EP0906482B1 - Structural member and process for producing a structural member - Google Patents

Abstract

PCT No. PCT/EP97/03240 Sec. 371 Date Feb. 25, 1999 Sec. 102(e) Date Feb. 25, 1999 PCT Filed Jun. 20, 1997 PCT Pub. No. WO97/49881 PCT Pub. Date Dec. 31, 1997A structural member, in particular for wall and ceiling shuttering, has a working surface and a structural frame on which the working surface is mounted; and frame members perpendicular to the working surface that form the structural frame. The working surface and the structural frame are formed integrally as an injection molded part.

Description

The invention relates to a component according to the preamble of claim 1 and a method for producing a component according to the preamble of Claim 60.

EP 0 353 637 A1 describes a formwork panel with a formwork panel made of plastic for system formwork for concrete formwork. This Formwork panel has a profile frame formed from hollow profile frame legs on. One made of PVC granulate, foamed using a foamable plastic Formwork panel is attached to the profile frame by, for example, gluing or attached in a conventional manner by riveting or screwing.

This formwork panel has the disadvantage that foaming of the PVC granulate is required which requires the addition of binders. Beyond that the time portion for a complete foaming considerably. It also requires a complex assembly of the formwork panel on the profile frame.

Components, in particular scaffolding coverings, have also become known. which are used in work scaffolds. These have a work surface that is made of wood. These work surfaces face at least on the narrow sides two hook elements, with which the scaffolding coverings on the scaffolding to be assembled. The wooden work surfaces have the well-known disadvantages on.

The object of the invention is therefore to create a component, which enables a simplification in production and still the Operations can absorb the corresponding loads and the previous one Construction largely corresponds.

The invention is also based on the object of a method for the production to create a component that allows the inventive Manufacture component quickly and inexpensively.

According to the invention, these tasks are achieved by the characterizing features of claims 1 and 60 solved.

The inventive design of a component as an injection molded part has the advantage that a shorter working time is required for its production is, whereby high wage and ancillary wage costs can be saved.

Furthermore, this configuration, in particular for a component for Wall and ceiling formwork and scaffold coverings, the advantage over that the previously known profile frame made of aluminum or steel a galvanic Pretreatment can be omitted. The complex coating of this type can also be used Profile frames for use on construction sites are no longer required.

The component also has the advantage that the work surface or Formwork sheet due to the use of a polymer material without splinters and can be made insensitive to impact. This can maintain the load-bearing capacity stay. The use of polymer materials for the element also leads to the fact that a long service life can be given. The polymeric materials are opposite Wood, or a multi-layer wood panel, weatherproof and lighter to clean. For example, a steam jet cleaner can easily and the formwork sheet can be cleaned quickly. This is relatively thin and has almost no thermal inertia. This leads to, for example, spraying the formwork panel with a steam jet cleaner occur between the concrete layer and the plastic, so that the concrete layer jumps off the formwork panel and the connection is released immediately. The use of Suitable polymer materials for the component lead to less adhesion cement glue and therefore the use of release agents can be dispensed with.

Furthermore, such a component designed as an injection molded part has the advantage that, compared to the components known hitherto, consisting of a metal profile frame and a multilayer board made of high-quality plywood, a further weight reduction of 10 to 20% can be achieved with the same dimensions. This allows even more manageable work and thus quick work. This reduction in weight advantageously has no loss in a concrete pressure or load to be absorbed, so that, just as in the known construction of the components with a metal profile frame, for example in the case of formwork elements, a concrete pressure of up to 60 kN / m ² can be absorbed.

The above advantages are also evident for a component that is used as a scaffold covering is trained.

In addition, these advantages also exist with other components, the one Work surface and a profile frame, with additional components still can be provided, which are required for the special operations.

According to a further advantageous embodiment of the invention it is provided that the Profile frame is formed by frame legs, which at least partially with Plastic molded carrier profiles exist. It can thereby be achieved that several elements for wall formwork can be securely connected. Furthermore, these support profiles can increase the rigidity of the elements cause so that the element is torsionally stiff and robust for construction site use is trained. In particular, the free ends of the profile frame are through Support profiles are less sensitive to impact than an impact-resistant polymer material educated.

Furthermore, these support profiles have the advantage that they are used for Slab formwork on a drop head or column head as well as main and / or secondary beams can be hung. This advantageously made of an aluminum alloy trained carrier profiles also have the advantage that the element is insensitive to creep. The polymer materials generally have one very high creep index and can hardly reduce creep stresses. Metals and synthetic resins have a very low creep index, so that even after one prolonged and high stress due to the preferred reinforcement by the Support profiles is given, creep can be almost prevented. So are high-performance elements designed that almost no delay - even after a long time Use - have.

Furthermore, the design of a profile frame with a support profile Advantage on that such formwork elements can be completely recyclable. It can Items that require repair due to the use of a thermoplastic Polymer material no longer seems worthwhile to be recycled. The Beam profiles are operated as electrical resistance, which makes them very heat up strongly and the plastic can be detached from the carrier profiles. This separation process can make up about 90% of the proportions of the carrier profile be removed from the plastic. Then the plastic and also the only parts of the carrier profile contained therein are shredded and ground so that after reprocessing this waste it can be reused for an element or other metal-plastic components for use in the construction industry, such as for formwork panels in slab formwork.

