Structural element and method for manufacturing the structural element

Abstract

The present invention relates to a structural element with improved functional properties in terms of load capacity, strength, thermal insulation and acoustic insulation, and to a method for manufacturing the structural element. The structural element consists of a metal tubular profile (1) characterised in that at least one of its faces comprises a plurality of grooves (2) distributed in a pattern. Each groove comprises at least one protrusion (3) oriented towards the interior of the tubular profile, wherein the tubular profile is filled with a polymer foam (5).

Description

[0001]STRUCTURAL ELEMENT AND MANUFACTURING METHOD FOR THE STRUCTURAL ELEMENT Description Technical Sector The present invention falls within the construction and building sector. Specifically, it relates to the load-bearing structures of residential, public and / or industrial buildings, as well as to the elements used for their manufacture. The object of the present invention is a structural element, which can function as a column or a beam, which comprises improved functional properties in terms of load-bearing capacity, strength, thermal conductivity and acoustic insulation. Background of the Invention Currently, building structures, which can be made of three materials, are widely known: reinforced concrete, metal or wood.First, reinforced concrete structures are characterized by a high load-bearing capacity due to the strength of concrete when working in tension or compression, allowing for the construction of high-rise buildings with great reliability and a long service life. Within reinforced concrete structures, we can find precast reinforced concrete and monolithic concrete. The former are more precise than the latter; however, they require the use of heavy lifting equipment, the presence of wet materials at the construction site, and long waiting times for the materials to dry. This also necessitates the use of sturdy foundations and skilled labor. All of this results in high construction costs.It's also worth noting that reinforced concrete structures lack thermal and acoustic insulation properties, so additional protection against temperature and noise is necessary, such as fiberglass, rock wool, or the use of polyurethane or expanded polystyrene panels or injections. Secondly, metal structures are highly precise in manufacturing and assembly, superior to that of reinforced concrete, making them suitable for any type of building, including high-rise buildings such as skyscrapers. However, they have certain drawbacks, such as high cost and low fire resistance, which requires additional protection and contributes to noise propagation, making soundproofing a critical issue.We also find the high thermal conductivity of metal structures, which requires greater insulation, especially of the parts that protrude from the rooms, so that they are protected from the transmission of heat due to convection. Thirdly, we find the wooden structures of buildings, with good thermal and acoustic insulation properties, and with the capacity to withstand high loads due to their good resistant characteristics when working in tension and / or compression. However, they also pose certain drawbacks that limit their use in construction, for example: flammability, which entails dependence on fireproofing agents, and the need for maintenance, through the application of repeated treatments when the useful life of the protection is reached.Furthermore, the thermal expansion of wood causes instability in the geometry of structures made of this material under the influence of ambient temperature and humidity. It also has a shorter lifespan compared to reinforced concrete and metal, is more susceptible to decay and insect attack, and has a lower load-bearing capacity. Therefore, a structural element is needed that overcomes the shortcomings of current methods used in the construction of load-bearing structures for buildings.Explanation of the invention The structural element and the manufacturing process for the structural element proposed by the invention are therefore configured as a notable novelty within its field of application, since, in accordance with its implementation and in a taxative manner, the objectives indicated below are achieved, the characterizing details that make it possible and that distinguish them being conveniently collected in the final claims that accompany this description. Particularly, the present invention describes a structural element with high resistant, thermal and acoustic characteristics. To achieve this, the invention describes a longitudinal element of tubular form, which in a manner preferably but not limited to is made from two U-shaped metal profiles, which are inserted one inside the other, and which are joined by means of the use of mechanical joints, such as a rivet or similar, or by welding.Specifically, the use of one or another joining system, welding or mechanical joining, is chosen based on the metal profiles themselves and whether they have undergone any surface treatment that is incompatible with welding. U-shaped metal profiles comprise a base from which two wings extend. Each of the profiles' wings has slots on its surface in a staggered pattern along the entire length of the profile, where each slot has a protrusion facing the interior of the metal profile cavity. This combination of slots and protrusions is used to provide greater thermal resistance, as they extend the heat flow path.Preferably, the slots and their corresponding protrusions are manufactured by stamping, preferably cold, in which the metal sheet that forms the U-shaped profiles is deformed using special presses and punches. This allows the required geometry to be obtained without the need to cut additional parts of the sheet. Once the U-shaped metal profiles are placed in their final position and joined by welding or riveting, we obtain the tubular metal element, which is filled with polymeric foam. The protrusions of the slots are embedded in the polymeric foam, acting as a mechanical fastener.Preferably, the tubular element is filled with a high-pressure polyurethane foam with a density between 50 and 100 kg / m3, preferably between 90 and 100 kg / m3, which acts as a thermal and acoustic insulation material. Due to its high adhesion and mechanical connection with the U-shaped metal profiles, the load-bearing capacity of the structural element is multiplied. It should be noted that, thanks to the possibility of bending the tubular profile, the cross-section of the structural element can be configured into different shapes, for example, into a T or I shape, or a closed channel. L shapes can also be created for the corners and corners of building structures.The structural element, the manufacturing process for the structural element, and the set of elements described represent an innovation with previously unknown structural and constitutive characteristics. These reasons, combined with their practical utility, provide sufficient grounds for obtaining the exclusive right requested. Brief. To complement the description being provided and in order to assist in a better understanding of the characteristics of the invention, a set of drawings is attached as an integral part of said description, in which the following is represented for illustrative and non-limiting purposes: Figure 1.