Girder-like structural element composed of individual parts connected to one another

A beam-like structural component (2) made up of individual parts connected to each other, comprising at least one flange (9) and at least one web (1), which structural component is easy to produce and exhibits high load-bearing capacity and torsional rigidity, is characterized in that the web (1) is formed by web members (6) extending transversely to the longitudinal extension of the web (1), with web members (6) forming a linear longitudinal area (4, 5) extending across the length of the web (1) and with, in each case, two adjacent web members (6) extending toward different narrow edges (7, 8) of the flange (9) starting from the longitudinal area (4, 5) of the web (1) so that one web member (6) rests against the flange (9) with one side of the web (1) and the adjacent web member (6) rests against the flange (9) with the opposite side of the web (1) and the web members (6) exhibit the shape of an “S” (FIG. 1E).

The invention relates to a beam-like structural component made up of individual parts connected to each other, comprising at least one flange and at least one web.

It is known to manufacture a structural component having one flange and two webs, with the two webs forming a triangle together with the flange, as an extruded profile.

From GB 560 913 A, a plate-shaped supporting member is known which is formed by an upper plate and a lower plate, between which a structural component having a meander-shaped cross-section is inserted which is connected both to the upper plate and to the lower plate.

AT 285 129 B relates to a wall element comprising a number of boards assembled in a zigzag-shaped manner and connected to each other at their ends, with projecting grooves being provided at the two longitudinal edges of each board, whereby the boards can be connected to form a continuous component part inserted between an upper plate and a lower plate.

Furthermore, it is known to insert honeycombed structures between two flat plates, wherein the honeycombs are formed by honeycombs extending vertically to the two plates.

It is the object of the invention to provide a structural component of the initially described kind which is manufacturable in a particularly simple manner and exhibits not only a high load-bearing capacity but also a very high torsional rigidity. Furthermore, it should be possible to form plate-shaped supporting members with such a structural component.

According to the invention, said object is achieved in that the web is formed by web members extending transversely to the longitudinal extension of the web, with web members forming a linear longitudinal area extending across the length of the web and with, in each case, two adjacent web members extending toward different narrow edges of the flange starting from the longitudinal area of the web so that one web member rests against the flange with one side of the web and the adjacent web member rests against the flange with the opposite side of the web and the web members exhibit the shape of an “S”.

A simple basic shape of the structural component is characterized in that web members form with one end a linear longitudinal edge extending across the length of the web, from which longitudinal edge adjacent web members extend toward different narrow edge regions of the flange.

Simple manufacture of a web can be effected if the web is formed by integrally connected web members, wherein, in each case, two adjacent web members are integrally connected to each other on at least one longitudinal area, in particular on one of the longitudinal edges.

Rationalization of the assembly can be achieved if the ends of the web members project into a notch of the flange and are connected there to the flange, whereby also a smooth web surface is achievable in this manner.

The last described embodiment is preferably developed further in that the notch exhibits an extension which is transverse to the longitudinal edge of the web members and is of a size that equals half the thickness of the web members at the longitudinal edge thereof.

For particularly stable structural components it is advantageous if the web members are arranged directly adjacent to each other and are separated from each other by a maximum distance on the order of the width of a saw kerf.

If webs are produced from plates by punching, material saving can be achieved in that adjacent web members are provided at a distance corresponding to at least the width of a web member.

An optically perfect construction is achievable if the ends of the web which extend along the longitudinal sidewall of the flange terminate flush with at least a portion of the outside of the flange, preferably as a result of machining which preferably is performed on a supporting member made up of several structural components.

In order to achieve a particularly high load-bearing capacity with, at the same time, excellent torsional rigidity, the ratio of the width of a flange to the height of the web ranges between 1:20 and 1:1, preferably from 1:6 to 1:1, in particular from 1:3.5 to 1:2.5.