According to a further advantageous embodiment of the invention it is provided that the Support profiles extend along side surfaces of the profile frame and with at least a connecting element such as a corner connecting element are interconnectable to form a support profile frame. This allows the support profiles are pre-fixed to each other and arranged securely in an injection mold be so that due to the high injection pressures a position shift within the Tool can be avoided. At the same time this corner connection can be achieved be that the rigidity of the profile frame can be increased, which in turn the connection rigidity and the absorption of the concrete pressure can be increased can.

According to a further advantageous embodiment of the invention it is provided that at small elements between the carrier profiles cross bars regularly over the length are spaced from each other, which also on the support profiles, for example brackets can be pre-fixed. With wider elements you can also to the central webs provided parallel to the carrier profiles arranged in the long sides be, which also about, for example, a parenthesis to the to End profiles arranged support profiles can be pre-fixed. Through this A further stiffening of the profile frame can be achieved. By the use of profile elements for the transverse and / or central webs can contrast these the alternatively made of plastic cross or center bars with a be made smaller wall thickness, so that a reduction in weight can be achieved while increasing the rigidity of the profile frame.

According to a further advantageous embodiment of the invention it is provided that the frame leg comprises a partially overmolded carrier profile, which has a free contact surface arranged at an angle to the vertical axis of the frame leg and a further, not overmolded, internal one at the free end of the frame leg Contact surface and a non-molded foot extending along the vertical axis. The remaining sections of the carrier profile are essentially extrusion-coated. These non-overmolded contact surfaces serve to arrange a switch lock in order to connect one or more elements to one another. A claw of the formwork lock can engage on the contact surface arranged at an angle to the vertical axis of the frame leg. The further inward-facing contact surface at the end of the frame leg can serve to create a projection in the root area of the claws. The foot, which extends freely along the vertical axis of the frame leg, enables the formwork lock to be braced towards the first contact surface, so that alignment of the two elements is made possible. This configuration of the non-overmolded contact surfaces advantageously enables a 5-point contact of the formwork lock, as a result of which the concrete pressure can be absorbed up to 60 kN / m ² . At least one 3-point system is ensured so that the elements can be aligned and aligned.

Furthermore, the invention is for the formation of a profile frame of an element a support profile is provided for wall and ceiling formwork, which the Stiffened profile frame and a secure by a lower L-shaped foot Allows attachment to main and secondary beams, drop heads or support heads. At the same time there is an insensitive closure through the lower foot. Of further the carrier profile has the advantage that at the upper vertical section of the An end portion is provided which can be designed such that this End portion forms a tight seal in an injection mold, so that the adjoining upper part of the carrier profile at least partially overmolded can be.

According to a further advantageous embodiment of the invention it is provided that a claw connects to the end section in the upper section of the support profile. This has the advantage that a simple arrangement of corner connecting elements can be provided. These can be designed, for example, as a plug connection be a secure pre-fixation of the support profiles to a support profile frame enables.

According to a further advantageous embodiment of the invention it is provided that in middle area of the upper section two substantially V-shaped to each other Arranged webs are provided, which are used to create free claw ends Scarf lock serve.

According to a further advantageous embodiment of the invention it is provided that the left and right of the system level extending webs, profile webs, V-shaped Crosspieces and the end section each in a parallel to the system level End plane and each have a contact surface or support surface in the injection mold form. This can make it possible that the carrier profiles in the injection molding tool maintain their position during the spraying process and not under the influence can experience disorientation due to the high spray pressure.

According to an advantageous embodiment it is provided that the element is preloaded which largely neutralizes itself under the intended load. This leaves enough reserves for the elements to meet the required Demonstrate safety and strength in limit loads.

The carrier profiles are advantageously plastic during the encapsulation with plastic and / or positioned pre-deformed elastically in the tool.

It can also be provided that the support profiles plastically preferably in the direction the vertical axis are preformed and then individually or as a frame in the tool can be inserted. As an alternative, the carrier profile or the one thereby composite frames are positioned undeformed in the tool and deformed via a tool control before and / or during the spraying process become. Thus, an element can be formed which has a center of the area the formwork panel, which at least partially increases relative to the edge zones is. Alternatively, other dome-shaped or curved designs of the Formwork panel provided according to the specific application and application be.

As far as transferable, the advantageous embodiments also apply, for example for a scaffold covering, a work platform to which brackets can be attached or for further components that build on the component according to the invention or tie in with it.

The method according to the invention for producing an element for wall and ceiling formwork has the advantage that a complex pretreatment and subsequent Coating the profile frame can be saved. Furthermore can produce a significant number by producing the element in one injection molding process saved from work steps such. B. attaching a silicone gasket in the formwork frame to accommodate a multi-layer panel. This can cause a considerable savings can be made. At the same time, the production rate can be significantly increased by the production of the element as an injection molded part.

