US3689970A

US3689970A - Method and device for making up metal bands into hollow rails

Info

Publication number: US3689970A
Application number: US67801A
Authority: US
Inventors: Raimund Falkner
Original assignee: RAPENA PATENT AND VERWALTUNGS AG
Current assignee: RAPENA PATENT AND VERWALTUNGS AG
Priority date: 1969-08-28
Filing date: 1970-08-28
Publication date: 1972-09-12
Anticipated expiration: 1989-09-12
Also published as: BE755358A; ZA705695B; ES383066A1; SE381584B; NO134034B; DE1943826A1; NL7012816A; AT313031B; NO134034C; JPS4840552B1; CA961350A; FR2064265B1; IL35142A0; DE1943826B2; CH515756A; IL35142A; AU467953B1; FR2064265A1; GB1301469A

Abstract

Apparatus and method for making at least two metal bands into a hollow rail, e.g. for door and window frames, wherein the bands are simultaneously drawn by a tractive force acting from the formed end, e.g. by a power-operated reciprocal clamp, through non-driven roll-type forming tools which shape the bands into profiles while under the tractive force so that the bands are strengthened and straightened in at least some longitudinal zones. While being drawn through the forming tools a non-metallic elastic shim liner is fed and applied to the edges of at least one of the bands and after both bands have been profiled, they are pressed together, by appropriate guiding and shaping tools, whereby the longitudinal edges of the bands are connected together by a folded welt that completely encloses the shim liner while the latter prevents friction metallic contact between the two bands.

Description

United States Patent Falkner [451 Sept, 12, 1972 [72] Inventor: Raimund Falkner, Roppen/Tirol,

Austria [73] Assignee: Rapena Patent & Verwaltungs AG, I

Vaduz, Liechtenstein [22] Filed: Aug. 28, 1970 [21] App1.No.: 67,801

[30] Foreign Application Priority Data Aug. 28, 1969 Germany... ..P 19 43 826.7

[52] US. Cl. ..29/155 R, 29/200 B, 29/430 [51] Int. Cl. ..B23p 17/00, B23p 19/00 [58] Field of Search....'.29/l55 R, 200 B, 200 R, 429, 29/430 [56] References Cited UNITED STATES PATENTS 2,678,488 5/1954 Erzer ..29/l55 R 3,505,719 4/1970 OMalley et al ..29/200 B Primary Examiner-Thomas H. Eager Attorney-Cushman, Darby & Cushman [57] ABSTRACT Apparatus and method for making at least two metal bands into a hollow rail, e.g. for door and window frames, wherein the bands are simultaneously drawn by a tractive force acting from the formed end, e.g. by a power-operated reciprocal clamp, through nondriven roll-type forming tools which shape the bands into profiles while under the tractive force so that the bands are strengthened and straightened in at least some longitudinal zones. While being drawn through the forming tools a non-metallic elastic shim liner is fed and applied to the edges of at least one of the bands and after both bands have been profiled, they are pressed together, by appropriate guiding and shaping tools, whereby the longitudinal edges of the bands are connected together by a folded welt that completely encloses the shim liner while the latter prevents friction metallic contact between the two bands.

21 Claims, 35 Drawing Figures PATENTEDSEP 12 I972 SHEET 1 [1F 8 lip-I22.

PATENTEDSEP 12 m2 ill=ilil l il w? a \Y. v a Q v R. QN QM y w QM -S RN m. \N U ml R\ Q Profiles in the most diverse forms, as well as hollow rails for doors and windows, have been known for a long time past. Similarly, there are numerous methods for the making of such profiles, but they generally show considerable shortcomings from the point of view of economy. Most of the known methods are too complicated to permit the obtention of low-cost profiles. Moreover, the known hollow rails usually have insufficient thermal insulation which especially in the case of widow-frames results in the formation of perspiration water.

Against that, the present invention is concerned with a method that permits an economical manufacture of hollow rails with improved characteristics by continuous processing of at least two metal hands by means of roll forming tools, joining the lateral longitudinal edges by folded welts. It is characteristic for this method that the metal bands are simultaneously drawn through the rotating forming tools by a tractive force acting from the formed end and that they are not exposed to any advance force in the roll forming tools, but they are formed into rails by a pressureacting on the surface of the bands, and while under the influence of the longituthrough the forming installations, not driven, located there for the profiling of metal bands, then through a greasing station located before the forming installation, through guiding organs to the joining of the travelling, profiled mental bands in a mutual position determined in advance, and through other forming installations, not driven, to the strengthening of the longitudinal edges of the metal bands by means of folded welts.

In the following, the method according to the invention is described in detail with regard to exemplified embodiments of hollow rails and parts of the device according to the invention by the help of the schematic drawings.

These drawings show:

FIGS. 1, 1A and 1B are lateral or side views of successive portions of the two working paths of the device.

FIG. 2 is a transverse sectional view of a section of 'the milling equipment shown in FIG. 1.

