A profile rail for a construction system, a construction system and a method

Abstract

The disclosure relates to a profile rail (1) for a construction system (2), said profile rail (1) comprises: a first flange portion (4) for interaction with at least one structural element (6); a second flange portion (8) opposite to the first flange portion (4); and a web portion (10) interconnecting the flange portions (4, 8) and extending between the flange portions (4, 8), 5 wherein at least one of the first flange portion (4) and the second flange portion (8) is configured in one piece with the web portion (10); wherein the at least one of the first flange portion (4) and the second flange portion (8) is shaped by a bend and folded extension of the web portion (10), and wherein the first flange portion (4) comprises a first part (24), a second part (26) and a third part (28); the first part (24) extends from the web portion (10) via a first 10 bending section (30), the second part (26) extends from the first part (24) via a second bending section (32), and the third part (28) extends from the second part (26) via a third bending section (34). An end section (36) of the third part (28) is at least partly arranged between the first part (24) and the second part (26). The disclosure further relates to a construction system (2) for attaching at least one structural element (6) to a profile rail (1) and 15 a method for manufacturing a profile rail (1).

Description

[0001] A profile rail for a construction system, a construction system and a method

[0002] Technical field

[0003] The present invention relates to a profile rail for a construction system, a construction system for attaching at least one structural element to a profile rail and a method for manufacturing a profile rail as defined in the introductory parts of the independent claims.

[0004] Background art

[0005] When building walls and ceilings, a framework with profile rails may be used. The framework for walls may comprise horizontally mounted top plates on the ceiling and bottom plates on the floor. Vertical profile rails are then placed between these with a mutual spacing. When the framework is mounted, wall panels are nailed or screwed to the framework. The distance between the profile rails is usually determined by the width of the wall panels to be fixed to the vertical profile rails. Common materials in wall panels are gypsum, MDF (Medium Density Fibre), OSB (Orientated Strand Board), shavings and wood chips. Magnesium oxide, calcium silicate, fibre cement and fibre gypsum boards as well as various types of composite boards also exist.

[0006] When constructing walls in general and interior walls in particular, profile rails and studs made from steel or wood may be used. Wooden studs are usually homogeneous and with a rectangular or square cross-section. Steel profile rails may be used in wall and ceiling structures by using so-called lightweight framing construction technique. Such structures comprise a framework of metal profile rails forming a support or frame which is then covered with sheet-shaped building boards. The framework for walls includes horizontal profile rails that form top plates and bottom plates, which profile rails usually have a U-shaped cross section. Vertical profile rails are mounted in the top and bottom plates with a predetermined mutual distance, on which plates and standing profile rails the building boards are then mounted.

[0007] Steel profile rails usually made from steel sheets which are cut and bent to obtain a desired profile. Typically, a steel profile rail comprises two parallel flange portions members which are joined by a transverse web member extending substantially perpendicular to the flange portions. The steel profile rail can thus obtain a substantially C-shaped or l-shaped cross-section. A problem with the solutions of the prior art is that the flange portions of the profile rail is resilient, which may result in a level difference or so-called toothing between adjacent boards, which are attached to the profile rail. This level difference or toothing between adjacent bords results in level differences in the wall, which is not desirable. A wall with level difference or toothing between adjacent boards may be processed by plaster applied on the wall and thereafter suitable tools may be used, such as sandpaper, to level the surface of the wall. However, this process is time-consuming due to the need of manual work by craftsmen, which increases the cost for building the wall.

[0008] Another problem with the solutions of the prior art is that in a framework consisting of steel profile rails, the profile rails may be too thin for nails and staples to attach in an intended way. Further, in the case of hard plasterboard, plywood and OSB, for example, the resistance that arises when a screw's skull is to be mechanically recessed in the wall panel may become so large that the interaction between the screw and the profile rails deforms the profile rails rather than pushing the screw into the profile rails. The screw thread then loses its traction in the steel stud.

[0009] There is thus a need for improved profile rail for a construction system.

[0010] It is an objective of the present disclosure to mitigate, alleviate or eliminate one or more of the above-identified deficiencies and disadvantages in the prior art and solve at least the above-mentioned problem.