According to a further advantageous embodiment of the method it is provided that a Prefabricated formwork panel, which is preferably a sandwich structure with stiffeners has, is inserted into the injection mold. This allows the injection molding process be shortened, while at the same time by overmolding the inserted parts, such as a formwork panel and a support profile frame, a firm connection to a one-piece element is possible.

Further advantageous refinements and developments of the invention are in the description, the claims and the drawings.

In the drawing, a preferred embodiment is shown.

Fig. 1

eine Schalung bestehend aus einem Verbund aus zwei Schalelementen mit Schalschlössern,

Fig. 2

eine schematische Schnittdarstellung längs der Linie II-II in Fig. 1 mit einer schematischen Schnittdarstellung eines Trägerprofils,

Fig. 3

einen schematischen Teilschnitt längs der Linie III-III in Fig. 1 mit einem schematischen Teilschnitt eines Quersteges und

Fig. 4

einen Schnitt längs der Linie IV-IV in Fig. 3 eines Quersteges,

Fig. 5

eine schematische Seitenansicht eines Eckenbereiches des Schalelementes,

Fig. 6

eine Seitenansicht eines als Gerüstbelag ausgebildeten Bauelementes,

Fig. 7

eine Ansicht von unten auf das Bauelement gemäß Fig. 6,

Fig. 8

eine schematisch vergrößerte Detailansicht eines Befestigungselementes und

Fig. 9

eine schematisch vergrößerte Detailansicht eines als Abhebesicherung ausgebildeten Befestigungselementes.

Show it:

Fig. 1

formwork consisting of a composite of two formwork elements with formlocks,

Fig. 2

2 shows a schematic sectional illustration along the line II-II in FIG. 1 with a schematic sectional illustration of a carrier profile,

Fig. 3

a schematic partial section along the line III-III in Fig. 1 with a schematic partial section of a crossbar and

Fig. 4

3 shows a section along the line IV-IV in FIG. 3 of a crossbar,

Fig. 5

1 shows a schematic side view of a corner area of the formwork element,

Fig. 6

2 shows a side view of a component designed as a scaffold covering,

Fig. 7

6 shows a view from below of the component according to FIG. 6,

Fig. 8

a schematically enlarged detail view of a fastener and

Fig. 9

a schematically enlarged detail view of a fastener designed as a lifting device.

1 shows a section of a composite 11 consisting of three formwork elements 12, 13 shown, which are arranged by means of scarf locks 19 to one another. The formwork element 12 has a scarf height of 160 cm and a width of 80 cm. The Scarf elements 13 are designed as a small version with a scarf height of 160 cm and a width of 40 cm. The formwork element 12 has a profile frame 14 which revolves around the outside and has a vertical central web 16. In the fields between extend the vertical frame legs of the profile frame 14 and the central web 16 horizontal crossbars 17 at an even distance. In between the central web 16 and the cross webs 17 enclosed fields is a ribbing 18 provided, which are formed by two ribs lying in the diagonal of the fields is. Other configurations that allow the fields to be stiffened, are also conceivable. For example, the height of the ribbing from the center of the surface remove the formwork panel 22 from the outside.

The adjacent vertical frame legs of the profile frame 14 of the Formwork elements 12, 13 are connected to formlocks 19, of which here, for example four are used. The formwork element 13 has an outer circumferential Profile frame 14 on. Between the vertical frame legs of the profile frame 14 are transverse webs 17 which are arranged at a regular distance from one another are. A ribbing 18 is also provided between the crossbars 17, which is designed analogously to the formwork element 12. The profile frame 14 of the formwork elements 12, 13 have an analog structure made of the same material with the same Cross section on. The formwork element 12 is with the formwork element 13 by means of form locks 19 connected. These engage on the frame legs of the profile frame 14 and define the two adjacent profile frames 14 to each other. Are analog the two formwork elements 13 fixed to each other, so that by such an arrangement a formwork element wall can be formed, the formwork elements 12, 13 can be arranged horizontally and / or vertically to one another.

In the fields of the formwork element 12 are between a frame leg of the profile frame 13 and a ribbing 18 anchor pockets 21 for the tension rods of formwork anchors intended. These are advantageously related to the fields of Formwork element 12 arranged so that they are symmetrical to the longitudinal and transverse axes of the formwork element 12 are arranged so that consideration for the alignment of the formwork panel 12 is not necessary. This also applies to the formwork panels 13.

FIG. 2 shows a schematic partial cross section along the line II-II in FIG. 1. The formwork panel 12 is shown as an injection molded part and has a frame leg 23 of the profile frame 14, which is formed from a partially extruded carrier profile 27 is. The frame leg 23 is arranged substantially perpendicular to the formwork plate 22. A front side 24 of the formwork plate 22, against which concrete rests during concreting the ribs 18 are arranged in order to allow a rigid construction of the formwork plate 22. The ribs 18 run diagonally to the left into a corner region 26.

