WO2015065170A1

WO2015065170A1 - Foldable structural plate element

Info

Publication number: WO2015065170A1
Application number: PCT/NL2014/000041
Authority: WO
Inventors: Wilhelmus Mathias Maria VAN RIJSINGEN
Original assignee: Ripstaal B.V.
Priority date: 2013-11-04
Filing date: 2014-10-31
Publication date: 2015-05-07
Also published as: NL1040481C2

Abstract

A method for the manufacture of a foldable building plate element by providing a flat plate (1), providing of at least one folding groove (2) in the flat plate, providing a folding profile (6), comprising two side wings (7) and an intermediate folding portion (8), and installing the folding groove into the folding profile in such a way, for example by gluing, that the side wings thereof form a tight connection with the two side faces (5) of the folding groove. The side wings are interconnected with each other through a bridging strip (9), which will be removed when the plate is folded. The wings are further provided with interconnection means (10, 10') that snap-connect with each other when the side wings are folded towards each other. If desired, a filling strip ( 11) can be inserted between the side wings.

Description

Title: Foldable structural plate element DESCRIPTION The invention relates to a foldable structural (building) plate element, including a method for the manufacture thereof and a building plate element comprising a folding profile.

If a flat plate is used in building construction, for example for covering of a wall which contains parts which are not located in the same plane, e.g. extending forward or backward, the plate (gypsum board or other plate) is sawn under 45° and the two parts are then glued to each other in order to create a corner element.

Object of the present invention is to provide a method, which enables production of foldable building plate elements in a factory instead of at the construction site, where the plate elements - entirely sized beforehand - can be transported in a flat state to the construction site and folded there. Further object of the invention is to provide that the production - in the factory - is performed under better-controlled conditions than usual at the construction site. Object of the invention is thereby to contribute to the quality of the respective building elements and also to reduction of production and installation time. Additionally, as will apparent hereinafter, a building element is obtained which has a tighter angle finish and which, moreover, is less susceptible to damage. Therefore, applying edge protectors (edge corners/profiles/sections) to prevent damaging of protruding corners, is no longer necessary prior to plastering.

The invention relates, more in detail, to a method for producing a foldable building plate element, comprising the steps of:

providing a flat plate (with predetermined properties and dimensions);

providing at least one (e.g., V-or U-shaped) folding groove in the flat plate;

- providing a folding profile, for example made of plastic or metal, comprising two side wings and a folding portion there between;

installing the folding profile into the folding groove such that the side wings form a tight connection with both side surfaces of the folding groove and/or, optionally/possibly, with areas of the flat plate adjacent located to the folding groove.

Such method and folding profile are known as such from WO2008012854A1. In order to provide that the folding profile is easy to handle during transport (during which the folding profile remains in a flat state) and does not undesirably fold, preferably, the (open) side wings of the folding profile are interconnected by means of a bridging strip (or locking strip) which can be removed, prior to folding the plate, from the space between the two (open) side wings, after which the plate can be folded using the folding profile which is released ("unlocked") by removal of the bridging strip. The use of such bridging or locking strip is known as such from DE3141709A1.

DE3141709A1 discloses a folding profile including an (integral) bridging strip which is completely (i.e. including its bridging strip) located under the plate's protective layers. The bridging strip has to be removed from between the side wings by cutting it loose (via the protective layer), after which removal the plate can be folded using the folding profile which is unlocked by removal of the bridging strip.

Preferably, the side wings of the profile are provided with interconnection means, which are arranged to interconnect with each other when the side wings are folded towards each another (i.e. in their closed position). In this way the building element has increased rigidity after the parts of the flat plate are folded together.