[0011] A further objective is to provide a profile rail, which reduces or eliminates a level difference or toothing between adjacent boards, which are attached to the profile rail.

[0012] A further objective is to provide a profile rail, which may be used in a construction system for inner and outer walls as well as in ceilings of buildings.

[0013] A further objective is to reduce the cost for finish the construction system.

[0014] These objectives are achieved with the above-mentioned profile rail for a construction system, a construction system for attaching at least one structural element to a profile rail and a method for manufacturing a profile rail according to the appended claims. According to a first aspect there is provided a profile rail for a construction system, the profile rail comprises: a first flange portion for interaction with at least one structural element; a second flange portion opposite to the first flange portion; and a web portion interconnecting the flange portions and extending between the flange portions, wherein the first flange portion comprises a first external surface for interaction with the at least one structural element, a first internal surface facing toward the second flange portion and a second internal surface facing toward the second flange portion, wherein the second flange portion comprises a second external surface, a third internal surface and a fourth internal surface, wherein the third internal surface and the fourth internal surface facing toward the first flange portion, wherein at least one of the first flange portion and the second flange portion is configured in one piece with the web portion; wherein the at least one of the first flange portion and the second flange portion is shaped by a bend and folded extension of the web portion, and wherein the first flange portion comprises a first part, a second part and a third part; the first part extends from the web portion via a first bending section, the second part extends from the first part via a second bending section, and the third part extends from the second part via a third bending section. An end section of the third part is at least partly arranged between the first part and the second part. The profile rail may have a suitable longitudinal extension, which is adapted to the construction system, such as an inner or outer wall or a ceiling in a building. The first and second flange portions may have the same or similar configuration. The first and second flange portions may have different configurations. The web portion sets the distance between the first and second flange portions. The web portion may be adapted to construction system. The structural element may be wall or ceiling panels. The structural element may be gypsum, MDF (Medium Density Fibre), OSB (Orientated Strand Board), shavings and wood chips. The structural elements may also be panels of magnesium oxide, calcium silicate, fibre cement and fibre gypsum boards as well as various types of composite boards. The structural elements are preferably flat. The first part, second part and third part of the first flange portion may increase the stability and strength of the first flange portion. The end section of the third part may be fixated in that it is clamped between the first part and the second part when the structural element is attached to the first flange portions, which may increase the stability, strength and stiffness of the first flange portion further. As a result, any level difference or toothing between adjacent boards attached to the profile rail can be avoided and a smooth wall or ceiling surface may be achieved. Since the second part of the first flange portion overlaps with the first and third parts, respectively, a fastener element for connecting the structural element to the first flange portion may be firmly attached to and in the first flange portion, which results in a firm interaction of the structural element with the first flange portion by the fastener element. Since the end section of the third part is at least partly arranged between the first part and the second part, the third part may not deflect when the fastener element is driven into the first flange portion. Thus, the fastener element may penetrate through the second part and the third part of the first flange portion and rigidly attach the structural element to the first flange portion.

[0015] The third part may be attached to the first part by a first weld or glue joint. By means of the attachment between the third part and the first part, the stability and strength of the first flange portion may increase further. As a result, any level difference or toothing between adjacent boards attached to the profile rail can be avoided due to reduced or eliminated resilience of the first flange portion.

[0016] The second flange portion may comprise a fourth part, a fifth part and a sixth part; the fourth part extends from the web portion via a fourth bending section, the fifth part extends from the fourth part via a fifth bending section, and the sixth part extends from the fifth part via a sixth bending section. The fourth part, fifth part and sixth part of the second flange portion may increase the stability and strength of the second flange portion. Since the fifth part of the first flange portion overlaps with the fourth and sixth parts, respectively, a fastener element for connecting the structural element to the first flange portion may be firmly attached to and in the first flange portion, which results in a firm interaction of the structural element with the second flange portion by the fastener element.