V path at the right-hand side of FIG. 1.

dinal feed they are strengthened and straightened at least in some of the longitudinal zones of their structure. Hereupon the longitudinal edgesof at least one profile are provided with an elastic nonmetallic shim liner, then the profiles are pressed together, bordered on at-least one of their longitudinal edges and, avoiding any metallic contact, frictionally connected between the longitudinal edges embracing one another by a folded welt which encloses the shim liner all round, is under initial stress and secured against transverse forces. The hollow rail is made in one operation.

The method according to the invention can be 'so performed that the metal bands are either drawn forward by the tractive force each time only on a stretch determined in advance and then .shaped into the proposed hollow rail, which is then cut off and the cycle of operation is automatically repeated, or they are continuously drawn forward and transformed into the proposed hollow rail from which each time a predetermined length is separated, without however interrupting the drawing process. The separation can be made either with a straight cut or by means of an adjustable mitering device. The elastic shim liner can be fed to the metal bands in the form of a profile and then united with the longitudinal edges of a band, or at least one of the bands can, already before or during its forming, be provided with an elastic coating on its longitudinal edges. The longitudinal edges can be provided with rugosities, such for instance as milling or perforation, so as to ensure a better adhesion of the elastic shim liner.

Furthermore, the invention is concerned with a device for the performance of this method with at least two working paths and along them with installations for the transformation of metal hands into profiles. The device is characterized by a drawing station located at its end, adapted to at least one profile to be manufactured, for the simultaneous drawing of at least two metal bands off the magazine rolls and for conveying the same along the pertaining working paths and FIG. 4 is a transverse sectional view through onev of the forming stations in the lower path shown at the ri t-hand side of FIG. 1.

FIGS. 5a, b, c and d are transverse sectional views through successive forming stations shown in the lower path at the left-hand side of FIG. 1A.

FIGS. 6a, b, c, and d are transverse sectional views through successive forming stations shown in the lower path at the left-hand side of FIG. 1A.

FIG. 7 is a plan view, with parts broken away, of the installation shown at the right-hand side of FIG. 1A for threading .up and shaping the elastic shim.

FIG. 8 is a transverse sectional view taken substantiallyon line 8-8 of FIG. 7.

FIGS. 90, b, c and d are vertical sectional views through successive stations shown at the left-hand side of FIG. 1B for joining of the two-part profiles.

FIG. 10 is a transverse sectional view of the pull down claws of the installation shown at the right-hand side of FIG. 1B.

FIG. 11 is a lateral view of a modified form of the pull downclaws of the installation shown at the righthand side of FIG. 1B.

FIGS. 12a, b, and c are views corresponding to FIGS. 3a, b and c showing-a modified form of the invention.

FIGS. 13a, b and c are views corresponding to FIGS. 5a, 0 and d showing a modified form of the invention.

FIG. 14 is a transverse sectional view of a forming station with three-part profile mill cutters.

FIG. 15 is a view of housing columns for forming stations seen in the direction of the metal bands coming down.

FIG. 16 is a lateral view of the housing columns shown in FIG. 15.

FIG. 17 is a view of an exemplified embodiment of a drawing installation.

FIG. 18 is a transverse sectional view of an exemplified embodiment of a symmetricalhollow rail.

FIGS. 19-25 are transverse sectional views showing various stages of operation during the manufacture of the hollow rails shown in FIG. 18.

FIG. 26 is a transverse sectional view of an exemplified embodiment of an unsymmetrical hollow rail.

FIGS. 27 to 33 are end profile views showing various stages of operation during the manufacture of the hollow rail shown in FIG. 26.

In the following, the present method if first described in connection with the manufacture of a hollow rail fromthe shape shown in FIG. 9d. Here two metal bands one beneath the other, preferably in aluminum, are simultaneously drawn through rotating forming tools by a tractive force acting from the formed end, thus on the finished hollow rail. But these tools exercise no advance force but pressure on the surface of the metal bands. The upper metal band is first formed into a U profile (FIGS. 3a, b and open downwards, and the two legs are chamfered outwards 90 (FIGS. 5a, b, c and d). During this process the underneath metal band is formed into a lower and narrower U profile, open downwards, with wider legs chamfered outwards (FIG. 4). Then on the edges of the upper U profile that are turned outwards a shim liner is drawn up, consisting of an elastic band folded up lengthwise (FIG. 7, 8), the lower parts of which tower inwards above the chamfered edge. Then the U profiles thus made are pressed one upon the other with theirchamfered longitudinal edges, and those of the underneath U profile are bent approx. 180 around the longitudinal edges of the upper U profile, which are coated with the shim liner (FIGS. 9a and c), and are pressed into the elastic shim liner which is enclosed all round (FIG. 9d).

During their transit rolling through the rotating forming tools, the metal bands are under a considerable longitudinal traction, they are strengthened in their structure at leastin some of the longitudinal zones by the forming tools, which only press on the surface of the band but do not exercise any upsetting advance force on the same, and they are at the same time straightened by the tractive force. This drawing process during the manufacture of profiles endows the part-profiles and, after their joining, the finished hollow rail with an accuracy to size and a mechanical strength which are superior to those of the hollow rails made by means of driven rotating forming tools, which exert an advance force on the metal bands and/or the part-profiles, upset the material and necessitate a subsequent straightening of the finished hollow rails.

