiting embodiments of multi-chamber structural elements are shown in cross section in Figures 4A-E.

[0054] Unlike the multi-chamber structural element described in embodiments 1-4, which was a structural element formed from three chamber profiles 1 as shown in FIG. 6A, other embodiments of the multi-chamber structural element may include a greater number of component chamber profiles 1. The multi-chamber structural element may include four chamber profiles 1 ( FIG. 6B ), six chamber profiles 1 ( FIG. 6C ), and / or eight chamber profiles 1 ( FIG. 6D ). Importantly, multi-chamber structural elements are not limited to multi-chamber structural elements formed from chamber profiles 1 of identical geometry; it is possible to have chamber profiles 1 of different geometries within the same multi-chamber structural element. Such an embodiment is shown in FIG. 6E, in which four chamber profiles 1 extending radially from and symmetrically about a connecting axis 4 have a first length, and the remaining four chamber profiles 1 positioned between the first four chamber profiles 1 have a second length that is longer than the first length. This embodiment shows the freedom in designing the multi-chamber structural element, whose technical parameters can be adjusted to the specific arrow force characteristics of a particular solution.

[0055] Various embodiments of the multi-chamber structural element according to the present invention include multi-chamber structural elements formed from chamber profiles 1 of different geometries. The geometry of the chamber profile 1 is strictly related to the geometry of the chamber profile preform 2, which undergoes deformation due to the introduction of a fluid under pressure into the hermetically sealed interior space of the chamber profile preform 2. The large surface of the wall 3 of the chamber profile preform 2 undergoes the most extensive deformation, while the area of ​​the seal 5 experiences limited or no deformation. This means that the geometry of the chamber profile 1 within the seal 5 is substantially identical to the geometry of the chamber profile preform 2, allowing the geometry of the chamber profile preform 2 to freely shape the final shape of the chamber profile 1 and, therefore, the final shape of the multi-chamber structural element. Figures 7A-F show side views of various geometries of chamber profile preforms 2, which will be used in further steps to manufacture the chamber profile 1, a component of the multi-chamber structural element.

[0056] In Fig. 7A, the chamber profile preform 2, and thus the chamber profile 1, has an inner edge that is oriented towards the connecting axis 4 of the multi-chamber structural element and extends in a straight line and parallel to the connecting axis 4, and an outer edge that is opposite the connecting axis 4 of the multi-chamber structural element and extends in a straight line parallel to the connecting axis 4. A multi-chamber structural element manufactured from the chamber profile 1 depicted in Fig. 7A is shown in a side view in Fig. 8A and in a cross-section in Fig. 9A.

[0057] In Figure 7B, the chamber profile preform 2, and thus the chamber profile 1, has an inner edge oriented toward the connecting axis 4 of the multi-chamber structural element, extending in a straight line parallel to the connecting axis 4, and an outer edge opposite the connecting axis 4 of the multi-chamber structural element, extending in a straight line inclined relative to the connecting axis 4, with the width of the chamber profile 1 increasing toward the bottom. A multi-chamber structural element manufactured from the chamber profile 1 depicted in Figure 7B is shown in a side view in Figure 8D and in a cross-section in Figure 9D.

[0058] In Figure 7C, the chamber profile preform 2, and thus the chamber profile 1, is oriented towards the connecting axis 4 of the multi-chamber structural element, has an inner edge that extends in a straight line parallel to the connecting axis 4, and an outer edge that extends in a straight line opposite the connecting axis 4 of the multi-chamber structural element and is inclined relative to the connecting axis 4, and the width of the chamber profile 1 decreases towards the bottom.

[0059] In Figure 7D, the chamber profile preform 2, and thus the chamber profile 1, has an inner edge that extends in a curve with upper and lower regions that are oriented toward the connecting axis 4 of the multi-chamber structural element and that extend in a straight line parallel to the connecting axis 4, and an outer edge that is opposite the connecting axis 4 of the multi-chamber structural element and that also extends in a straight line parallel to the connecting axis 4. The multi-chamber structural element formed from the chamber profile 1 depicted in Figure 7D is shown in a side view in Figure 8E and in a cross section in Figure 9E.