The frame leg 23 has one along a cross-sectional area of the carrier profile 27 a system level 28. The carrier profile 27 has a lower section 29 which is not overmoulded with plastic and an upper section overmolded with plastic 31 on. The lower section 29 is formed by an L-shaped foot 32, whose horizontal section 33 faces the center of the formwork element 12. This L-shaped foot 32 is used for the secure arrangement and support of the formwork element 12 Main and secondary girders of a scaffold for slab formwork. Furthermore serves the lower contact surface 34 for aligning the formwork element 12 to another Scarf element 12 or 13 with a scarf lock 19. A vertical section 36 of the foot 32 is delimited by an end section 37. The end section 37 separates the lower, not overmolded section 29 from the upper overmolded section 31. This End section 37 also serves to make the injection molding tool opposite the one from the Injection mold to complete protruding foot 32. The end section has one right arm 38, which is L-shaped. This is opposite left projection 39 is provided, the height of which essentially corresponds to the wall thickness, with which the carrier profile 27 is extrusion-coated to the outside substantially. One The inside of the carrier profile 27 is significantly less than the outside trained wall thickness provided. The inner strength of a plastic layer can be, for example, 1 to 2 mm.

Looking up along the system level 28, the end section 37 follows at a distance then an upper and lower guide groove 41, 42, which is U-shaped and are arranged facing each other. This to the middle of the formwork element 12 facing guide groove 41, 42 serves to receive a corner connecting element 43, in order to fix two carrier profiles 27 arranged at right angles to one another. The corner connecting element 43 can be designed as an isosceles angle be formed, the free ends of which can be inserted into the guide grooves 41, 42. As a result, the carrier profiles 27 can be arranged relative to one another to form a carrier profile frame 46 that forms the profile frame 14 after at least partial extrusion coating. The connection of the support profiles 27 over a corner should have a certain rigidity, however, on the other hand, it should also be possible for the support profile frame formed thereby 46 is so flexible that when inserting the support profile frame 46 in an injection mold still a slight alignment and Arrangement is possible. The corner connecting element 43 can be clamped, Snap / snap connection or the like with the guide grooves 41, 42 be connectable.

Outside the corner area 26, the guide grooves 41, 42 are extrusion-coated with plastic and serve as a claw to the plastic. This can make a better connection be given between the plastic and the carrier profile 27. Between the guide grooves 41, 42 a crank 47 is provided, which is used to stiffen the support profile 27 is provided. The carrier profile 27 has from the end section 37 to the end region 49 has a substantially constant cross section. The wall thickness is about 1.5 mm. In the area of the offset 47 are in the longitudinal axis of the support profile 27 seen several holes (not shown) provided. The plastic can get from the outside of the frame leg 23 through the bore to the inside and completely surround the area between the guide grooves 41, 42.

Along the system plane 28 there are 48 above the guide groove 42 in the central region of the upper section 31 two V-shaped webs 51 arranged to each other, which point to the middle of the formwork element 12. At their free end are essentially End sections 52 arranged parallel to the system plane 28 are provided. The lower Web 51 is larger than the top web 51. The webs 51 are preferably arranged at an angle of approximately 100 ° to one another. The lower footbridge 51 is provided, for example, at an angle of approximately 25 to 45 ° to system level 28. The upper and lower web surface 51 are functional surfaces as well as an outer one Contact surface 53 of the right arm 38 from the end portion 37. These functional surfaces are not encapsulated in plastic. This applies to these surfaces 51, 53 and 34 Shawl lock 19 on. This configuration allows a 5-point support , a claw of the formwork lock 19 at least on the lower web surface 51 abuts and with a projection in the root area of the claw on the contact surface 53 abuts and at the same time to align the front 24 of the formlining 22 of two Formwork panels arranged to each other through the contact surface 34 enables. It follows also that the end portions 52 and abutment surface 53, which in a Level runs parallel to the system level 28, are provided.

Between the wall section of the support profile running in the system plane 28 27 and the upper and lower web 51 is filled with polymer material. This is used for Support and stiffening of each V-shaped to the wall section upper and lower webs 51. The guide groove also serves for the lower web 51 52 as reinforcement or stiffening.

Between the upper and lower web 51 is opposite and facing outwards a web 54 arranged essentially at right angles to the system level 28 is provided. The web 54 is formed with interruptions when viewed in the longitudinal direction. An end face 56 of the web 54 rests in a tool wall. When closed Injection molding tool is further provided that the free end portions 52 on one lie against the opposite wall section, which can ensure that a correct fixation of the central region 48 of the support profile 27 in Injection molding tool can be given even under the influence of the large injection pressure.

Another is between the V-shaped webs 51 and one end region 49 Crank 57 is provided, which in turn is arranged for stiffening. The end area 49 has two opposing profile webs 58, 59, which in are arranged substantially perpendicular to the system plane 28. The left profile web 58 forms a stiffening of an edge 61 which between the frame leg 23 and the Front 24 of the formwork plate 22 is formed. An end face 62 of the profile web 58 directly adjoins a contact surface 63 of the projection 64. The amount of the projection 64 corresponds to the height of a projection 66 as seen from the system level 28, the latter being arranged opposite the guide groove 41. Thereby can have a substantially linear contact between the upper and lower Projection 64, 66 of a formwork element 12 with the corresponding projections of the further formwork element. Thus, a dirt-insensitive System be given, which can be ensured so that between no seam can arise between the two edges 61 of the formwork elements 12.