- Example of an embodiment of a structural element with a rectangular section. Figure 2.- Example of an embodiment of a structural element with a rectangular section with injected polymeric foam. Figure 3.- Example of an embodiment of a structural element with an L-shaped section and reinforcement in the outer corner. Figure 4.- Example of an embodiment of a structural element with an L-shaped section and reinforcement in the outer corner with injected polymeric foam. Figure 5.- Example of an embodiment of a structural element with an L-shaped section and reinforcement in inner wings. Figure 6.- Example of an embodiment of a structural element with an L-shaped section and reinforcement in outer wings with injected polymeric foam.• Figure 7.- Example of a structural element with an I-section, or double T, using injected polymer foam.• Figure 8.- Example of a structural element for a crown beam.• Figure 9.- Detail of a tongue and groove connection between different structural elements.• Figure 10.- Example of a complete supporting structure.• Figure 11.- General view of a formwork for the manufacture of structural elements.• Figure 12.- Detail of the mobile cover of the formwork.• Figure 13.- Detail of the fixed cover of the formwork.• Figure 14.- Section of the formwork with an example of an application for a rectangular profile with two reinforcements at the ends, and with details of the spacers.• Figure 15.- Section of the formwork with an example of an application for an I-section, or double T, and with details of the spacers.List of references and figures:1. Tubular profile 2. Slots 3. Projections 4. Reinforcements 5. Polymeric foam 6. Formwork 7. Longitudinal walls of the formwork 8.Formwork end caps 9. Spacers 10. Removable mechanical fastening means Preferred Embodiment of the Invention In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part of this specification and in which specific preferred embodiments are shown by way of illustration in which the invention may be embodied. These embodiments are described in sufficient detail to enable those skilled in the art to carry out the invention, and it is to be understood that other embodiments may be utilized and that logical structural, mechanical, electrical and / or chemical changes may be made without departing from the scope of the invention. To avoid details not necessary to enable those skilled in the art to carry out the detailed description, it should not, therefore, be taken in a limiting sense.Specifically, the present invention describes a structural element formed from a metallic tubular profile, where at least one of its faces comprises a plurality of slots distributed according to a pattern, for example staggered, where each slot comprises at least one projection facing the interior of the tubular profile. Preferably, the slots are arranged in a staggered pattern along the entire length and width of the tubular profile, and provide the metal sheet with additional thermal resistance since they lengthen the path of the heat flow that passes through it, maximizing thermal insulation. Preferably, the slots are manufactured by stamping, particularly cold stamping, whereby the metal sheet is deformed using presses, allowing the holes required to create the slot to be obtained.This offers certain advantages, such as mass production, process repetition and industrialization, and high efficiency in the use of metal, as no scrap or similar material is wasted. Preferably, the tubular profile is filled with polymer foam, preferably high-pressure rigid polyurethane foam, with a density between 50 and 100 kg / m3, preferably between 90 and 100 kg / m3, which acts as a thermal and acoustic insulator. It is also worth noting that the polyurethane thermal and acoustic insulator has high adhesion properties, so its application is carried out without additional reinforcement or fixation, simply by injection into the cavity of the outer frame of the structural element, which serves as a formwork. Furthermore, the protrusions of the tubular profile's slots are embedded within the polyurethane, thereby increasing the structural element's load-bearing capacity.In a preferred embodiment, the structural element comprises internal reinforcements configured from a metal tube, preferably square in shape, with windows made in its interior wall, which allow the reinforcement to penetrate and be filled with polyurethane. Preferably, the reinforcement is made of carbon steel or galvanized steel. Additionally, the structural element comprises a tongue-and-groove joint at its ends, to allow the connection between two consecutive structural elements. In a particular example, the columns made according to the structural element object of the present invention comprise a slot at their top and bottom, and the beams comprise protrusions at their ends, configured to insert into the slots of the columns.In another particular example, the beams made according to the structural element object of the present invention comprise slots at their ends, and the columns comprise projections, configured to fit into the column slots. This allows, by using structural elements according to the present invention, the complete structure of a building to be configured, through the use of tongue-and-groove joints, and the use of floors placed between the beams. In this way, the structural element object of the present invention provides sufficient load-bearing capacity to support the weight of the floors and operational loads, in addition to achieving acoustic and thermal insulation of the interior of the building.It should be noted that the structural element object of the present invention may have any type of section, not only including a square or rectangular profile, but also being able to be made in the form of a T, double T or in a closed channel. The structural element thus described allows the configuration of any type of profile, so it can be used to act as any type of element of a