[0017] An end section of the sixth part may be at least partly arranged between the fourth part and the fifth part. The end section of the sixth part may be fixated in that it is clamped between the fourth part and the fifth part when the structural element is attached to the second flange portion, which may increase the stability and strength of the second flange portion further and thus any level difference or toothing between adjacent boards attached to the second flange portion can be avoided. Since the end section of the sixth part is at least partly arranged between the fourth part and the fifth part, the sixth part may not deflect in a direction away from the structural element when the fastener element is driven into the second flange portion. Thus, the fastener element may penetrate through the fifth part and the sixth part of the second flange portion and rigidly attach the structural element to the second flange portion.

[0018] The sixth part may be attached to the fourth part by a second weld or glue joint. By means of the attachment between the sixth part and the fourth part, the stability and strength of the first flange portion may increase further. As a result, any level difference or toothing between adjacent boards attached to the profile rail can be avoided due to reduced or eliminated resilience of the second flange portion.

[0019] The first flange portion, the second flange portion and the web portion may be constituted by a single piece of material. The single piece of material may be a sheet plate. The sheet plate may be made of a suitable material, which is bendable. The sheet plate may have a thickness adapted to the profile rail for a specific application area, such as a construction system for an inner wall in a building or for an outer wall of the building.

[0020] The single piece of material may be a sheet metal. A metal profile rail may have characteristics suitable for a construction system in a building, such as inner and outer walls, and in ceilings. Sheets of metals may be bendable to profile rails. A sheet metal may be performed with a suitable thickness. Sheet metals of different thickness may be available. The sheet metal may be alloyed and heat treated to achieve a profile rail with specific and suitable characteristics regarding processability, flexibility and strength.

[0021] The web portion may comprise a plurality of recesses. The recesses may reduce the sound transmission in the construction system. Thin sheet material in the web portion together with the recesses in the web portion provides better reduction of sound propagating through the construction system. Further, from a cost perspective the recesses result in material savings. The recesses may at their periphery be provided with collars, which increase the bending resistance and torsional strength and the profile rail.

[0022] The profile rail may have an l-shaped cross-section. The l-shaped cross-section may have the first and second flange portions symmetrically arranged in relation to the web portion. The l-shaped cross-section may have the first and second flange portions asymmetrically arranged in relation to the web portion. The relations between the length of the first and second flange portions in relation to the web portion may be adapted to application area of the construction system. The profile rail with an l-shaped cross-section may be an I-beam. The profile rail with an l-shaped cross-section may have a similar cross section to a profile rail with an H-shaped cross-section.

[0023] At least one line of weakness may be arranged in the profile rail, parallel with a longitudinal extension of the profile rail, and in that at least one of the first flange portion and the second flange portion is foldable to the web portion along the at least one line of weakness. An advantage related to such line of weakness is that the profile rails can be folded during transport and storage and thus be placed closed to each other. In this way, the volume that the profile rails take up can be reduced, which is important from a storage perspective and considering costly and environmentally harmful transports. It is also of great importance in workplaces, where there is often a lack of storage space. Before installing the profile rail in the construction system, the profile rail is unfolded along the line of weakness.

[0024] According to a second aspect there is provided a construction system for attaching at least one structural element to a profile rail according to the first aspect, the system comprises: the profile rail comprising the first flange portion for interaction with the at least one structural element, the second flange portion opposite to the first flange portion and the web portion interconnecting the flange portions and extending between the flange portions; wherein the first flange portion is configured in one piece with the web portion; and the first flange portion is shaped by a bend and folded extension of the web portion; and wherein the at least one structural element is attached to the first flange portion by a fastener element.

[0025] The fastener element may comprise a pair of legs and a head, which head extends between the legs and which head is connected to the legs. The fastener element may be a staple, which is applied through the structural element and into the first or second flange portion of the profile rail.

[0026] The fastener element may comprise a nail. Alternatively, or in combination with a staple, a nail may be used to attach the structural element to the first or second flange portion of the profile rail.