[0060] In Fig. 7E, the chamber profile preform 2, and thus the chamber profile 1, is oriented toward the connecting axis 4 of the multi-chamber structural element, with an inner edge extending in a straight line parallel to the connecting axis 4, and an outer edge extending in a concave curve opposite the connecting axis 4 of the multi-chamber structural element. The multi-chamber structural element formed from the chamber profile 1 depicted in Fig. 7E is shown in a side view in Fig. 8C and in a cross section in Fig. 9C.

[0061] In Figure 7F, the chamber profile preform 2, and thus the chamber profile 1, is oriented toward the connecting axis 4 of the multi-chamber structural element, with an inner edge extending in a straight line parallel to the connecting axis 4, and an outer edge extending in a convex curve opposite the connecting axis 4 of the multi-chamber structural element. The multi-chamber structural element formed from the chamber profile 1 depicted in Figure 7F is shown in a side view in Figure 8B and in a cross-section in Figure 9B.

[0062] In other embodiments, multi-chamber structural elements may be formed from chamber profiles 1 having different geometries, forming axially asymmetric multi-chamber structural elements. A non-limiting embodiment of an axially asymmetric multi-chamber structural element is shown in side view in FIG. 10A and cross-section in FIG. 11A, where the multi-chamber structural element is fabricated using the chamber profile 1 depicted in FIGS. 7A and 7B. Another embodiment of an axially asymmetric multi-chamber structural element is shown in side view in FIG. 10B and cross-section in FIG. 11B, where the multi-chamber structural element is fabricated using the chamber profile 1 depicted in FIGS. 7A and 7F, where the outer edge of the chamber profile 1 is curved, extending from the top of the multi-chamber structural element and gently passing through a straight segment at the bottom of the multi-chamber structural element. Yet another embodiment of an axially asymmetric multi-chamber structural element is shown in side view in Figure 10C and cross-sectional view in Figure 11C, in which the multi-chamber structural element is manufactured using the chamber profile 1 depicted in Figures 5A and 5E, and the outer edge of the chamber profile 1 is curved, extending from the bottom of the multi-chamber structural element and gently passing through a straight segment at the top of the multi-chamber structural element.

[0063] Importantly, the number of chamber profiles 1 that are part of a multi-chamber structural element, as well as the geometries of the chamber profiles 1 that are part of a multi-chamber structural element, are not limited to the ranges depicted in these embodiments, which are merely examples of possible implementations of the present invention. In alternative embodiments, a multi-chamber structural element may include four or more chamber profiles 1, and the chamber profiles 1 may have shapes other than those depicted, including shapes that are combinations of the shapes disclosed herein.

[0064] Implementation form 6 The multi-chamber structural element manufactured using the method of the present invention underwent comparative testing (based on numerical calculations) with standard structural elements commonly used in the art. The results of the comparative testing are presented in Table 1. The tested multi-chamber structural element manufactured using the method of the present invention was designated FIDU200 in Table 1. The compared structural element, designated HEB120, was a standardized width, flange I, profile with a flange width of 120 mm, a profile height of 120 mm, and a web thickness of 6.5 mm. The material used in the simulation for the HEB120 profile was steel S235JR. The multi-chamber structural element of the present invention was formed from four chamber profiles 1, shown in Figure 7A and shown in cross section in Figure 6B. Each component chamber profile 1 had a width of 200 mm, i.e., the radial dimension relative to the connecting axis 4, and was formed from 2 mm thick sheet steel S235JR using the process parameters described in Example 1.

[0065] [Table 1]

[0066] As can be seen from Table 1, the cross-sectional area of ​​the FIDU200 element is approximately 0.8% smaller than the cross-sectional area of ​​the HEB120 profile. Additionally, the FIDU200 element is approximately 5.9% lighter than the HEB120, and the minimum geometric moment of inertia of the FIDU200 cross section is approximately 7.5 times larger than that of the HEB120. As a result, the FIDU200 element is characterized by a buckling force that is approximately 7.5 times larger and a material yield force that is approximately 0.8% smaller than that of the HEB120.