load-bearing structure, such as a beam, a column or the frame of a building. In particular, a beam according to the present invention will have a greater section height to withstand bending moments, including a metallic reinforcement on the opposite side of the assembled structure. Furthermore, the pillar will have a larger section to withstand tensile and compressive forces.In parallel, the frame of a building can be made using the structural elements described in the present invention, which, in addition to providing resistant characteristics, also provide thermal and acoustic insulation in these parts, which are so critical in terms of insulation of the supporting structure of a building. This involves the creation of structural elements with L-shaped sections, for example, which can be used in internal and / or external corners, as well as parapet beams that connect the insulation of the walls with the insulation of the roof, creating an insulating envelope for the building. Preferably, the metal profile is made from at least two open metal profiles joined at their open sides by permanent mechanical connections, such as welding or rivets, forming the hollow tubular profile.According to this last embodiment, and thanks to the high adhesion properties of the polymers, especially polyurethane, the window projections are embedded in the polymeric foam, functioning as a mechanical fixation within the thickness of the insulation. Furthermore, due to the mechanical connection with the tubular metal profile of the structural element, the load capacity is multiplied several times. In order to improve the understanding of the invention, but without the intention of limiting the invention, different configurations of the invention can be seen in the figures. In Figure 1, we can see an example of application of the structural element according to a rectangular configuration, in which the tubular profile (1), the slots (2), and the projections (3) can be seen. Two reinforcements (4), located at both ends of the profile, can also be seen. This type of profile can be used, for example, in the columns of a building.In Figure 2, we can see the previous example, with the injected polymeric foam (5), embedding the protrusions (3), which reinforce the joint and improve the resistant characteristics of the structural element. In Figure 3, we can see a particular configuration, in which the tubular profile (1) has an L-shaped section, including a reinforcement (4) in its outer corner. In this view, the windows of the reinforcement (4) can be seen through which the polymeric foam (5) penetrates, improving the fixation and increasing the resistance of the assembly. In Figure 4, we can see the previous example, with the injected polymeric foam (5), embedding the protrusions (3) and the reinforcement (4), improving the fixation and increasing the resistance of the assembly. In Figure 5, we can see a particular configuration, in which the tubular profile (1) has an L-shaped section, but including the reinforcements (4) in the inner wings of the tubular profile (1).Figure 6 refers to the same example with injected polymeric foam (5). L-shaped tubular profiles can be used in the corners of load-bearing structures. In Figure 7, we can see a particular configuration in which the tubular profile (1) has an I-shaped section, or double T, of those mainly used in the horizontal beams of load-bearing structures, since, due to their geometry, they are suitable for withstanding bending forces. In this case, the representation has been made directly with the injected polymeric foam (5). In Figure 8, we can see an example of the construction of a crown beam. In Figure 9, we can see a detail of the tongue-and-groove joint between different structural elements, such as two columns and several beams.Figure 10 shows a construction example of a supporting structure made using structural elements according to the present invention, which have been joined using tongue-and-groove joints. The remaining elements are placed on this structure, such as the floors, windows or glazing, walls, etc. The present invention also describes the manufacturing process for the structural element described in the previous embodiments. Specifically, the present invention begins with the manufacture of the tubular profile and the creation of the grooves and / or protrusions using stamping techniques, preferably cold. Subsequently, once the mechanical shaping of the tubular profile has been completed, it is placed in a formwork, and the polymeric foam is injected at high pressure to completely fill the tubular profile. Finally, the tubular profile is removed from the formwork.In a preferred embodiment, the tubular profile is made from at least two different profiles that are joined using mechanical joining means, such as welding or the use of rivets. This union will be reinforced subsequently with the injection of the polymeric foam. Additionally, the metal profile may include reinforcements that are placed prior to the introduction of the profile into the formwork. Specifically, in Figures 11 to 14 a preferred example of formwork (6) can be seen, comprising at least four longitudinal walls (7) and two covers (8) at the ends, where at least one of the covers (8) is removable by means of removable mechanical fastening means (10), preferably removable fastening screws, to allow the injection of the polymeric foam.In a preferred embodiment, the removable cover (8) is used to place the tubular profile (1) and the corresponding reinforcements (4) inside the formwork (6), and is subsequently placed at the end. Where the cover (8) includes at least two entry holes to inject the two components that end up forming the polymeric foam, as can be seen in Figure 12. Preferably, the formwork (6) comprises separators (9), preferably made of wood, which allow the dimensions of the profile housed inside the formwork (6) to vary, and can be used for any type. In a preferred embodiment, the manager (6) comprises removable joining means, which allow the modularity of the assembly to be achieved, and the length of the manufactured structural elements can be increased or decreased.Having sufficiently described the nature of the present invention, as well as the manner of putting it into practice, it is not considered necessary to explain it further so that any expert in the field may understand its scope and the advantages derived from it, stating that, within its essence, it may be put into practice in other embodiments that differ in detail from the one indicated as an example, and which will also achieve the protection sought provided that its fundamental principle is not altered, changed or modified.