The hollow rail manufactured according to the method herein described shows no metallic contact on the longitudinal edges embracing one another between the upper and the lower part-profiles, owing to the shim liner for which a nonmetallic elastic material is used. This characteristic results in a considerable thermal insulation between the two part-profiles, which in the case of windowand door-frames prevents the formation of undesired perspiration water and greatly reduces the thermal losses from inside to outside and vice versa. Moreover, the transmission of sound between the part-profiles is considerably damped, which practically prevents the occurrence and/or transmission of noises, especially those caused by the opening and shutting of windows and doors. As the insulating shim liner is practically enclosed all round by the folded border of the lower part-profile, neither wetness nor light can affect the shim liner, so it practically has an unlimited lifetime.

The fact that the lower partprofile is pressed with its benbaround edge into the elastic shim liner results in an elastic initial stress of the folded welt, so that the part-profiles forming the hollow rail are frictionally connected one with the other. Known hollow rails formed in a similar way but with metallic contact between the part-profiles along their folded welt have no tensional connection at this spot, are considerably inferior to the hollow rails manufactured according to the present method as far as mechanical strength is concerned and cannot be utilized as load-bearing constructional elements. The hollow rails manufactured according to the method herein described are also secured against transverse forces, since the elastic shim liner extends also along the leg of the lower U profile that laps into the inside space of the upper U profile and frictionally connects the lower U profile with the upper one.

In the following, an exemplified embodiment of a device for the manufacture of the above hollow rail is described in detail. As shown schematically in FIG. 1, this device has two working

paths

1 and 2 which are disposed one beneath the other and serve for forming the two

metal bands

4 and 5 which are drawn off the two magazine rolls 6 and 7. The

bands

4, 5 are turned back through the rollers 8, 9 and pass through a greasing station 10 which is for instance constructed as a reservoir and contains a lubricant, such for instance as bring about that the longitudinal edges of the band 4 1 are knurled on both sides and those of the band 5 only on the upper side. If desired, instead of the knurling installations can be used differently constructed stations in order to provide the longitudinal edges with rugosities or perforations.

FIG. 1-4 show the rollers located along the working

paths

1 and 2, which serve for forming the

bands

4, 5. Three

rollers

12, 13, 14 freely rotating around their axes are acting on the band 4, transforming it around the fixed forming core 15 into a U profile open downwards. The forming of the band 5 takes place by means of a pair of profile mill cutters 16, 16' along the working path 2, for which no forming core 15 as in the case of the rollers of the working path 1 is necessary.

The

profile mill cutters

16, 16 also are individually freely rotating around their axes.

The upper U profile is, as indicated in FIGS. 1A and 5, along the working path I pressed by three freely rotating

rollers

17, 18, 19, acting together from time to time, from above and from the sides against the forming

cores

23, 23, 23" which during the passage of the U profile bring about, by means of chamfered flanks, a lateral outward folding of the protruding

longitudinal edges

21, 22 of the legs. The rectangularity of the chamfered edges is ensured by further drawing of the profile 4 through two

pointed rollers

24, 25.

The two pairs of rollers 20, 20' of FIG. 6 located along the working path 2 for further forming of the flat U profile 5 with wide longitudinal edges are constructed with only such a width that the two wide

longitudinal edges

26, 27 laterally protrude and while drawing through the profile 5 these bead edges 28,29 can be straightened out by means of two oblique, freely rotating

rollers

30, 31.

The longitudinal edges 21, 22 of the upper profile 4, which are bent outwards, are now provided with an elastic shim liner which, according to FIGS. 1A, 7 and 8, in the form of two longitudinally folded plastic bands, is drawn off the magazine rolls 32, opened by the

deflectors

35, 36 and drawn over the

longitudinal edges

21, 22. Owing to the knurling by the rollers 11, the static friction of the plastic bands is so strong that they cannot shift.

Now, as shown in FIGS. 1B, 9a, b and c, the two U profiles are fit together, pressed together with their longitudinal edges and the straightened

bead edges

28, 29 of the profile 5 are, by interaction with the three freely rotating

rollers

37, 38, 39 and the freely rotating profile cut millers 40 as well as with a fixed steel core 40', bent around the

longitudinal edges

21, 22 which are lined with the

shim liner

33, 34. During this forming process the fixed wedge gibs 41, 42 are used, which ensure a gradual bending over of the bead edges 28, 29, as shown in FIG. 9b, by forming a rim 29' and thereby prevent any pushing out or in or damaging of the

shim liners

33, 34. The bending over of the bead edges 28, 29 takes place according to FIG. 90 by means of the freely rotating rollers 43. The pressing of the bead edges 28, 29 into the elastic shim liner takes finally place, as shown in FIG. 9d, by means of the freely rotating rollers 44. An especially solid folded welt is obtained by perforating the

longitudinal edges

21, 22 of the profile 4 and milling or dotting the surfaces of the bead edges 28, 29 that are facing the

shim liners

33, 34.