[0027] According to a third aspect there is provided a method for manufacturing a profile rail according to the first aspect, wherein the method comprises the steps of: defining a rectangular area in a rectangular sheet plate, which rectangular area is configured to constitute the web portion of the profile rail with an l-shaped cross-section; and bending a first and second area of the sheet plate outside of the defined rectangular area for shaping the first flange portion and the second flange portion. Such manufacturing of the profile rail may be performed by a roll forming process in a roll forming machine. The sheet plate may be a sheet metal blank or a sheet metal which is coil fed through the roll forming machine.

[0028] The step of bending areas of the sheet plate outside of the defined rectangular area for shaping the first flange portion and the second flange portion may comprise: bending the sheet plate at the first bending section, the second bending section, and the third bending section for shaping the first flange portion, and bending the sheet plate at the fourth bending section, the fifth bending section, and the sixth bending section for shaping the second flange portion. Bending the sheet plate at the first bending section, the second bending section, and the third bending section may be performed in the roll forming machine.

[0029] The first flange portion comprises a first part, a second part and a third part; the first part may extends from the web portion via a first bending section, the second part extends from the first part via a second bending section, and the third part extends from the second part via a third bending section; and wherein the step of bending areas of the sheet plate outside of the defined rectangular area for shaping the first flange portion further comprises: arranging an end section of the third part at least partly between the first part and the second part. Arranging the end section of the third part at least partly between the first part and the second part may be performed in the roll forming machine. Arranging the end section of the third part at least partly between the first part and the second part may be performed in the roll forming machine. In a further manufacturing step or in connection with the step of arranging the end section of the third part at least partly between the first part and the second part, the third part may be attached to the first part by welding or gluing.

[0030] The second flange portion may comprise comprises a fourth part, a fifth part and a sixth part; the fourth part extends from the web portion via a fourth bending section, the fifth part extends from the fourth part via a fifth bending section, and the sixth part extends from the fifth part via a sixth bending section ; and wherein the step of bending areas of the sheet plate outside of the defined rectangular area for shaping the second flange portion further comprises: arranging an end section of the sixth part at least partly between the fourth part and the fifth part. Arranging the end section of the sixth part at least partly between the fourth part and the fifth part may be performed in the roll forming machine. In a further manufacturing step or in connection with the step of arranging the end section of the sixth part at least partly between the fourth part and the fifth part, the sixth part may be attached to the fourth part by welding or gluing.

[0031] Recesses may be arranged in the web portion before or after the step of bending of the first and second area of the sheet plate outside of the defined rectangular area for shaping the first flange portion and the second flange portion. Further, collars may be arranged at the periphery of the recessed simultaneous as the recesses are arranges in the web portion. However, the recesses may be arranged in another step before or after the recesses are arranged in the web portion.

[0032] Before or after the step of bending of the first and second area of the sheet plate outside of the defined rectangular area for shaping the first flange portion and the second flange portion, at least one line of weakness may be arranged in the web portion, parallel with a longitudinal extension of the web portion. At least one of the first flange portion and the second flange portion is foldable to the web portion along the at least one line of weakness.

[0033] The present disclosure will become apparent from the detailed description given below. The detailed description and specific examples disclose preferred embodiments of the disclosure by way of illustration only. Those skilled in the art understand from guidance in the detailed description that changes and modifications may be made within the scope of the disclosure.

[0034] Brief of the

[0035] The above objects, as well as additional objects, features and advantages of the present disclosure, will be more fully appreciated by reference to the following illustrative and non-limiting detailed description of example embodiments of the present disclosure, when taken in conjunction with the accompanying drawings.

[0036] Fig. 1 schematically illustrates a side view of a profile rail according to prior art;

[0037] Fig. 2 schematically illustrates a side view of a profile rail, according to an example;

[0038] Fig. 3 shows a section view along line A - A of the profile rail in fig. 2;

[0039] Fig. 4 schematically illustrates a construction system with structural elements attached to a profile rail according to an example;

[0040] Fig. 5 schematically illustrates in a view of perspective, a profile rail according to an example;

[0041] Fig. 6 schematically illustrates in a view of perspective, a profile rail according to a further example;

[0042] Figures 7a - 7d schematically illustrates a method for manufacturing a profile rail according to an example;

[0043] Figures 8a - 8c schematically illustrates a method for manufacturing a profile rail according to a further example; and

[0044] Fig. 9 shows a flowchart of a method according to an example. Detailed description

[0045] The present disclosure will now be described with reference to the accompanying drawings, in which preferred example embodiments of the disclosure are shown. The disclosure may, however, be embodied in other forms and should not be construed as limited to the herein disclosed embodiments. The disclosed embodiments are provided to fully convey the scope of the disclosure to the skilled person.