Claims

MODIFIED CLAIMS received by the International Bureau on June 9, 2025 (06.09.2025) 1. Structural element with integrated load-bearing structural properties and thermal and acoustic insulation, comprising a closed metal profile formed by joining two U-shaped profiles made of cold-formed sheet metal, said profile having, on at least one of its internal faces, stamped areas in the form of slots with projections facing towards the interior of the profile, said slots being distributed in a staggered pattern, and the interior volume of the profile being completely filled with a rigid polymeric foam that surrounds said projections.

2. Structural element according to claim 1, characterized in that the grooves with projections are arranged in a staggered pattern on the opposite faces of the metal profile.

3. Structural element according to any of the preceding claims, characterized in that the polymeric foam is a high-pressure rigid polyurethane foam.

4. Structural element according to any of the preceding claims, characterized in that the profile may additionally contain an internal reinforcement, consisting of at least one tubular metal profile with through holes or windows in its walls.

5. Structural element according to claim 4, characterized in that the internal reinforcement is made of carbon steel or galvanized steel.

6. Structural element according to any of the preceding claims, characterized in that at least one of its ends comprises a tongue and groove configuration to facilitate its assembly with other similar structural elements.

7. Structural element according to any of the preceding claims, characterized in that the tubular profile is obtained by joining two metal profiles open on their longitudinal side by welding or riveting. DECLARATION ACCORDING TO ARTICLE 19 (1) The applicant submits, pursuant to Article 19 of the PCT, the following declaration concerning the modifications made to the claims, intended to improve the clarity, technical consistency and formal conformity of the application, without adding new material.

1. Claim 1 has been worded more precisely to clearly reflect that the structural element comprises a closed metal profile, formed by joining two cold-formed U-profiles, with internal stampings in the form of slots with inward-facing protrusions, arranged in a staggered pattern, and completely filled with rigid polymeric foam.

2. Claim 2 has been modified to expressly specify that the protruding slots are arranged in an alternating (staggered) pattern on opposite faces of the metal profile, with the aim of reinforcing the structural understanding of the design without expanding the scope of the initial application.

3. Claim 4 has been amended to establish that the profile may additionally contain at least one internal reinforcement in the form of a second tubular metal profile with windows or through holes, rather than requiring it to be made. This wording makes the interpretation more flexible without introducing material not previously considered.

4. Claim 7 has been adapted to recover the technical content present in the initial application, specifying that the tubular profile is obtained by joining two open metal profiles along their longitudinal sides, by welding or riveting.

5. Claim 8 has been deleted, since it referred to the thickness of the metal (0.5 mm to 2 mm), information that was not included in the original specification, so its inclusion could lead to an unauthorized extension of the subject matter of the application. The new set of claims consists of seven (7) claims numbered 1 through 7, completely replacing the claims previously filed on May 28, 2025.

Images