The tools located along the working path 1 for forming the metal band 4 are indicated above as freely rotating rollers which act together with fixed forming cores or wedge gibs. For forming the metal band 5, an upper and a lower profile mill cutter are provided at some spots. In a preferred exemplified embodiment of a device for the manufacture of hollow rails according to the present method mostly such profile mill cutters are used as those described in the following with the aid of FIGS. 12 to 15. If for instance a U profile open downwards is to be made from the metal band 4, as explained above by the help of the upper parts of FIG. 14, 4 and 5, the

rollers

12, 13, 14 freely rotating around their axes in each case act together with a counterroller 45 which is also freely rotating. For chamfering the two lower ends of legs, besides the three freely rotating

rollers

17, 18, 19 there is a three-parted

counterroller

46, 46", 46", the three parts of which are individually freely rotatable around a common axle, independently of each other. As shown in Fig. 14, in each case three-parted counterrollers with adequately shaped, individually freely rotating parts are used for the finishing of the U profile. As shown in FIG. 14, profile mill cutters consisting of three or more parts that are in each case freely rotatable independently of each other around a common axle can be disposed also in pairs above and below the metal band.

In a preferred exemplified embodiment of a device for the manufacture of hollow rails according to the present method the roll forming tools consisting of onepart or multiple-part profile mill cutters and rollers, as shown in FIGS. 15 and 16, are disposed freely rotating at the front end of each of the carrying

bolts

70, 71 above and below the metal band 4 and at the front end of each of the carrying bolts 72, 73 above and below the metal band 5. The rear parts of these carrying bolts are in each case held by a

massive socket

74, 75, 76, 77.

All four sockets are mounted on the two

housing columns

78, 79, where the

sockets

75, 76 are fixed by means of the clamping

jaws

80, 81 and 80', 81' respectively in their unique position on the

housing columns

78 and 79, whereas the

sockets

74 and 77 are fixed by means of the bearing

bushes

82, 83 and 82, 83 respectively, which are movable along the

housing columns

78, 79. In FIG. 16 only the setting mechanism for the bearing bush 83 is shown and it can for instance consist of an elevating screw 84 on the hand wheel 85 which is tumable in a nut 86 fixed on the housing column 78 and can displace the bearing bush upwards or downwards. A similar setting device is fixed on the back housing column 79 and is connected with the elevating screw 84 eg by means of a chain so that when turning the hand wheel 85 thetwo bearing bushes 83 and 83' are simultaneously displaced along the

housing columns

78 and 79 respectively. Thus the profile mill cutters can relatively be adjusted one to the other and to the

metal bands

4 and 5 running through. The described disposition of the profile mill cutters self-supporting on the end of each of the carrying bolts also permits a quick exchange of one or several profile mill cutters, which makes possible repairs easy and, in particular, permits the change-over of the whole device to the production of another hollow rail within a short time. Of course, besides the profile mill cutters described above, also the necessary freely rotating lateral rollers are mounted on the housing stands, which rollers are also relatively adjustable to the metal bands or the profile mill cutters respectively and they are so mounted on the self-supporting ends of the corresponding carrying bolts that they can easily be exchanged.

According to the present method, the two

metal bands

4, 5 are drawn from the formed end, thus from the finished hollow rail, through all the forming stations forwards along the working paths. An exemplified embodiment of an adequate drawing device, as represented schematically in FIG. 17, shows the drawing station 85 which is moved from an initial position on the driving mechanism 87 by the lead screw 88 along the guide rail 86 to an end position determined by the limit switch 89. The limit switch, which can be fixed at any point along the guide rail 86, effects, when actuated by the drawing station 85, the switching off of the driving mechanism 87 and a temporary drawdown of the separating device 90 along the column 91, so that the circular saw 92 cuts off the finished hollow rail 93. Subsequently the clamping mechanism 94 on the drawing station 85 is opened for the hollow rail 93, the drawing station is brought back to its initial position, the cut-off piece of the hollow rail is taken away, the clamping mechanism 94 is again closed around the end of the hollow rail and the driving mechanism 87 is again switched on, whereby a new cycle of the drawing process, and thus of the hollow rail production, is started. By means of the column 91 the separating device can be swivelled for the separation of the hollow rail with a miter cut, so that finished hollow rails that are already cut in miter can be manufactured in any length without loss by cutting.

According to another exemplified embodiment, in conformity with FIGS. 18 and 10, a continuously working drawing mechanism 47 can be provided with two

endless roller chains

48, 49. These

endless roller chains

48, 49 run over wheels 50, 51 and are provided with profile-gripping claws 52, 53. Preferably the profilegripping claws 52, 53 are so designed that by using

elastic buffers

59, 60, 61 no deformations of the finished profile 4, can occur. In order to ensure a uniform gripping of the

finished profile

4, 5

pressure shoes

54, 55 are provided which under the effect of

adjustable springs

56, 57 exert a pression on the

roller chains

48, 49 and thus on the profile-gripping claws 52, 53. The drawing device 47 is followed by a cutting device with swivelling saw, which needs no further description as such separating devices are well known. The saw swivelling and therefore can make miter cuts in various directions. It turned out to be advantageous to provide the

elastic buffers

59, 60 of the profilegripping claws, or the profile-gripping claws themselves, as shown in FIG. 22, with levers62 inclined towards the running direction of the profile, so that when moving the

chains

48, 49 in the direction of arrow on purpose to advance the hollow rail a clamping effect arises between the

buffers

59, 60 and the profile PP 1 The present method and some exemplified embodiments of a device are explained above with the aid of a relatively simple hollow rail of box-type design. However, much more complicated hollow rails, such as those described in the following, can also be manufactured in this way. These two hollow rails practically meet all requirements regarding windowand doorprofiles in modern buildings.