[0046] Fig. 1 schematically illustrates a view from above of a part of a construction system 2', such as a vertical wall, comprising a U or C-shaped profile rail 1' according to prior art. Structural elements 6', such as gypsum panels are connected to the profile rail 1' by means of fastener elements 62'. The U or C-shaped profile rail 1' is made of sheet metal and comprises two flange portions 4', 8' connected to a web portion 10' in the shape of a U or a C. Due to resilient characteristics of the flange portions 4', 8', adjacent structural elements 6' attached to one of the flange portions 4', 8' may not receive the same level in relation to each other. This level difference or toothing between adjacent structural elements 6' results in level differences in the wall, which is not desirable.

[0047] Fig. 2 schematically illustrates a side view of a profile rail 1, according to an example of the present disclosure. The profile rail 1 comprises a first flange portion 4, a second flange portion 8 opposite to the first flange portion 4 and a web portion 10 interconnecting the flange portions 4, 8. The web portion 10 extends between the flange portions 4, 8.

[0048] Fig. 3 shows a section view along line A - A of the profile rail in fig. 2. The profile rail 1 has an l-shaped cross-section. The profile rail 1 comprises the first flange portion 4; the second flange portion 8 opposite to the first flange portion 4 and the web portion 10 interconnecting the flange portions 4, 8 and extending between the flange portions 4, 8. The first flange portion 4 comprises a first external surface 12, a first internal surface 14 facing toward the second flange portion 8 and a second internal surface 16 facing toward the second flange portion 8. The second flange portion 8 comprises a second external surface 18, a third internal surface 20 and a fourth internal surface 22. The third internal surface 20 and the fourth internal surface 22 facing toward the first flange portion 4. The first flange portion 4 and the second flange portion 8 are configured in one piece with the web portion 10. The first flange portion 4 and the second flange portion 8 are shaped by a bend and folded extension of the web portion 10. The first flange portion 4 comprises a first part 24, a second part 26 and a third part 28. The first part 24 extends from the web portion 10 via a first bending section 30, the second part 26 extends from the first part 24 via a second bending section 32, and the third part 28 extends from the second part 26 via a third bending section 34. An end section 36 of the third part 28 is at least partly arranged between the first part 24 and the second part 26. The third part 28 can be attached to the first part 24 by a first weld or glue joint 38. The second flange portion 8 comprises a fourth part 40, a fifth part 42 and a sixth part 46. The fourth part 40 extends from the web portion 10 via a fourth bending section 48, the fifth part 42 extends from the fourth part 40 via a fifth bending section 50, and the sixth part 46 extends from the fifth part 42 via a sixth bending section 52. An end section 54 of the sixth part 46 is at least partly arranged between the fourth part 40 and the fifth part 42. The sixth part 46 is attached to the fourth part 40 by a second weld or glue joint 56. The first flange portion 4, the second flange portion 8 and the web portion 10 are constituted by a single piece of material. The single piece of material is a sheet metal.

[0049] Fig. 4 schematically illustrates a construction system 2 with structural elements 6 attached to a profile rail 1 according to an example. The first external surface 12 of the first flange portion 4 of the profile rail 1 interacts with two structural elements 6. Since the end section 36 of the third part 28 is at least partly arranged between the first part 24 and the second part 26, the resilience of the first flange portion 4 is reduced and the strength of the first flange portion 4 is increased. The border line 57 between the two structural elements 6 is preferably positioned in an area along the position of the web portion 10. Similar to the first flange portion 4, a structural element 6 is attached to the second flange portion 8. The structural elements 6 are attached to the flange portions 4, 8 by fastener elements 62. The fastener elements 62 may be staples, comprising a pair of legs 64 and a head 66, which head 66 extends between the legs 64 and which head 66 is connected to the legs 64. Alternatively, or in combination, the fastener elements 62 comprise nails.