Bores (not shown) are also provided in the area of the crank 57. so that an inside of the carrier profile 27 can be extrusion-coated with plastic. Of the Profile web 59 points in the direction of the formwork panel 22 and thus forms a secure Transition to take up the concrete pressures from the formwork plate 22 to the frame legs 23 of the profile frame 14.

The carrier profile 27 is designed as an extruded profile and is preferably made of aluminum or an aluminum alloy, such as AlMgiSI 0.5 or titanium or Titanium alloy. Furthermore, other light metals as well as metals can be used become. High-strength plastics or fiber-reinforced plastics, for example, are also carbon-kevlar reinforced plastic, for the formation of carrier profiles possible.

Furthermore, to increase the rigidity, it can be provided that the wall thickness of the support profile 27 can be enlarged. Alternatively, it can also be provided that the carrier profile 27 is formed as a hollow profile body with one or more chambers is, which in turn has a higher stiffness or torsional stiffness of a Formwork element 12 can be achieved. Furthermore, the carrier profiles 27 can be preformed be, preferably plastically pre-deformed.

FIG. 3 shows a schematic partial section along the line III-III according to FIG. 1. The partial section shows the arrangement of the crossbar 17 to the support profile 27 as also its design. According to the sectional view along the line IV-IV in Fig. 4, the crossbar 17 has a T-profile 67, which at one lower end with a Completes crossbar 68. The crossbar 17 is completely embedded in the plastic. This T-profile 67 is also an extruded profile made of aluminum or an aluminum alloy educated. At an end 69 facing the support profile 27 there is an opposite the width of the T-profile 67 tapered projection 71 formed on the Free end has two tabs 72 and 73, which in a bore 74 of the support profile 27 intervene. The bore 74 is provided in the area of the crank 47. For fixation the tabs 72, 73 are bent in the opposite direction (FIG. 5), whereby the crossbar 17 is fixed in its position relative to the support profile 22. The crossbar 17 extends from the formwork plate 22 to below the crossbar 68 of the T-profile 67.

Seen in the longitudinal direction of the T-profile 67, several bores 76 are provided that between a left and right to the T-profile 67 formed plastic wall Bridge or connection can be created. The bores 76 are V-shaped to one another staggered at regular intervals. Furthermore, are on one upper edge region of the T-shaped profile two fingers 77 at regular intervals provided in the opposite direction from the longitudinal plane of the T-profile 67th be deflected. This can maintain a distance for the T-profile 67 in the tool be created. This can alternatively take place in that on a finger 77 of the T-profile 67 a plastic clip or the like is placed.

In the final state, both the tab-shaped connection between the crosspiece 17 and the carrier profile 27 and the crossbar 17 are completely encapsulated. Alternatively, you can further simple and quick to install connections between the crossbar 17 and the support profile 27 may be provided.

The transverse webs 17 can furthermore have an opening which acts as a handle opening is trained. Alternatively, it can also be provided that in this opening Handle can be arranged so that easy handling of the formwork elements 12, 13th can be given.

6 is a side view of a component designed as scaffolding covering 80 shown. The scaffolding covering 80 has a profile frame which supports the working surface 22 14, which is arranged perpendicular to the work surface 22. The profile frame 14 forms Frame legs 23 that surround the work surface 22. The function and the Structure of the scaffolding covering 80, as shown in Figures 6 to 9, corresponds the formwork elements 12, 13.

With the scaffolding covering 80, it is provided that 81, 82 on narrow end faces Fastening elements 83, 84 are attached to the scaffolding covering 80 on a scaffolding, preferably frame frame to attach. Such scaffolds are particularly used for plastering, painting or the like. The Fastening elements 83 are designed as hooks, as shown schematically 8 shows an enlarged side view. The hooking element 83 is on attached to the carrier profile 27, for example by a welded connection, clamp connection, Adhesive connection or the like. The scaffolding covering 80 can be used in a simpler manner Be used from above in a horizontal tube, not shown.

In this embodiment, the carrier profiles 27 are advantageously as hollow chamber profiles educated. This can also be provided for the formwork elements 12, 13 be. In the case of the configuration as hollow chamber profiles, the extrusion coating can be carried out analogously to the configuration according to the support profiles 27 of the formwork elements 12, 13.

On the narrow side 82, the fastening element 84 is preferably used as an anti-lift device formed, as shown in Fig. 9 enlarged. This can increase Building security can be made possible. For the assembly of scaffolding covering 80 the anti-lift device 84 is first placed on horizontal pipes of the Scaffolding, in order to then lower the scaffolding covering 80 into the horizontal plane, the fasteners 83 also on a horizontal tube of the scaffold intervenes. In this case, the lead-in chamfer 86 can preferably be used.