[0067] A comparison of these parameters demonstrates that the cross section of the multi-chamber structural element according to the invention (FIDU200) is better used than the standard profile commonly applied in the art (HEB120). Furthermore, with a lower mass and a smaller cross section, the multi-chamber structural element according to the invention reaches a 7.5 times larger moment of inertia and a 7.5 times larger buckling strength. [Explanation of symbols]

[0068] List of Reference Numbers 1. Chamber Profile 2. Chamber Profile Preform 3. Chamber Profile Preform Walls 4 Connecting shaft 5 Seals 6 Valve elements 7 Supply Duct 8 Pressure Plate

Claims

1. A method for manufacturing a multi-chamber structural element extending along a predetermined connecting axis (4) and supporting a vertical load acting in the direction of said connecting axis (4), comprising the steps of: a) providing at least three chamber profile preforms (2), each chamber profile preform (2) made from a sheet of metal material and including two opposing walls (3) with a gap therebetween, the edges of the walls (3) being gathered, and a valve element (6) being disposed on at least one wall (3) of each chamber profile preform (2); b) the edges of each wall (3) of said chamber profile preform (2) are sealed with a seal (5) to form a sealed interior space of said chamber profile preform (2); c) a fluid under pressure is introduced through the valve element (6) into the interior space of the chamber profile preform (2) to form a deformed chamber profile (1); d) the edge portion has an inner edge portion and an outer edge portion, and the inner edge portions of the at least three chamber profile preforms (2) are welded to each other to form the connecting axis (4) extending in the direction in which the multi-chamber structural element extends, A method for manufacturing a multi-chamber structural element, characterized in that steps c) and d) may be performed in reverse order.

2. 2. A method for manufacturing a multi-chamber structural element according to claim 1, characterized in that the chamber profile preform (2) is made from a single sheet of metal material bent along one edge to form the two walls (3).

3. 3. A method for manufacturing a multi-chamber structural element according to claim 1 or 2, characterized in that step c) is carried out after the chamber profile preform (2) has been introduced between pressure plates (8) in such a way that the pressure plates (8) are in contact with the walls (3) of the chamber profile preform (2).

4. 4. Method for manufacturing a multi-chamber structural element according to claim 3, characterized in that during step c) a force is applied to the pressure plate (8) in the direction of the chamber profile preform (2).

5. A method for manufacturing a multi-chamber structural element according to any one of claims 1 to 4, characterized in that step c) is carried out by connecting said valve element (6) to a source of fluid under pressure.

6. 6. A method for manufacturing a multi-chamber structural element according to claim 1, characterized in that step c) is performed simultaneously for all of the chamber profile preforms (2) corresponding to the chamber profiles (1) in the multi-chamber structural element.

7. 7. A method for manufacturing a multi-chamber structural element according to any one of claims 1 to 6, characterized in that in step d) the chamber profiles (1) are connected while keeping their symmetrical configuration with respect to the connection axis (4).

8. Method for manufacturing a multi-chamber structural element according to any one of claims 1 to 7, characterized in that step b) and / or step d) are realized by fusion welding, crimping, gluing or crimping.

9. A method for manufacturing a multi-chamber construction element according to any one of claims 1 to 8, characterized in that the fluid is air, water, oil, fluid concrete or fluid plastic.

10. 10. Method for manufacturing a multi-chamber structural element according to any one of claims 1 to 9, characterized in that the pressure of the fluid introduced into the chamber profile preform (2) is 5 bar.

11. 11. A method for manufacturing a multi-chamber structural element according to any one of claims 1 to 10, characterized in that in step c) a fluid under pressure is introduced into the interior space of the chamber profile preform (2) for 1 minute, after which the pressure inside the chamber profile preform (2) is kept constant for 30 seconds.

12. Method for manufacturing a multi-chamber structural element according to any one of claims 1 to 11, characterized in that steps b) and d) are realized simultaneously.

13. A method for manufacturing a multi-chamber structural element as described in Claim 12, characterized in that the simultaneous sealing and connecting of the at least three chamber profile preforms (2) to form the connecting axis (4) is achieved by laser welding.

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