The structural component is preferably characterized in that it is formed from wood, with the flange preferably being manufactured from sawn timber and the web preferably being manufactured from plywood, the web suitably being formed from a plywood having at least three layers of wood with the wood fibres of the outside of the plywood extending in the longitudinal direction of the structural component. Constructions of this kind provide a particularly good ratio between the dead weight and the load-bearing strength. In addition, low-grade sawn timber from the sawmill industry can be used for the flange, resulting in an increase in the added value of said timber.

An adhesive material, in particular glue, preferably synthetic resin glue or PU-glue, is suitably used for connecting the individual parts.

Suitably, the cavity defined by the web and the flange is filled with a material such as silica sand, cellulose flakes, pearlites, PU-foam, etc. This filling leads to solutions for all kinds of problems, such as, e.g., for satisfying thermic and acoustic demands. As desired, the filling can occur prior to or after the installation of a structural component, the latter involving the advantage of easier manipulation, particularly since in that case only the lightweight hollow structural components have to be transported.

According to a preferred embodiment, the web members extend beyond the flange on both sides thereof and are interconnected on both ends with a double-S and a linear longitudinal edge being formed, whereby load-bearing capacity and also torsional rigidity may be increased even further.

Preferably, the longitudinal edges of the web which project beyond the flange are formed integrally.

Thereby, the flange is furthermore suitably arranged on a central plane of symmetry of the structural component.

Preferably, a further flange is provided on at least one longitudinal edge of the web, whereby the structural component is provided with two flanges arranged spaced apart from each other for the dissipation of power.

A preferred variant is characterized in that adjacent web members are formed by cutting into a plate alternately, namely once from a longitudinal edge region and once from the opposite longitudinal edge region, wherein the end regions of the web members, which project beyond the flange, are in each case connected to each other by means of a further flange.

A further preferred variant is characterized in that the web members are designed so as to be integrally connected in a preferably central area located between their ends with regard to their lengths and that the parts of the web members which extend away from said area toward one side and toward the other side in each case extend toward a flange in a manner bent in the same direction or in an opposite direction.

The structural components according to the invention can be excellently used for the formation of a planar-shaped supporting member, wherein the structural components are arranged next to each other and are connected to each other, preferably stuck together, with the flanges being arranged in one plane.

According to a preferred embodiment, flanges lying on one surface, in particular one plane, are formed integrally with a plate being formed, wherein the end regions of the web members are inserted into grooves incorporated in the plate.

According to the embodiment illustrated inFIG. 1D, a web1of a structural component2is formed by a plate1′ (cf.FIG. 1A) which is divided into web members6integrally connected at the continuous longitudinal edge5by parallel incisions3(cf.FIG. 1B) which extend from a longitudinal edge4of the plate1′ toward the opposite longitudinal edge5. Adjacent web members6are bent by right- and left-hand bending, respectively (cf.FIG. 1C), toward different narrow edges7,8of a flange9so that one web member6rests against the flange9with one side of the web1and the adjacent web member6rests against the flange9with the opposite side of the web1. The web members6form the shape of an “S”, with the shape of the “S” being designed in a more or less stretched manner, which, however, depends on the longitudinal extension10of the web members6. Since the web members6exhibit the same longitudinal extension10, a symmetrical cross-section is produced. Also an asymmetrical cross-section can be achieved by different longitudinal extensions10of respective web members6adjacent to each other.

According to the variant illustrated inFIG. 1D, the free ends of the web members6are connected to the narrow edges7,8of the flange9across the entire contact surface, for example, if the structural component is manufactured from wood by bonding or gluing, respectively.

The ends of the web members6terminate flush with the outside10′ of the flange4, which can be achieved in a simple manner by machining the structural component2which has been finished, e.g., by bonding or gluing, respectively.

As can be seen inFIG. 1E, flanges9can be arranged on both sides of the web1in the area of the longitudinal edge5of the web1where the web members6are integrally connected so that it is possible to manufacture a supporting member11formed from two or several or a plurality of structural components2arranged next to each other and connected to each other, e.g., by bonding or gluing, respectively, which is shown, for example, inFIG. 3. Preferably, this is done in such a way that the web members6bent on the left and on the right engage the free flanks of the added structural component2in a zipper system, wherein, furthermore, a flange9opposite the flanges9of the structural components2is inserted between the free end regions of the web members6of the adjacent structural components2and is connected to the end regions of the web members6.