Alternatively, it can be provided that 81, 82 of the scaffold covering also on both end faces 80 hooking elements are provided as fastening element 83.

To reinforce the scaffolding covering 80, horizontal cross bars 17 are provided, which optionally introduced through a T-profile or other type of profile. The beam profiles 27 have inclined surfaces 51 on their outside. This enables be that in the case of a plurality of scaffolding coverings 80 arranged parallel to one another a connection of the scaffolding coverings 80 can be created by means of scarf locks, so that a closed work surface 22, which serve as a tread or shelf can, is trained.

Furthermore, it can be provided that the component in which the work surface 22 and the profile frame 14 are integrally formed as an injection molded part, as a working platform is used. The profile frame 14 can be modified in this way, for example be that shots are attached that allow the attachment of consoles. In addition, 14 more attachment options can be attached to the profile frame be provided to attach a railing, preferably foldable.

The component according to the invention thus offers a basic concept for a large number of embodiments that can not only be used in construction.

The component according to the invention is produced by the method described below manufactured. The support profiles 27 are cut to the appropriate length and width tailored. The carrier profiles 27 are via corner connecting elements 43 assembled into a carrier profile frame 46. At the same time become addicted the size between the support profiles 27 cross and central webs 16, 17 attached. The carrier profile frame 47 thus represents a relatively rigid frame, however is slightly resilient in itself. This support profile frame 46 is into a multi-part injection molding tool formed with a plurality of slides inserted. The injection mold is then closed, the end section 37 is arranged such that it is a termination to the injection molding tool forms. A thermoplastic is made under high pressure of, for example, 300 to 500 bar via one or more injection points, preferably at the intersection of the Ribs 18 and the central and transverse webs 16, 17 are provided in the injection molding tool brought in. The spraying time for a formwork element 13 of 160 cm 40 cm is about 6 to 8 seconds. After a slight hold and foaming of the plastic and a certain cooling time the finished Formwork element 12 can be removed from the injection mold.

The carrier profile 27 is or will advantageously be before the introduction of the thermoplastic coated with an adhesion promoter, so that full-surface adhesion of the plastic on the support profile 27 is made possible.

Polypropylene is preferably used to produce the formwork element 12, 13, which is preferably filled with a glass fiber content of 5 to 40% and beyond is provided with a blowing agent which preferably foams between 5 and 30% effects. Furthermore, additives such as for UV resistance, for lower water absorption, for good concrete repellency or the like added or applied as a top layer. Alternatively, it can also be provided be that polyamide or other thermoplastics can be used have high rigidity and low water absorption. The plastic is advantageous bright white to eggshell colored, so that the formwork element 12, 13 does not absorb heat when exposed to sunlight. Alternatively, it can be provided that the formwork plate 22 has stiffeners, for example, by a continuous or at least partially coherent metal or Light metal insert as well as a woven, knitted or knitted fabric can. Furthermore, it can alternatively be provided that after the support profile frame 46 is inserted into the tool, a formwork panel with a sandwich structure, the has two metal inserts to stiffen it, inserted into the injection mold is and by subsequent molding to a formwork element 12, 13 with each other is connected.

Furthermore, it can be provided that a lamination is inserted into the tool is so that the formwork element 12, 13 by the lamination provided on the formwork plate 22 is recognizable. Thus, the formwork panel 22 or the front 24 can be used simultaneously serve as advertising space.

The central web 16 can be designed analogously to the cross section 17. Likewise, at the crossing points of which an analogous attachment is provided.

The structure and design of the elements 12, 13 described above is not only limited to formwork elements, but can be used for all other support systems be where the creeping of the plastic is a significant hindrance represents that by metallic reinforcements or plastic reinforcements, such as can be compensated for by the support profiles. Such support systems can for example doors, cassettes, roof covers, molded parts in Vehicle construction, roof panels and emergency shelters.

Claims (66)

1. A structural member comprising a working surface (22), a profile frame (14) that supports the working surface (22) and is arranged perpendicular to the working surface (22) and has one frame member (23) forming the profile frame (14) , the at least one frame member (23) comprising:

   a beam profile (27) that is at least partially embedded in injection moulded plastic,

   an upper section (31) that includes a portion of the beam profile (27) that is embedded in injection moulded plastic immediately adjoining the working surface (22) and at least one internal free abutment surface (50) of the beam profile (27), and