[0050] Fig. 5 schematically illustrates in a view of perspective, a profile rail according to an example. The profile rail 1 comprises the first flange portion 4, the second flange portion 8 opposite to the first flange portion 4 and the web portion 10 interconnecting the flange portions 4, 8. The end section 36 of the third part 28 is at least partly arranged between the first part 24 and the second part 26. The end section 54 of the sixth part 46 is at least partly arranged between the fourth part 40 and the fifth part 42.

[0051] Fig. 6 schematically illustrates in a view of perspective, a profile rail 1 according to a further example. The profile rail 1 comprises the first flange portion 4, the second flange portion 8 opposite to the first flange portion 4 and the web portion 10 interconnecting the flange portions 4, 8. The end section 36 of the third part 28 is at least partly arranged between the first part 24 and the second part 26. The end section 54 of the sixth part 46 is at least partly arranged between the fourth part 40 and the fifth part 42. Further, the web portion 10 comprises a plurality of recesses 58. The recesses 58 are at their periphery provided with collars 59, which increases the bend resistance and torsional strength and the profile rail 1.

[0052] A line of weakness 60 is arranged in the profile rail 1, parallel with a longitudinal extension of the profile rail 1, and in that at least one of the first flange portion 4 and the second flange portion 8 is foldable to the web portion 10 along the at least one line of weakness 60.

[0053] Figures 7a - 7d schematically illustrates a method for manufacturing a profile rail 1 according to an example. According to fig. 7a, a rectangular area 68 in a rectangular sheet plate 70 is defined, which rectangular area 68 is configured to constitute the web portion 10 of the profile rail 1 with an l-shaped cross-section. Thereafter a first and second area 72, 74 of the sheet plate 70 outside of the defined rectangular area 68 are bent for shaping the first flange portion 4 and the second flange portion 8. According to fig. 7b the first and second areas 72, 74 are bent in the same direction around the first and fourth bending sections 30, 48. Thereafter, the third part 28 is bend around the third bending section 34 and the sixth part 46 is bend around the sixth bending section 52. However, the third and sixth parts 28, 46 may be bent around the third and sixth bending sections 34, 52, respective, before the first and fourth parts 24, 40 are c around the first and fourth bending sections 30, 48, respective. Thereafter, shown in fig. 7c, the second and fifth parts 26, 42 are bend around the second and fifth bending sections 32, 50, respective. The first and second area 72, 74 of the sheet plate 70 have been designed with such a width that the end section 36 of the third part 28 will at least partly be arranged between the first part 24 and the second part 26 when bending the third part 28 around the second bending section 32, and that end section 52 of the sixth part 46 will at least partly be arranged between the fourth part 40 and the fifth part 42 when bending the fifth part 42 around the fifth bending section 50. Finally, the respective parts of the first and second flange portions 4, 8 are pressed together, which is shown in fig. 7d, and optionally the third part 28 is attached to the first part 24 by a first weld or glue joint 38, and the sixth part 46 is attached to the fourth part 40 by a second weld or glue joint 56.

[0054] Figures 8a - 8c schematically illustrates a method for manufacturing a profile rail 1 according to a further example. According to this further example, shown in fig. 8a, the first and second areas 72, 74 are bent in opposite directions at the first and fourth bending sections 30, 48. Further, the sixth part 46 has been bent around the sixth bending section 52 in the opposite direction compared to the direction shown in fig. 7a. This bending results in a second flange portion 8 shown in figures 8b and 8c which is mirror-inverted in relation to the second flange portion 8 shown in figures 7c and 7d. The profile rail 1 shown in figures 7a - 8c may be shaped and manufactured by a roll forming process.