Interconnecting both walls of a V-groove provided in a plate element is known as such from GB1570761A, which discloses to apply a contact adhesive to both walls of a V- groove which is used to fold the plate element. The contact adhesive thus forms interconnection means for interconnecting both side walls in this prior art configuration. It is noted that GB1570761A does not disclose the use of a folding profile. According to the present invention the interconnection means of the folding profile are snap-action type ("clickable") interconnection means which feature is neither known from, nor rendered obvious by the available prior art. It may be clear that using a plate element provided with a (i.e. at least one) folding groove and a folding profile mounted therein, interconnecting both side wings of the folding profile using snap- action type interconnection means arranged to interconnect both side wings of the folding profile when those side wings are folded together, has great advantages w.r.t. efficiency, flexibility and reliability over the use of a contact adhesive (which also will badly/hardly adhere to the side walls of a V-groove in a gypsum plate) as suggested in GB1570761A.

Preferably, snap-action type interconnection means are also be used for the (preferred) bridging/locking strip, intended - in its locking position - to maintain the folding profile in its open position during transport and storage (i.e. prior to folding the plate element). Unlocking the folding profile, prior to folding of the plate element is performed by removing the bridging strip from between the (open) folding profile, holding the wings at distance from each other.

In order to provide that the opening angle of the folding groove is not directly dependent on the mutual angle between the plate elements, a filling strip may be provided, arranged to be mounted between the side wings of the folding profile. Application of such a filling strip is known as such from DE3141709A1 and (more or less) from DE29910878U1.

According to a preferred embodiment of the present invention the filling strip and the side wings of the folding profile are also interconnected with snap-action type interconnection means, arranged to interconnect with each other when the side wings and the filling strip are folded together.

Thus, by means of a method as described hereinbefore, a building plate element can be obtained, comprising a flat plate with at least one folding groove, having mounted therein a folding profile comprising, in cross-sectional view, two side wings and an intermediate folding portion, wherein the side wings form a tight connection with both side faces of the folding groove and/or with the areas of the flat plate located adjacent to the folding groove. Preferably, in order to increase the stability of the plate during transport etc., the opening of the side wings is locked by a bridging strip, which must be removed before the plate element is to be folded.

It is observed that the profile according to the invention offers good protection of the corners, including the (invisible) inside of the cardboard layer of a gypsum board, or the plastic layer of other plates such as chipboard. Due to the invention corners can be made on the construction site without gluing, since the plates can quickly and efficiently be folded and locked by means of the snap- action type ("clickable") interconnection means. Due to the profile mounted to the inside of the protective layer (cardboard, polystyrene or laminated layer) good mechanical protection is offered against damage (which will become clear in more detail from the following description of the figures).

The system proposed by the invention is therefore quick and easy. No gluing is required, and it is also essential that the plate-shaped building elements, before they are installed, are stored and transported in their flat state. The plates are not folded until arrival at the construction site as during storage and transport, the side wings of the folding profile are locked by an easily removable bridging or locking strip.

The invention will be hereinafter further explained by means of the description of the drawing.

Figures la-e illustrate the method as outlined in the preceding and an example of an embodiment of the result thereof;

Figures 2a-e show the same method in which, however, use is made of a folding profile with a bridging strip which can be torn loose;

Figures 3a-c show an alternative folding profile with a bridging strip which can be torn loose;

Figures 4a-b show a first embodiment of a bridging strip with two snap-action type interconnection means in combination with a folding profile as shown in Figures lb-e;

Figures 5a-b show a second embodiment of a bridging strip with snap-action interconnection means on one side and an interconnection area which has to be torn loose on its other side, in combination with a folding profile as shown in Figures lb-e.

Figures la-e show schematically the method according to the invention for the manufacture of a foldable building plate element, comprising the steps of:

- (see Figure la) providing a flat plate 1 and providing, e.g. by means of milling or sawing, of a folding groove 2 into the flat plate 1. In particular, gypsum boards and other boards are envisaged, such as, for example, coated (e.g. plastic-coated) chipboard or plywood, which are (usually on both flat sides) provided with a protective layer 3. The folding groove 2 is so deep milled or sawed into the plate that it (just) does not extend through the opposite protective layer. The protruding (projecting) parts 4 of the protective layer 3 on the side of the folding groove 2 are pressed into the side faces 5 of the folding groove 2.