For the manufacture of the hollow rail shown in FIG. 18, in the last sequence of operation, according to the present method the upper of two

metal bands

100, 101 moved one beneath the other is formed into a U profile open downwards, then its legs are chamfered outwards 90 at the lower end and further bent upwards at their outer edge 104, 105 (FIG. 19). Then a band-shaped

elastic shim liner

102, 103 with a wide base plate and a hook-shaped, projecting rib 106 and 107 respectively, which embraces the corresponding edge is drawn onto the two

edges

104, 105. During this process, the lower metal band 101 is transformed into a wide U profile, open upwards, (FIG. by bending up its longitudinal edges 108,109. The two upright longitudinal edges are bent outwards approx. 90 below (FIG. 21) and by two other nearly rectangular folding welts a U-shaped groove 110 and 111 respectively is formed on both sides (FIG. 22). By further bending of the

inside edges

112, 113 the two

longitudinal edges

108, 109, which are now both provided with a U-shaped groove, are again righted and the U-shaped grooves are then compressed into a

dovetailed groove

114 and 115 respectively (FIG. 24) and the extremities of the

legs

116, 117 are flanged inwards approx. 45. Now the lower U profile is pressed against the base plates of the

shim liners

102 and 103 which are on the

longitudinal edges

104, 105 of the upper U profile, the

longitudinal edges

108, 109 of the lower U profile are bent upwards round the two top edges of the base plates (FIG. 25), the two

longitudinal edges

108, 109 provided with the

dovetailed grooves

114, 115 are pressed into the upper sides of the

shim liners

102, 103 and the longitudinal edges 104, embraced by the ribs 106, 107 of the shim liners are pressed around the upper U profiles.

welt of the

longitudinal edges

108, 109 is under initial stress, thus the two profiles are frictionally connected one with the other. The

longitudinal edges

104, 105 of the upper U profile, which are surrounded by the ribs 106, 107 of the shim liners and held by the

longitudinal edges

108, 109 of the lower U profile, ensure great resistance to transverse forces. The hollow rail manufacturedin the way described above, whose two partprofiles have no metallic contact with one 'another, has all the advantages mentioned in connection with the box-shaped hollow rail (FIG. 9d) with regard to thermal and sound insulation. The dovetailed grooves 114, in the upper side of the folded welts on both sides permit the fitting of sealing profiles which are desirable in the case of windows and doors. If such sealing profiles are not wanted, the dovetailed grooves can, of course, be renounced.

However, the present method permits not only the manufacture of hollow rails that are formed symmetrically with a central axis according to FIGS. 9d and 18, but also the making of unilateral profiles. An example of a hollow rail of such kind in one of the last courses of manufacture is shown in FIG. 26. This hollow rail is also manufactured with the utilization of two

metal bands

118, 119 moved one beneath the other, but they are now simultaneously formed into the mirror image of one another. First the lower metal band 118 is bent upwards 90 at its left-hand longitudinal edge 120 (FIG. 27), the upper part is bent outwards further 90 (FIG. 28), whereas the right-hand longitudinal edge 121 of the metal band 118 is chamfered downwards. By two further nearly rectangular chamferings of the lefthand longitudinal edge 120, there is created a U- shaped groove 122 (FIG. 29), which is further bent around its inside edge 123 and thereby the longitudinal edge 120 again righted. Then the U-shaped groove is compressed into a dovetailed groove 124, the extremity of the leg 125 is flanged inwards approx. 45 (FIG. 31) and the right-hand part 126 of the metal band 118 with the longitudinal edge 121 is bent upwards (FIGS. 30 and 31). Finally the leg 126 is put upright, so that the longitudinal edge 121 runs nearly horizontally, and then the outside longitudinal edge 127 if flanged downwards approx. 90 (FIG. 32) and the left-hand longitudinal edge 120 is bent inwards approx. 45.

The upper metal band 119 has undergone an analogous forming in mirror image (FIG. 33). It is provided with a right-hand longitudinal edge 128, bent inwards approx. 45, which has a dovetailed groove 129 and a leg edge 130 flanged inwards and is formed into a vertical leg 131 and a nearly horizontal left-hand longitudinal rim 132 with a longitudinal edge 133 bent over approx. 90. Now two band-shaped

elastic shim liners

134, 135, each provided with a wide base plate and a hook-shaped, projecting

rib

136 and 137 respectively embracing the

longitudinal edges

127 and 133 respectively, are drawn onto the outermost

longitudinal edges

127 and 133 of the

longitudinal rims

121 and 132 respectively. The two profiles thus prepared are joined, pressed together, the left-hand longitudinal rim 120 of the lower profile is bent upwards around the outside edge of the shim liner 135 and its longitudinal rim 129 provided with the dovetailed groove is pressed into the upper side of the shim liner 135 and around the longitudinal rim 133 of the upper profile, which is embraced by the rib 137- of the shim liner. At the same time the right-hand longitudinal rim 128 of the upper profile is bent downwards around the outside edge of the shim liner 134 and the longitudinal edge 128 provided with the dovetailed groove is pressed into the lower side of the shim liner 134 and around the longitudinal edge 127 of the lower profile, which is embraced by the rim- 136 of the shimliner.

