Welded Steel Support Profile for Facades with Integrated Screw Channel
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Solution Overview
Problem
Existing steel support profiles for facades and conservatories are limited by uniform wall thickness and design constraints, restricting their production and versatility.
Innovation Solution
A steel support profile composed of multiple parts, featuring a welded box-shaped basic profile with a side wall containing an integrated screw channel, allowing for varied wall thicknesses and cross-sections, and an optional intermediate plastic profile for enhanced sealing and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the support profile is made in one piece from bent sheet steel with an integrated screw channel, then the production process is simplified, but the wall thickness is limited to maximum approx. 1.5 mm and design options are restricted
Solution Approach 1:
The support profile is divided into two separate components: a basic profile and a side wall with integrated receiving channel. These components are manufactured separately and then joined through welding. This segmentation allows the basic profile to be produced with various wall thicknesses and cross-sections while the side wall component can be independently optimized for the receiving channel function, thereby resolving the contradiction between manufacturing simplicity and design versatility.
2Strength
If the wall thickness is increased beyond 1.5 mm, then the structural strength is improved, but the conventional screw channel profiles can no longer be manufactured
Solution Approach 1:
By separating the support profile into a basic profile and a side wall component, the receiving channel can be integrated into the side wall which is manufactured separately. This allows the basic profile to have increased wall thickness for structural strength while the side wall component with the receiving channel is produced independently and attached through welding, overcoming the manufacturing limitation of conventional integrated profiles.
Solution Approach 2:
The side wall component merges the function of the profile wall with the integrated receiving channel for fastening screws. This combined component is then attached to the basic profile, allowing the receiving channel functionality to be preserved while enabling greater wall thickness in the overall support structure for improved strength.
3Strength
If the support profile is designed with varied wall thicknesses and cross-sections, then the statics and design requirements are improved, but the production complexity increases
Solution Approach 1:
The basic profile is designed as a hollow profile with two longitudinal walls that can have varied wall thicknesses and cross-sections to meet static requirements. The side wall with the receiving channel is produced separately as a standardized component. This segmentation allows customization of the basic profile for structural optimization while keeping the side wall component production standardized, thereby managing production complexity.
Solution Approach 2:
Different parts of the basic profile can have different wall thicknesses and cross-sectional properties tailored to local structural requirements. The side wall component with the receiving channel maintains consistent dimensions suitable for its fastening function. This local quality differentiation allows optimization of statics where needed while maintaining manufacturing efficiency in standardized components.
4Reliability
If the weld seam is placed at the transition between side wall and base profile, then the fastening is secured, but the weld may be visible from the outside affecting appearance
Solution Approach 1:
A groove is formed at the transition between the side wall and the basic profile before welding. This groove serves as a receptacle for the weld seam, allowing the weld to be placed in a location that is invisible from the outside. The groove is created as part of the component design, so the weld is pre-positioned to be concealed, maintaining both fastening security and aesthetic appearance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible design options, improved statics, and efficient assembly of support structures with secure fastening and enhanced thermal insulation, while maintaining a clean exterior appearance.
Implementation Method 1
the side wall provided with the receiving channel for the fastening screws can be welded to the basic profile
Implementation Method 2
The advantage of this is that no metallically conductive parts protrude into the sealing area and the thermal insulation is significantly improved
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a steel support profile (1) for supporting structures of facades or conservatories, in which a receiving channel (8) for receiving fastening screws (6) for fastening retaining profiles (5) is formed by an outwardly facing side wall (7) of the steel support profile (1), and to a supporting structure for facades and conservatories with a steel support profile (1) to which at least one facade element (2a, 2b) is attached by means of a retaining profile (3) fixed to the steel support profile (1) by means of fastening screws (6) and sealed via inner and outer seals (4, 5). The invention solves the problem of creating an easily manufactured steel support profile and a supporting structure that allow for greater design possibilities by means of a steel support profile in which the side wall (7) is welded to a base profile (9), and a supporting structure with such a steel support profile.