- (see Figure lb) providing a folding profile 6, comprising, in cross-sectional view, two side wings 7, and a there between located folding portion 8;

- (see Figure lc) installing the folding profiles 6 into the folding groove 2 in such a way, that the side wings 7 form a tight connection with both sides faces 5 of the folding groove 2. Preferably, the side wings 7 and any (optional) extensions 7a are glued against the side faces 5 (partly covered by the protruding layer parts 4) of the folding groove and, optionally, against the layer areas la adjacent to the folding groove 2. The optional extensions 7a may optionally be attached slightly recessed into the flat plate 1 by providing a shallow recess into the flat plate 1 - for example by milling - in the areas la adjacent to the folding groove 2. This ensures that the extensions 7a do not project outside the surface of the flat plate 1, so that the plates 1 can be stacked entirely flat, without being hampered by the material thickness of said extensions 7a. Moreover, the application of the extensions 7a is optional; they are in particular intended for the situation when the adhesion between the wings 7 and the side faces 5 would not be sufficient. In order to indicate that the extensions 7a are optional, they are shown in in dotted lines, only in Figure lc of Figure 1.

It is stressed that the side wings 7 may form a solid connection with either (only) the sides 5 of the folding groove 2, or, optionally, via the side wing extensions 7a, with (only) the areas la next to the folding groove 2, or with both, i.e. the actual side wings 7 with the side faces 5 and the side wing extensions 7a with the flat outer regions la.

The side wings 7 of the folding profile 6 are provided with snap-action type interconnection means 10, which are arranged to be interconnect with each other when the side wings 7 are folded towards each other. The interconnection means 10 are snapped together when the wings 7 are folded towards each other. In many cases the opening angle a, in cross-sectional view, of the folding groove is 90°; however if appropriate, the opening angle a may be chosen greater than or less than 90°.

Figure lc shows the result of gluing the folding profiles 6 into the folding groove 2. In this way - of which Figure lc is an illustration - the plate elements are made in a factory - beforehand fully customized in size - and transported in their flat state to the construction site, and folded there, during their installation, in a desired form, as is illustrated in Figure Id. Figure Id shows the same plate 1 as shown in Figure lc, however, now in the "bent" or folded state, e.g. mounted having an angle of 90°. In order to provide a tight corner connection, the side wings 7 are moved towards each other - at the construction site - so that at the end of that movement the side wings 7 are coupled to each other with their snap connections 10.

When an angle other than 90° is desired, while the opening angle a of the folding groove is 90°, a filling strip 11 may be provided - as illustrated by figure 1 - which is arranged to be mounted between the side wings 7 of the folding profile 6. The filling strip 11 and the side wings 7 of the folding profile 6 are provided with snap-action type interconnection means 10 (previously mentioned) and 12, which are arranged to interconnect with each other when the side wings 7 and the filling strip 11 are folded towards each other. The interconnection means 10 and 12 are mutually snap-action type when the side wings 7 and the filling strip 11 are folded towards each other, so that also here a robust corner connection is formed, corresponding to the embodiment where no filling strip 11 is used.

It should be noted that preferably the (remaining intact) protective layer 3 extends over the folding portion 8 on the side of the folding portion 8, so that the folding portion 8 is not visible from the outside, since it is located under the original protective layer 3 of the plate material.

The installation of a building plate element manufactured as described hereinbefore, and shown in Figures la-e, therefore comprises the following steps:

- providing a building plate element as shown in Figure lc;

- applying, if necessary, a filling strip 11 between the side wings 7 of the folding profiles 6;

- folding the flat plate by means of the folding profile 6 (or folding profiles when a building element has more folds) into the desired form. Figures 2a-e show the same method as the Figures la-e where, however, use is being made of a folding profile with a bridging strip 9. In this embodiment the bridging strip 9 is integral with the rest of the profile 6, which may be entirety (i.e. including the parts 7-10) manufactured by means of extrusion. The bridging strip 9 is connected to the ends of the side wings 7 by means of thin passage areas 9a. As a result, the bridging strip 9, which closes and locks the outspread side wings 7 during storage and transport, can be torn away with little effort from between the side wings 7, wherein the passage areas 9a act as tearing grooves. After the bridging strip 9 is removed (see arrow) the folding profile 6 can be folded, and thereby the entire plate 1.