This profile is also manufactured in one operation according to the present method and has all the advantageous characteristics mentioned above in connection with the hollow rails according to FIGS. 9d and 18.

The present method is, of course, not limited to the three forms of hollow rails described in detail in the foregoing paragraphs. It can also be employed for the manufacture of a great number of hollow rails of different forms and also for the forming and joining of more than two metal hands into hollow rails.

I claim:

1. Method for making up at least two metal bands into a hollow rail by means of roll forming tools and by joining the lateral edges by means of folded welts, characterized by the fact that the metal bands are simultaneously drawn through the rotating forming tools by a tractive force acting from the formed end, in the roll forming tools without advance force they are formed into profiles only by a pressure acting on the surface of the bands and at the same time under the effect of the longitudinal feed they are strengthened in at least some zones of their structure and thereby straightened, the longitudinal edges of at least one of the profiles are provided with a nonmetallic elastic shim liner and then the profiles are pressed together, bordered on at least one of their longitudinal edges and without metallic contact frictionally connected with one another between the longitudinal edges embracing one another by means of a folded welt embracing the shim liner all round, which folded welt is under initial stress and secured against transverse forces, and thus the hollow rail is made in one operation.

2. Method according to claim 1, characterized by the fact that the metal bands are in each case drawn forward by the tractive force on a stretch determined in advance and formed into the proposed hollow rail, which is then separated, and hereupon the cycle of operation is automatically repeated.

3. Method according to claim 1, characterized by the fact that the metal bands are continuously drawn forward and formed into the proposed hollow rail from which each time a predetermined length is separated without interruption of the drawing process.

4. Method according of claim 1, characterized by the fact that the elastic shim liner is fed to the metal bands in the form of a profile and united with the longitudinal edges of one band.

5. Method according to claim 1, characterized by the fact that at least one of the bands is provided already before, or during, its forming with an elastic coating on its longitudinal edges.

6. Method according to claim 1, characterized by the fact that the longitudinal edges of at least one of the bands is provided with rugosities, in particular with knurling or perforation.

7. Method according to claim 1, characterized by the fact that the upper (4) of two metal bands (4, 5) moved one beneath the other is formed into a U profile open downwards and the two legs are chamfered outwards (21, 22), during which process the underneath metal band (5) is transformed into a lower and narrower U profile with wider longitudinal rims chamfered outwards (26, 27), then a shim liner consisting of an elastic band doubled longitudinally (33 34) is drawn onto each of the rims (21, 22) turned outwards of the upper U profile, the lower parts of the shim liner protruding inwards above the chamfered edge up to its end, the aforesaid two U profiles are pressed upon one another and the rims (28, 29) of the lower U profile are bent approx. 180 around the longitudinal rims (21, 22) of the upper U profile, which longitudinal rims are coated with the shim liner, and then pressed into the elastic shim liners (33, 34) which are enclosed all round.

8. Method according to claim 1, characterized by the fact that the upper of. two metal bands (100, 101) moved one beneath the other is formed into a U profile open downwards, the two legs of which are chamfered outwards 90 at their lower ends and at their outer rims (104, 105) are further bent upwards 90, then a band-shaped elastic shim liner (102, 103) with a wide base plate and hook-shaped protruding ribs (106, 107) embracing the rims (104, 105) is drawn onto the rims (104, 105), during which process the lower metal band (10) is formed into a broad U profile open above with upright longitudinal rims (108, 109) which are both bent outwards 90 and by two further nearly rectanagular folding welts are provided with a U- shaped, groove (110, 111), then they are further bent around the inside edges (112, 113) and set vertically, the aforesaid U-shaped grooves are then compressed into dovetailed grooves (114, 115) and flanged outwards on the longitudinal edges (114, 115), hereupon the lower U profile is pressed against the base plates of the shim liners (102, 103), which are on the longitudinal rims (104, 105 of the upper U profile, the longitudinal rims (108, 109) of the lower U profile are bent upwards around the two top edges of the base plates and the two longitudinal rims (108, 109) provided with the dovetailed grooves (114, 115) are pressed into the upper sides of the shim liners (102, 103) and around the longitudinal edges (104, 105) of the upper profile, which are embraced by the ribs (106, 107) of the shim liners.