   a lower section (29) that is not embedded in plastic, including an abutment surface (34) that is arranged substantially at right angles to the system plane (28) of the frame member (23) and a foot (32) extending along the system plane (28), characterised in, that the working surface (22) and the at least one frame member (23) being formed integrally as an injection moulded part, and the free abutment surface (50) of the beam profile (27) being arranged at an angle that is not parallel to the system plane (28).
2. Structural member according to claim 1, characterised in that the working surface (22) is a shuttering panel and the structural member is provided as a shuttering panel for a wall shuttering and ceiling shuttering.
3. Structural member according to claim 1, characterised in that the working surface (22) is constituted as a tread surface and the structural member is provided as a scaffold flooring for scaffolds, preferably frame scaffolds.
4. Structural member according to claim 1, characterised in that the beam profiles (27) and the plastic portion of the working surface (22) and structural frame (14) have substantially the same load bearing capacity fraction.
5. Structural member according to one of the preceding claims, characterised in that the load bearing capacity amounts to up to 60 kN/m².
6. Structural member according to claim 1, characterised in that the lower section (29) is constituted as a L-shaped foot (32).
7. Structural member according to claim 1, characterised in that the frame member (23) has on its outer surface two abutment surfaces (62,65) which stand out opposite a side wall and which form an abutment surface for a further frame member (23) when building a ceiling and wall shuttering.
8. Structural member according to claim 7, characterised in that the first abutment surface (62) adjoins an edge (61) bounding the shuttering panel (22) and the second abutment surface (65) is formed by a projection (66) which is arranged near the lower section (29).
9. Structural member according to claim 8, characterised in that the first and second abutment surfaces (62, 65) have substantially two webs (51, 52), preferably mutually arranged in a V-shape, for the reception of a claw of a shuttering lock (19) in the middle region of the frame member (23).
10. Structural member according to claim 1, characterised in that middle webs (16) and/or transverse webs (17) are provided between the frame members (23) and are constituted by a profile (67) which is embedded in injection moulded plastic.
11. Structural member according to claim 10, characterised in that the profile (67) which is embedded in injection moulded plastic is T-shaped.
12. Structural member according to claim 10 or 11, characterised in that the profile (67) has at its free ends (69) a projection (71) on which means (72, 73) for connection to a beam profile (27) can be arranged.
13. Structural member according to claim 12, characterised in that the connecting elements (72,73) are constituted as lugs which engage in a bore (74) of the beam profile (27) and are bent around opposite to each other.
14. Structural member according to claim 10, characterised in that a rib structure (18) is provided between the middle webs (16) and/or transverse webs (17) and is constituted of plastic.
15. Structural member according to claim 14, characterised in that the rib structure (18) runs in a star shape to intersection points between the middle web (16) and transverse web (17) or that the rib structure (18) runs along diagonals between middle webs (16) and frame member (23) or in a honeycomb form or in a polygonal form.
16. Structural member according to claim 15, characterised in that an anchor pocket (21) to receive anchor bars is constituted between the frame member (23) and the rib structure (18).
17. Structural member according to claim 1, characterised in that the beam profiles (27) extend along the frame members (23) of the profile frame (14).
18. Structural member according to claim 1, characterised in that a further internal abutment surface is provided at the free end of the frame member (23).
19. Structural member according to claim 1, characterised in that the beam profiles (27) are connected together with at least one corner connecting element (43) to give a beam profile frame (46).
20. Structural member according to claim 19, characterised in that the beam profile (27) and the corner connecting element (34) are connected together by means of a plug connection, a clamp connection, and/or a latch connection.
21. Structural member according to claim 19 or 20, characterised in that the corner connecting element (43) is inserted in a claw catch, formed by guide grooves (41, 42), of the beam profile (27).
22. Structural member according to claim (14), characterised in that the middle and transverse webs (16, 17) are constituted wider in contrast to a rib structure (18) arranged between them.
23. Structural member according to claim 14, characterised in that the middle and transverse webs are constituted with different widths, the transverse webs (17) preferably being constituted wider than the middle webs (16).
24. Structural member according to one of the preceding claims, characterised in that a wall thickness of the working surface (22) is constituted to be greater or equal to the thickness of the middle and/or transverse webs (16, 17) and/or the rib structure (18).
25. Structural member according to claim 23 or 24, characterised in that an opening is provided on a middle web (16) and/or transverse web (17), and is constituted as a handle, or a handle is insertable in it.
26. Structural member according to one of the preceding claims, characterised in that an impact resistant polymer material, preferably polypropylene or polyamide, is used.
27. Structural member according to one of the preceding claims, characterised in that a polymer material is filled with a glass fiber fraction of at least 5 %.
28. Structural member according to one of the preceding claims, characterised in that a polymer material is foamed to a extent of at least 5 %.
29. Structural member according to one of the preceding claims, characterised in that a polymer material is filled or coated with weather resistant, UV resistant, and/or concrete deflecting additives.
30. Structural member according to one of the preceding claims, characterised in that a polymer material is coloured white to eggshell colour.
31. Structural member according to claim 1, characterised in that the beam profile (27) runs along a cross sectional surface of the beam profile (27) of a system plane (28), and has an upper section (31) around which plastic is injection moulded, with sections (38, 39, 41, 42, 51, 52, 54, 58,59) and a lower section (29), which is not embedded in injection moulded plastic, with a foot (32).
32. Structural member according to claim 31, characterised in that the lower and upper sections (29, 31) are separated by an end section (37).
33. Structural member according to claim 31 or 32, characterised in that the foot (32) is L-shaped and has an abutment surface (34) on its underside.
34. Structural member according to claim 31, characterised in that the end section (37) has a right arm (38) which is constituted L-shaped and has an abutment surface (53) which runs parallel to the system plane (28).
35. Structural member according to one of claims 31 to 34, characterised in that the end section (37) has a left projection (39) whose height substantially corresponds to the outwardly situated wall thickness consisting of plastic of a frame member (23).
36. Structural member according to one of claims 31 to 35, characterised in that a lower and an upper guide groove (41, 42) are provided above the end section (37).
37. Structural member according to claim 36, characterised in that an offset (47) is provided between the lower and upper guide grooves (41, 42).
38. Structural member according to claim 37, characterised in that it has bores, which are preferably regularly spaced apart from each other, along the offset section (47).
39. Structural member according to one of claims 32 to 38, characterised in that two webs (51) which are substantially arranged mutually in a V-shape form a reinforcing crease in the middle region (48) of the upper section (31), and the webs (51) have end sections (52) running substantially parallel to the system plane (28).
40. Structural member according to claim 39, characterised in that a web (54) running substantially at right angles to the system plane (28) is arranged mutually in a V-shape.
41. Structural member according to claim 40, characterised in that the web (54) is sectionally interrupted seen in the longitudinal direction.
42. Structural member according to one of claims 33 to 41, characterised in that an offset (57) is formed between the middle section (48) and an end region (49) of the upper section (31), and preferably has bores which are regularly spaced apart from each other in the longitudinal direction.
43. Structural member according to one of claims 31 to 42, characterised in that the upper section (31) has an end region (49) with at least two profile webs (58, 59) which face in opposite directions and which are arranged substantially at right angles to the system plane (28).
44. Structural member according to one of claims 31 to 43, characterised in that the webs (38, 39, 51, 52, 54, 58, 59) which extend left and right of the system plane (28).
45. Structural member according to one of claims 31 to 44, characterised in that the end section (37) and end region (49) have a thickening.
46. Structural member according to one of claims 31 to 45, characterised in that the beam profile (27) is an extruded profile.
47. Structural member according to one of claims 31 to 45, characterised in that the beam profile (27) is a rolled profile.
48. Structural member according to claim 46, characterised in that the beam profile (27) is constituted of light metal, preferably of aluminium or an aluminium alloy.
49. Structural member according to claim 47, characterised in that the beam profile (27) is constituted of metal.
50. Structural member according to claims 31 to 45, characterised in that the beam profile (27) is of plastic, preferably of reinforced plastic.
51. Structural member according to claim 50, characterised in that a fibre reinforced or fabric reinforced plastic is provided.
52. Structural member according to one of the preceding claims, characterised in that at least an upper section (31) of the beam profile (27) has an adhesion primer.
53. Structural member according to claim 1, characterised in that the beam profile (27) is plastically and/or elastically preformed.
54. Structural member according to claim 53, characterised in that the beam profile (27) is preformed in the direction of the principal axis.
55. Structural member according to claim 1, characterised in that the beam profile (27) is deformed with a tool control after being placed in an injection mould.
56. Structural member according to claim 53 or 55, characterised in that a surface midpoint situated in the shuttering panel is arranged raised with respect to the edges of the shuttering panel.
57. Structural member according to one of claims 1 to 3, characterised in that the beam profile (27) is constituted at least partially as a hollow chamber profile.
58. Structural member according to claim 3, characterised in that fastening elements (84, 86) are provided at least at two mutually opposed sides of the working surface (22).
59. Structural member according to claim 58, characterised in that the fastening element (84) on one side is constituted as hooking element, and that on the opposite side as a securement against lifting (86).
60. Process for the production of a structural member (12) according to one or more of the preceding claims, characterised in that