Figures 3a-c show schematically the method of Figure 2 using an alternative folding profile 6. This folding profile 6 is intended to provide an improvement with regard to the dimensional stability of the profile, in particular of the "click connection". Returning to Figure 2b, it is clearly shown there that the two parts 10, which form a snap connection, are located within a space that is bounded by the wings 7 and the bridging strip 9. When the profile 6 is manufactured by extrusion, that profile 6, after having been pressed out of the respective extruder head, is guided through a cooling bath, in which it is cooled. The profile shape shown in Figure 2b may possibly have the disadvantage that the snap members 10 cannot optimally be cooled down by the cooling bath, because they are located inside the profile shape and therefore cannot be reached directly by the cooling liquid. The profile 6', shown in Figures 3a-c, comprises snap-action type parts 10', which in particular can be reached from the outside by the coolant of the cooling bath. Thereby is provided that the shape retention of the snap component 10' is improved with respect to the parts 10 in the previous Figures. Figures 4a-b show a preferred embodiment of a bridging/locking profile or strip, in combination with a folding profile as shown in Figures lb-e. In this embodiment the bridging strip 9 comprises snap-action type interconnection means 13, which cooperate with the interconnection means 10 on the side wings 7 of the folding profile. The interconnection means 13 on the bridging strip 9 are arranged to connect the bridging strip 9 to the side wings 7 of the folding profile, in the opened position of the side wings 7, as long as the plate element 1 is stored or transported. The bridging strip 9 is removed - by pulling the bridging strip 9 loose from the space between the side wings 7 - when the plate element 1 is to be folded (wherein the side wings 7 move towards each other and are interconnected with each other by means of the interconnection means 10, or - if desired - are connected to a filling strip 11 between the side wings 7. Figures 5a-b show yet another, still more preferred, folding profile, provided with an integrally manufactured bridging strip. The folding profile 7/8 and the (integral) bridging strip 9, which together form an assembly, are interconnected via a thin, flexible interconnection area 14 on one longitudinal edge of the bridging strip 9. Before or after mounting the assembly 7/8/9 into the folding groove the bridging strip 9 is pressed down so that it "snaps" with its free longitudinal edge into the corresponding side wing 7 where the thickened edge 15 is pressed and clamped between two (more or less resilient) ridges 16. In this way the edge 15 and the ridges 16 function in this embodiment as snap-action interconnection (clickable link) between the bridging strip 9 and the respective side wing 7. Further, in the Figures 4a-b a pair of abutting edges 17 can be seen, ensuring that the distance between the two side wings 7 will be maintained after the side wings 7 are (after the bridging strip has been removed) moved to each other and secured, by means of the above - described "clickable" interconnection means 10, correctly in that state.

Removal of the bridging strip 9 from between the side wings 7 when the plate 1, during construction operations on the building site, must be folded, is performed by, on one side, tearing loose the bridging strip 9 along the thin interconnection area 14, which thereby functions as a tearing strip, and by, on the other side, of snapping loose the "clickable" interconnection 15/16, by pulling upwardly the thickened edge 15 from between the ridges 16. Removing the bridging strip 9 from between the opened side wings 7 thus is performed in a single operation, wherein the strip 9 is pulled upwardly and both interconnections 14 and 15/16 are broken simultaneously, one by tearing loose, the other by snapping loose.

The advantage of the embodiment shown in Figures 5a-b is that the two (sub)components of the assembly, the folding profile and the bridging strip, are manufactured at the same time, using one extrusion die. The extrusion die (extrusion head) is formed so that the bridging strip 9 is separate (at its topside in figure 4a) from the rest of the folding profile, due to which the profile part 7/8 and the bridging strip part 9 can be cooled, immediately after the actual extrusion process, excellently as the coolant is able to cool the profile 7/8/9 at all sides. Consequently, accurate dimensioning and thereby proper operation of the integral profile assembly 7/8/9 can be guaranteed. CLAIMS Method for manufacturing a foldable building plate element, comprising the steps of:

- providing a flat plate (1);

- providing at least one folding groove (2) in the flat plate;

- providing a folding profile (6), comprising, in cross-sectional view, two side wings (7) and an intermediate folding portion (8);

- installing the folding profile into the folding groove (2) such that the side wings (7) thereof form a tight connection with the side faces (5) of the folding groove (2) and/or, optionally/possibly, via optional side wing extensions (7a) with areas (la) of the flat plate located adjacent to the folding groove;

- wherein the side wings of the folding profile are provided with snap-action type interconnection means (10, 10') arranged to interconnect both side wings when the side wings are folded towards each other. Method according to claim 1, the folding profile being arranged that its side wings are interconnected or arranged to be interconnected via a removable bridging strip,

wherein the side wings and the bridging strip (9) comprise snap-action type interconnection means ( 10/13, 15/16) arranged to connect the bridging strip to at least one of the side wings (7) in the open position of the side wings, and to enable pulling loose the bridging strip from between the side wings,

where the bridging strip is pulled loose from between the side wings before the side wings are folded towards each other. Method according to claim 1 or 2, wherein a filling strip (11) is provided, arranged to be mounted between the side wings of the folding profile, the side wings and the filling strip being provided with snap-action type interconnection means ( 10, 12) arranged to interconnect the side wings and the filling strip when the side wings and the filling strip are folded towards each other.

Claims

Method according to claim 1, wherein said flat plate ( 1) includes a protective layer (3) on one or both sides and wherein said at least one folding groove (2) in the flat plate is provided such that protruding parts (4) of the protective layer are formed on both sides of the folding groove, which are pressed into the folding groove under the folding profile and wherein the side wings are glued to the surfaces of the protruding parts pressed into the folding groove.

Profile, arranged to be used as a folding profile in a method according to any of the claims 1-4, the profile comprising, in cross sectional view, two side wings (7, 7a) and an intermediate folding portion (8), wherein the side wings are arranged to be able to form a tight connection with both side faces of the folding groove and/or with said areas of the flat plate located adjacent to the folding groove, wherein the side wings of the folding profile are provided with snap-action type interconnection means (10, 10'), arranged to interconnect both side wings when the side wings are folded towards each other.

Profile according to claim 5, the folding profile being arranged that its side wings are interconnected or arranged to be interconnected via a bridging strip, wherein the side wings and the bridging strip (9) comprise snap-action type interconnection means (10/13, 15/16) arranged to connect the bridging strip to at least one of the side wings in the open position of the side wings, and to enable pulling loose the bridging strip from between the side wings.

Profile according to claim 6, wherein the bridging strip is comprised by the profile via a thin interconnection area (14) interconnecting one side of the bridging strip to one side wing and where its other side and the other side wing are interconnected or arranged to be interconnected via snap-action type interconnection means (15/16).

Profile according to claim 5, 6 or 7, arranged for co-operation with a filling strip, arranged to be mounted between the side wings of the folding profile, the side wings and the filling strip being provided with snap-action type interconnection means (10, 12) arranged to interconnect the side wings and the filling strip when the side wings and the filling strip are folded towards each other.

9. Bridging strip (9) arranged for co-operation with a profile according to claim 6, wherein the bridging strip (9) comprises snap-action type interconnection means (13), arranged to co-operate with the interconnection means ( 10) of the side wings of the profile in order to connect to the side wings in their open position.

10. Filling strip, arranged for co-operation with a profile according to claim 8, wherein the filling strip is arranged to be mounted between the side wings of the folding profile by means of snap-action type interconnection means, interconnecting the filling strip with the side wings when the side wings and the filling strip are folded towards each other.

11. Assembly comprising a profile according to any of the claims 5-8 and/or a bridging strip according to claim 9 and/or a filling strip according to claim 10.

12. Building plate element, produced by means of a method according to any of the claims 1-4, comprising a flat plate with at least one folding groove, and therein a folding profile according to any of claims 5-8.

13. Building plate element according to claim 12, comprising a bridging strip (9) according to claim 9.