9. Method according to claim 1, characterized by the fact that two metal bands (118, 119) moved one beneath the other'are simultaneously formed into the mirror image of one another, during which process the lower metal band (118) is bent upwards 90 at its lefthand longitudinal rim (120) (FIG. 32) and this leg is further bent outwards 90, by two further rectangular chamferings is provided with a U-shaped groove (122), by further bending around its chamfered inner edge (123) is righted again, the U-shaped groove is compressed into a dovetailed groove (124) and the outermost edge of the leg (125) is bent inwards, whereas the metal band (118) is chamfered downwards 90 at the right-hand longitudinal rim and then together with this leg (121) bent over 90, put vertically and flanged downwards 90 at the outermost longitudinal edge (127), then a band-shaped elastic shim liner (134) with a wide base plate and a hook-shaped protruding rib (136) embracing the longitudinal edge (127) is drawn onto the longitudinal edge (127), whereupon this lower profile together with ist shim liner (134) is pressed together with the upper profile which is formed as a mirror image and is also provided with a shim liner (135), the left-hand longitudinal rim (120) of the lower profile is bent upwards around the top edge of the shim liner (135) and its longitudinal rim (120) provided with the dovetailed groove is pressed into the upper side of the shim liner (135) and around the longitudinal edge (133) of the upper profile, which longitudinal edge is embraced by the rib (137), whereas, at the same time, the right-hand longitudinal rim (128) of the upper profile is bent downwards around the top edge of the shim liner (134) and its longitudinal rim (128) provided with the dovetailed groove is pressed into the lower side of the shim liner (134) and around the longitudinal edge (127) of the lower profile, which longitudinal edge is embraced by the rib (136) of the shim liner.

10. Device for the performance of the method according to claim 1 with at least two working paths and, along them, installations for forming the metal bands into profiles, characterized by a drawing station located at the end of the device, which drawing station is adapted to at least one profile to be manufactured and serves for the simultaneous drawing of at least two metal bands off the magazine rolls and their moving along the pertaining working paths through the nondriven forming installations located there for the forming of metal bands in longitudinal direction, through a greasing station located before the forming installations, and through further, non-driven forming installations to the strengthening of the longitudinal rims of the metal bands by means of folded welts.

11. Device according to claim 10, characterized by a pair of rollers acting on one longitudinal rim of the metal bands, for coining, knurling or perforating.

12. Device according to claim 10, characterized by a drawing station that is movable from a firm initial position to an adjustable end position, on reaching the end position effects the switching on of a separating device for the finished product, then returns automatically to its initial position and grasps the end of the profile, whereupon the whole cycle of movement repeats itself.

13. Device according to claim 10, characterized by a stationary drawing device with endless drawing chains running over guiding and driving wheels, which are provided with profile-gripping claws, under spring action, with elastic buffers for gripping the profile to be manufactured from at least two sides.

14. Device according to claim 13, characterized by profile-gripping claws and puffers located on the levers inclined towards the profile erection for the obtention of a clamping effect of these profile-gripping claws on the profile gripped by exerting a pushing force on the profile.

15. Device according to claim 13, characterized by a separating device following the profile moved, for straight cuts and cuts in miter at angles adjustable to the profile.

16. Device according to claim 10, characterized by forming installations consisting of profile mill cutters, each of which is mounted freely rotating on the front end of a carrying bolt (70, 71, 72, 73), the rear part of which is held in a socket (74, 75, 76, 77) which is fixed on columns and is vertically adjustable to the axis of the bolt for the purpose of adjusting the bolt and the profile mill cutters carried by it relatively to the other carrying bolts mounted on the same columns (78, 79).

17. Device according to claim 10, characterized by multiple-part profile mill cutter whose single parts are rotatable on a carrying bolt freely and independently of each other.

18. Device according to claim 10, characterized by forming rollers (12, 13, 14 and 17, l8, 19 respectively) located along the first working path, three of which are in each case disposed, with their axes of rotation inclined towards each other, on-a plane vertical to the metal band running through, during which process the central rollers (13, 18) of each group of three have an axis of rotation parallel with the surface of the metal band and act together with the forming cores (15, 23) or forming rollers (45, 46, 46', 46"), corresponding in each case to the form of the profile, under the metal band, whereas the lateral rollers (12, 14) show an increasing diagonal position of their axes and the last of the groups of three form a split between the three rollers on the one hand and between the forming core or forming roller on the other, which split corresponds to the desired profile of the metal band.

19. Device according to claim 18, characterized by analogous groups of forming rollers, located along a second working path, whose last group of three forms a split corresponding to a second profile of metal band which is difi'erent from the first profile.

20. Device according to claim 19, characterized by a disposition of the second working path vertically below the first working path.

21. Device according to claim 10, characterized by a threading device located on at least one working path (1) behind the forming installations (17, 18, 19), consisting of sheet-metal deflectors (35, 36) for drawing a profiled shim liner (33, 34) onto the longitudinal rims (21, 22) ofa formed metal band (4).

Claims

7. Method according to claim 1, characterized by the fact that the upper (4) of two metal bands (4, 5) moved one beneath the other is formed into a U profile open downwards and the two legs are chamfered outwards 90* (21, 22), during which process the underneath metal band (5) is transformed into a lower and narrower U profile with wider longitudinal rims chamfered outwards (26, 27), then a shim liner consisting of an elastic band doubled longitudinally (33, 34) is drawn onto each of the rims (21, 22) turned outwards of the upper U profile, the lower parts of the shim liner protruding inwards above the chamfered edge up to its end, the aforesaid two U profiles are pressed upon one another and the rims (28, 29) of the lower U profile are bent approx. 180* around the longitudinal rims (21, 22) of the upper U profile, which longitudinal rims are coated with the shim liner, and then pressed into the elastic shim liners (33, 34) which are enclosed all round.