[0055] Fig. 9 shows a flowchart of a method for manufacturing a profile rail 1 according to an example. Examples of profile rails 1 manufactured by the method is shown in figures 2 - 8. The method comprises the steps of: defining slOl a rectangular area 68 in a rectangular sheet plate 70, which rectangular area 68 is configured to constitute the web portion 10 of the profile rail 1 with an l-shaped cross-section; and bending sl02 a first and second area 72, 74 of the sheet plate 70 outside of the defined rectangular area 68 for shaping the first flange portion 4 and the second flange portion 8. The step of bending sl02 areas of the sheet plate 70 outside of the defined rectangular area 68 for shaping the first flange portion 4 and the second flange portion 8 comprises: bending the sheet plate 70 at the first bending section 30, the second bending section 32, and the third bending section 34 for shaping the first flange portion 4, and bending the sheet plate 70 at the fourth bending section 48, the fifth bending section 50, and the sixth bending section 52 for shaping the second flange portion 8. The first flange portion 4 comprises a first part 24, a second part 26 and a third part 28; the first part 24 extends from the web portion 10 via a first bending section 30, the second part 26 extends from the first part 24 via a second bending section 32, and the third part 28 extends from the second part 26 via a third bending section 34; and wherein the step of bending sl02 areas of the sheet plate 70 outside of the defined rectangular area 68 for shaping the first flange portion 4 further comprises: arranging an end section 36 of the third part 28 at least partly between the first part 24 and the second part 26. The second flange portion 8 comprises a fourth part 40, a fifth part 42 and a sixth part 46; the fourth part 40 extends from the web portion 10 via a fourth bending section 48, the fifth part 42 extends from the fourth part 40 via a fifth bending section 50, and the sixth part 46 extends from the fifth part 42 via a sixth bending section 52; and wherein the step of bending sl02 areas of the sheet plate 70 outside of the defined rectangular area 68 for shaping the second flange portion 8 further comprises: arranging an end section 54 of the sixth part 46 at least partly between the fourth part 40 and the fifth part 42.

[0056] The person skilled in the art realizes that the present disclosure is not limited to the preferred embodiments described above. The person skilled in the art further realizes that modifications and variations are possible within the scope of the appended claims.

[0057] Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed disclosure, from a study of the drawings, the disclosure, and the appended claims.

Claims

CLAIMS1. A profile rail (1) for a construction system (2), said profile rail (1) comprises: a first flange portion (4) for interaction with at least one structural element (6); a second flange portion (8) opposite to the first flange portion (4); and a web portion (10) interconnecting the flange portions (4, 8) and extending between the flange portions (4, 8), wherein the first flange portion (4) comprises a first external surface (12) for interaction with the at least one structural element (6), a first internal surface (14) facing toward the second flange portion (8) and a second internal surface (16) facing toward the second flange portion (8), wherein the second flange portion (8) comprises a second external surface (18), a third internal surface (20) and a fourth internal surface (22), wherein the third internal surface (20) and the fourth internal surface (22) facing toward the first flange portion (4), wherein at least one of the first flange portion (4) and the second flange portion (8) is configured in one piece with the web portion (10); wherein the at least one of the first flange portion (4) and the second flange portion (8) is shaped by a bend and folded extension of the web portion (10), and wherein the first flange portion (4) comprises a first part (24), a second part (26) and a third part (28); the first part (24) extends from the web portion (10) via a first bending section (30), the second part (26) extends from the first part (24) via a second bending section (32), and the third part (28) extends from the second part (26) via a third bending section (34), characterized in that an end section (36) of the third part (28) is at least partly arranged and fixated between the first part (24) and the second part (26) when the at least one structural element (6) is attached to the first flange portion (4).

2. The profile rail (1) according to claim 1, wherein the third part (28) is attached to the first part (24) by a first weld or glue joint (38).

3. The profile rail (1) according to any one of the claims 1 and 2, wherein the second flange portion (8) comprises a fourth part (40), a fifth part (42) and a sixth part (46); the fourth part (40) extends from the web portion (10) via a fourth bending section (48), the fifth part (42) extends from the fourth part (40) via a fifth bending section (50), and the sixth part (46) extends from the fifth part (42) via a sixth bending section (52).