A particularly economic material utilization for the web material is illustrated with the aid ofFIGS. 2A to 2D. According toFIG. 2A, two webs1are punched from a plate1″, with the line of punching following line12, which is indicated in a dashed manner. Thus, two webs1are produced from one plate1″, as illustrated inFIG. 2B. Adjacent web members6of a web1are thereby located at a larger distance, which, in turn, corresponds to the width13of a web member6. The left- and right-hand bending for the integration of a flange9is designed analogously to the variant depicted inFIG. 1D.

FIG. 4illustrates an embodiment of a structural component2in which the web members6project with their free ends into a notch14of a flange9and are connected there to the flange9. The depth of the notch14equals half the thickness15of the web members6, the height of the notch14can be chosen according to the demands made on the structural component2.FIG. 5shows several structural components2designed according toFIG. 4, which are assembled into a supporting member11.

If an individual structural component2is not desired but merely a supporting member11made up of several structural components2is required, it is also possible to design the flanges9in an integrally connected manner as a plate16, wherein the webs1and the web members6, respectively, are inserted into grooves17of the plate16and are connected to the plates16in those grooves17. Such a variant is shown inFIG. 6in an oblique view with the upper plate16being omitted and inFIG. 7in profile. The groove depths conform to the thickness of the plates16; they may account for up to a third of the thickness of the plates16.

According toFIGS. 8A to 8D, web members6are formed by cutting completely through a plate1′ to form individual elements. In doing so, it is required to fasten the web members6to the longitudinal edge5of the web1, which is formed by the adjacent web members6, by means of a flange9, preferably inserting them between two adjacent flanges9, which, in turn, can of course also be achieved if the flanges9are integrally connected and the web members6project into a groove, as illustrated inFIG. 6.

According to the embodiments illustrated inFIGS. 9A to 18, the web members6extend beyond a flange9on both sides thereof and are connected on both ends with a double “S” and a linear edge region being formed, namely either integrally, as illustrated inFIGS. 9B to 9D, or with the aid of one or two adjacent flanges9, as shown inFIG. 13D.FIGS. 10D,11D and12D show hybrids, i.e., the web members6are connected to a flange at one longitudinal edge4or5, respectively, of the web1and are integrally connected to each other at the opposite longitudinal edge.

According to the variant depicted inFIG. 9D, a plate1′ forming the web1(cf.FIG. 9A) is slotted only between the longitudinal edges4,5(cf.FIG. 9B) so that the web members6are still integrally connected on both sides. This is then followed by left-right-bending of the sections of adjacent web members6which are central with regard to height and by threading a flange9into the space formed by the convexities of the web members6.

According toFIG. 10D, the web members6are integrally connected only at one longitudinal edge5.

A special feature is also shown byFIG. 11B, according to which adjacent web members6are integrally connected once at one longitudinal edge4and once at the opposite longitudinal edge5of the web1. Also in that case, threading of a flange9into the space formed by the bulges of the web members6is required.

FIG. 12A, in turn, shows an economic utilization of a plate1″ for the web1so that two webs1can be formed from said plate1″. This is again effected by punching along the dashed line12ofFIG. 12A. Said variant—like the variant according to FIG.2D—is of interest if a larger web member distance is sufficient for the load-bearing capacity of the structural component2.

FIG. 13D, in turn, shows a structural component2in which the web members6are individual parts which are completely separate from the respective adjacent web member6.

FIGS. 14 to 18show variants of the formation of a supporting member11formed from two, several or a plurality of structural components2, as shown inFIGS. 9D,10D,11D,12D and13D, wherein the ends of the web members6again terminate planely with flanges9(FIG. 14) or project into notches14of the flanges9, namely of those flanges which are arranged on the outside of the supporting member11.FIGS. 17 and 18, in turn, illustrate an integral design of the outside flanges as plates16of the supporting member11, with the web members6again projecting into grooves17of those plates, analogously to the illustration ofFIG. 7.