8. Method according to claim 1, characterized by the fact that the upper (100) of two metal bands (100, 101) moved one beneath the other is formed into a U profile open downwards, the two legs of which are chamfered outwards 90* at their lower ends and at their outer rims (104, 105) are further bent upwards 90*, then a band-shaped elastic shim liner (102, 103) with a wide base plate and hook-shaped protruding ribs (106, 107) embracing the rims (104, 105) is drawn onto the rims (104, 105), during which process the lower metal band (10) is formed into a broad U profile open above with upright longitudinal rims (108, 109) which are both bent outwards 90* and by two further nearly rectanagular folding welts are provided with a U-shaped groove (110, 111), then they are further bent around the inside edges (112, 113) and set vertically, the aforesaid U-shaped grooves are then compressed into dovetailed grooves (114, 115) and flanged outwards on the longitudinal edges (114, 115), hereupon the lower U profile is pressed against the base plates of the shim liners (102, 103), which are on the longitudinal rims (104, 105) of the upper U profile, the longitudinal rims (108, 109) of the lower U profile are bent upwards around the two top edges of the base plates and the two longitudinal rims (108, 109) provided with the dovetailed grooves (114, 115) are pressed into the upper sides of the shim liners (102, 103) and around the longitudinal edges (104, 105) of the upper profile, which are embraced by the ribs (106, 107) of the shim liners.

9. Method according to claim 1, characterized by the fact that two metal bands (118, 119) moved one beneath the other are simultaneously formed into the mirror image of one another, during which process the lower metal band (118) is bent upwards 90* at its left-hand longitudinal rim (120) (FIG. 32) and this leg is further bent outwards 90*, by two further rectangular chamferings is provided with a U-shaped groove (122), by further bending around its chamfered inner edge (123) is righted again, the U-shaped groove is compressed into a dovetailed groove (124) and the outermost edge of the leg (125) is bent inwards, whereas the metal band (118) is chamfered downwards 90* at the right-hand longitudinal rim and then together with this leg (121) bent over 90*, put vertically and flanged downwards 90* At the outermost longitudinal edge (127), then a band-shaped elastic shim liner (134) with a wide base plate and a hook-shaped protruding rib (136) embracing the longitudinal edge (127) is drawn onto the longitudinal edge (127), whereupon this lower profile together with ist shim liner (134) is pressed together with the upper profile which is formed as a mirror image and is also provided with a shim liner (135), the left-hand longitudinal rim (120) of the lower profile is bent upwards around the top edge of the shim liner (135) and its longitudinal rim (120) provided with the dovetailed groove is pressed into the upper side of the shim liner (135) and around the longitudinal edge (133) of the upper profile, which longitudinal edge is embraced by the rib (137), whereas, at the same time, the right-hand longitudinal rim (128) of the upper profile is bent downwards around the top edge of the shim liner (134) and its longitudinal rim (128) provided with the dovetailed groove is pressed into the lower side of the shim liner (134) and around the longitudinal edge (127) of the lower profile, which longitudinal edge is embraced by the rib (136) of the shim liner.

10. Device for the performance of the method according to claim 1 with at least two working paths and, along them, installations for forming the metal bands into profiles, characterized by a drawing station located at the end of the device, which drawing station is adapted to at least one profile to be manufactured and serves for the simultaneous drawing of at least two metal bands off the magazine rolls and their moving along the pertaining working paths through the non-driven forming installations located there for the forming of metal bands in longitudinal direction, through a greasing station located before the forming installations, and through further, non-driven forming installations to the strengthening of the longitudinal rims of the metal bands by means of folded welts.

18. Device according to claim 10, characterized by forming rollers (12, 13, 14 and 17, 18, 19 respectively) located along the first working path, three of which are in each case disposed, with their axes of rotation inclined towards each other, on a plane vertical to the metal band running through, during which process the central rollers (13, 18) of each group of three have an axis of rotation parallel with the surface of the metal band and act together with the forming cores (15, 23) or forming rollers (45, 46, 46'', 46''''), corresponding in each case to the form of the profile, under the metal band, whereas the lateral rollers (12, 14) show an increasing diagonal position of their axes and the last of the groups of three form a split between the three rollers on the one hand and between the forming core or forming roller on the other, which split corresponds to the desired profile of the metal band.

19. Device according to claim 18, characterized by analogous groups of forming rollers, located along a second working path, whose last group of three forms a split corresponding to a second profile of metal band which is different from the first profile.

21. Device according to claim 10, characterized by a threading device located on at least one working path (1) behind the forming installations (17, 18, 19), consisting of sheet-metal deflectors (35, 36) for drawing a profiled shim liner (33, 34) onto the longitudinal rims (21, 22) of a formed metal band (4).