4. The profile rail (1) according to claim 3, wherein an end section (54) of the sixth part (46) is at least partly arranged and fixated between the fourth part (40) and the fifth part (42) when the at least one structural element (6) is attached to the second flange portion (8).

5. The profile rail (1) according to any one of the claims 3 and 4, wherein the sixth part (46) is attached to the fourth part (40) by a second weld or glue joint (56).

6. The profile rail (1) according to any one of the preceding claims, wherein the first flange portion (4), the second flange portion (8) and the web portion (10) are constituted by a single piece of material.

7. The profile rail (1) according to claim 6, wherein the single piece of material is a sheet metal.

8. The profile rail (1) according to any one of the preceding claims, wherein the web portion (10) comprises a plurality of recesses (58).

9. The profile rail (1) according to any one of the preceding claims, wherein the profile rail (1) has an l-shaped cross-section.

10. The profile rail (1) according to any one of the preceding claims, wherein at least one line of weakness (60) is arranged in the profile rail (1), parallel with a longitudinal extension of the profile rail (1), and in that at least one of the first flange portion (4) and the second flange portion (8) is foldable to the web portion (10) along the at least one line of weakness (60).

11. A construction system (2) for attaching at least one structural element (6) to a profile rail (1) according to any one of the preceding claims, wherein said system (2) comprises: the profile rail (1) comprising the first flange portion (4) for interaction with the at least one structural element (6), the second flange portion (8) opposite to the first flange portion(4) and the web portion (10) interconnecting the flange portions (4, 6) and extending between the flange portions (4, 8); wherein the first flange portion (4) is configured in one piece with the web portion (10); and the first flange portion (4) is shaped by a bend and folded extension of the web portion (10); and wherein the at least one structural element (6) is attached to the first flange portion (4) by a fastener element (62).

12. The system (2) according to claim 11, wherein the fastener element (62) comprises a pair of legs (64) and a head (66), which head (66) extends between the legs (64) and which head (66) is connected to the legs (64).

13. The system (2) according to any one of the claims 11 and 12, wherein the fastener element (62) comprises a nail.

14. A method for manufacturing a profile rail (1) according to any one of the claims 1 - 10, wherein the method comprises the steps of: defining (slOl) a rectangular area (68) in a rectangular sheet plate (70), which rectangular area (68) is configured to constitute the web portion (10) of the profile rail (1) with an l-shaped cross-section; and bending (sl02) a first and second area (72, 74) of the sheet plate (70) outside of the defined rectangular area (68) for shaping the first flange portion (4) and the second flange portion (8).

15. The method according to claim 14, wherein the step of bending (sl02) areas of the sheet plate (70) outside of the defined rectangular area (68) for shaping the first flange portion (4) and the second flange portion (8) comprises: bending the sheet plate (70) at the first bending section (30), the second bending section (32), and the third bending section (34) for shaping the first flange portion (4), and bending the sheet plate (70) at the fourth bending section (48), the fifth bending section (50), and the sixth bending section (52) for shaping the second flange portion (8).

16. The method according to claim 15, wherein the first flange portion (4) comprises a first part (24), a second part (26) and a third part (28); the first part (24) extends from the webportion (10) via a first bending section (30), the second part (26) extends from the first part (24) via a second bending section (32), and the third part (28) extends from the second part (26) via a third bending section (34); and wherein the step of bending (sl02) areas of the sheet plate (70) outside of the defined rectangular area (68) for shaping the first flange portion (4) further comprises: arranging an end section (36) of the third part (28) at least partly between the first part (24) and the second part (26).

17. The method according to any one of the claims 15 and 16, wherein the second flange portion (8) comprises a fourth part (40), a fifth part (42) and a sixth part (46); the fourth part (40) extends from the web portion (10) via a fourth bending section (48), the fifth part(42) extends from the fourth part (40) via a fifth bending section (50), and the sixth part (46) extends from the fifth part (42) via a sixth bending section (52); and wherein the step of bending (sl02) areas of the sheet plate (70) outside of the defined rectangular area (68) for shaping the second flange portion (8) further comprises: arranging an end section (54) of the sixth part (46) at least partly between the fourth part (40) and the fifth part (42).

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