A structural component2of a special type is also shown inFIGS. 19D and 20D. In said structural component, the web members6are integrally connected at the centre of their longitudinal extension, which is accomplished by cutting into a plate1′ for the web from both longitudinal edges4,5as far as to a central linear longitudinal area18(cf.FIGS. 19B and 20B). After folding the ends of the web members6on the left and on the right, two flanges9, which are connected to the ends of the web members6, may be inserted between the ends of the web members6. In that case, the structural component2does not require a flange9which is central with regard to height.

According toFIG. 19D, the two ends of a web member6are, in each case, bent toward the same flange side7or8, respectively, according to the variant illustrated inFIG. 20D, they are, in each case, bent toward different sides7or8, respectively, of the flange9.

The structural components2according toFIGS. 19D and 20Dmay again be assembled—as described before according to the zipper type—by arranging them next to each other and connecting them to form a plate-shaped supporting member11.

With such a plate-shaped supporting member11, a flange9which is central with regard to height can of course also be used to provide a particular reinforcement, as illustrated inFIGS. 21 and 22. Said flange will then rest against the web members6at the height of the integrally connected areas18thereof and will also be connected to the web members6in those areas, again by bonding or gluing.

The invention is not only restricted to linear structural components; rather, those components may also be designed in an arcuate manner, which is illustrated inFIG. 23. In that case, the arc shape is predetermined by the arc shape of the flange9or of the flanges9, respectively. By arranging such arcuate structural components next to one another, arcuate plane-shaped supporting members11may also be formed (cf.FIG. 24).

In order to achieve a high load-bearing capacity with, at the same time, good torsional capacity, the ratio of the width of the flange to the height of the structural component2ranges between 1:20 and 1:1, preferably from 1:6 to 1:1, in particular from 1:3.5 to 1:2.5.

The structural component2is preferably formed entirely from wood, with the flange9preferably being manufactured from plywood and the web1suitably being formed from a three-layered plywood or a five-layered plywood and the wood fibres of the outer layers of the plywood extending in the longitudinal direction of the structural component2. Constructions of this kind provide a particularly good ratio between the dead weight and the load-bearing capacity. In addition, low-grade sawn timber from the sawmill industry can be used for the flange9, resulting in an increase in the added value of said timber.

If the structural component2is joined together by an adhesive material, glues, in particular synthetic resin glues and PU-glues, are preferably used as adhesive materials for wood. Modern adhesives which are microwave or UV-curing offer further possibilities. It is likewise possible to use a film glue instead of a liquid glue.

Preferably, the continuous cavity formed by the web1and the flange9is filled with a material such as, for example, silica sand, cellulose flakes, PU-foam, pearlites, etc.

The filling leads to various solutions for all kinds of problems, such as, e.g., for satisfying thermic and acoustic demands. As desired, the filling can occur prior to or after the installation of the structural component, the latter involving the advantage of easier manipulation, particularly since in that case only the lightweight hollow structural components2have to be transported.

A structural component2with a symmetrical cross-section characterized in that the end region of the web1lies in the centre of the width of the flange9is advantageous in terms of stress.

A further preferred use of a structural component2according to the invention becomes evident after assembling several of the structural components to form sheet materials which may serve as wall elements and wall coverings, respectively. The sheet materials can also be used as formwork elements for concrete construction and as moulding elements for large trusses, silos, etc.

The structural component2according to the invention has the advantage that, in principle, it can be formed from all kinds of materials on the whole and also from various materials for the flange9and the web1, respectively, wherein, for the web1, predominantly materials are considered which are able to absorb shearing forces and, in addition, are flexible and preferably glueable. The web1can, for example, be made of cardboard, plastic, sheet metal, multi-layered plywood or other wood materials. It is likewise possible to make the flange9from various materials such as plastic, cardboard, multi-layered plywood or also from metal.