    at least one beam profile (27) and at least one transverse web (17) are cut to size,

    that the beam profiles (27) and the transverse webs (17) arranged thereon are placed in an injection mould, and

    in one injection process an element (12) with a shuttering panel (22) an a structural frame (14) running around on the outside and having frame members (23) running perpendicular to the shuttering panel (22) and constituted by means of beam profiles (27) which are partially embedded in injection moulded plastic is produced.
61. Process according to claim 60, characterised in that the beam profiles (27) form, by means of corner connecting elements (43), a preferably resilient beam profile frame (46) which is placed in the injection mould.
62. Process according to claim 60 or 61, characterised in that before the injection process at least one inlay which reinforces the shuttering panel (22), preferably a metallic or non-metallic foil or lattice, woven fabric, knitted fabric or the like is placed in the injection mould.
63. Process according to claims 60 to 62, characterised in that a prefabricated shuttering panel (22), which preferably has a sandwich structure with stiffenings, is placed in the injection mould and is at least partially embedded in injection moulded plastic.
64. Process according to one of claims 60 to 63, characterised in that an element (12) with a length of up to 300 cm and a width of up to 125 cm is produced in an injection moulding process within less than 10 seconds.
65. Process according to one of claims 60 to 64, characterised in that injection points by means of which polymer material is injected are provided between intersection points of transverse webs (17) and middle webs (16) .
66. Process according to one of claims 60 to 65, characterised in that, in elements (12) with a with of 40 cm, injection points by means of which polymer material is injected are provided in intersection points of a rib structure (18).

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