WO2017160142A1

WO2017160142A1 - Method for manufacturing a support structure

Info

Publication number: WO2017160142A1
Application number: PCT/NL2017/050142
Authority: WO
Inventors: Martin Gerret VENHUIZEN
Original assignee: Remko Mark B.V.
Priority date: 2016-03-18
Filing date: 2017-03-08
Publication date: 2017-09-21
Also published as: EP3429775A1; NL2016454B1

Abstract

Method for manufacturing a support structure including: - providing at least a first flat elongated element (1) having a curvature in a corresponding first plane (P1) that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1); - providing at least a second flat elongated element (2), to be joined with a said first element (1), the second element (2) having a curvature in a second corresponding plane (P2) that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element (2); - further curving both the first elongated element (1) and a respective second element (2) by bending the respective element (1, 2) out of the respective first and second plane (P1, P2) such that they can be joined with a first side surface of the first element (1) receiving a first lateral edge of the respective second element (2); and - joining at least the first element (1) and respective second element (2).

Description

Method for manufacturing a support structure

The invention relates to a method for manufacturing a support structure including:

-providing at least a first flat elongated element having a curvature in a corresponding first plane that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element;

-providing at least a second flat elongated element, to be joined with a said first element, the second element having a curvature in a second corresponding plane that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element;

-further curving both the first elongated element and a respective second element by bending the respective element out of the respective first and second plane such that they can be joined with a first side surface of the first element receiving a first lateral edge of the respective second element; and

-joining at least the first element and respective second element. Such a method is known e.g. from US8,507,827. An advantage of the known method is that it can lead to a metal section of complex shape at relatively low cost, for example curved T-shapes (e.g double or triple curved T-shapes), and reduced mechanical stress in the elements.

Particularly, the known method includes a manufacturing method for metal sections in which the cross section is composed of at least two individual, non-aligned parts. The known method is characterised in that it is applied to the manufacturing of complex shaped sections exclusively composed of non-plane parts that form an angle that can be of any degree and evolutionary according to the length of the section, and in that the method also consists of cutting out the elements in at least one metal plate, according to the measurements that correspond to each one of the said parts, and the assembly of these elements together to form said metal section. It is preferred that said elements are cut as flat pieces from flat metal plates, then formed before assembly. For example, the elements are cut from previously formed metal plates. The elements are attached to each other by laser beam welding.

A disadvantage of the known method is that it is relatively hard to join the curved elements firmly together, because of their curvature which makes it rather difficult to hold the elements stably during a relatively long welding period. Also, the resulting metal structure has a relatively high heat conductivity which is not always desired.

The present invention aims to provide an improved method.

Particularly, the invention aims to improve manufacturability, decrease of expenses, as well as a durable elegant system.

According to an aspect of the invention there is provided a method that is characterized by the features of claim 1.

The first side surface of the first element and the first lateral edge of the second element are provided with an alignment structure for mutual alignment during joining.

In this way, good alignment of the elements can be achieved during joining, so that a firm and accurate joint can be obtained. For example, the alignment structures of the elements can cooperate with one another when the elements are brought together to be integrally attached (the resulting connection particularly being such that disconnection is not possible unless the elements are mechanically damaged) to hold the elements in their desired final position.

The skilled person will appreciate that the alignment structure can have various configurations. For example, the alignment structure can include a certain predefined relief in opposite sections of the elements that are to be connected, an interacting or interlocking cam -groove structure, alignment holes and respective alignment protrusions, or different

(mutually engaging) structure. The manufacturing of a said first element and a said second element as such can be the same as, or similar to, the method described in US8,507,827 which is incorporated by reference in the present application in its entirety. For example, each of the elements can be made of metal.

Alternatively, however, one or more of the elements can be made from or consists of non-metal material, for example a thermally insulating material, a plastic, a fiber -reinforced material, a fiber reinforced plastic, a compound or composite material or the-like. In this way, a thermally insulating structure can be achieved, providing respective advantages and a relatively broad field of application. One of the particular applications is using the resulting structure in assembling one or more thermally insulating frames, for example to build a fa ade of a building, maritime structure of the-like. Particularly, a said element, e.g. the second element, can be configured to form a thermal separation in such a frame or supporting system.

It should be observed that besides said bending steps, one or more of the elongated elements can also be deformed by torsional deformation (e.g. by cold bending over an axial center line), providing further complex support structure shapes/configurations.

A said thermally insulating material preferably is a material having a thermal heat conductivity of at most 1 W/(m K), preferably at most 0.2 W/(m K), providing good results.

Furthermore, one of the elements (e.g. a metal element) can have a thermal heat conductivity that is significantly higher than the thermal heat conductivity of the thermally insulating material, for example higher by a factor of at least 10 or 100.

It should be noted that the term 'metal' is to be construed broadly in this application, since it can mean one of:: consisting of at least one metal or alloy, substantially comprising at least one metal and/or alloy. A metal element does not have to entirely consist of metal. The metal element can be for example a steel element, an aluminum element, or an element made of a different metal or alloy.

One of the elements, particularly each second element, may be made of a rigid composite material, being particularly rigid at room temperature (e.g. at 20 °C). In an embodiment, the rigidity of a said rigid element may be temporarily reduced to allow a said deformation (bending) of that material. For example, the rigidity may be reduced by a heat treatment, wherein the element is heated to a bending temperature higher than room temperature (e.g. to a temperature higher than about 100 °C), wherein the element is deformed/bended when it has achieved the bending temperature.

The two elements (i.e. a said first and second element) can be joined e.g. to form a T-shaped profile or L-shaped profile, with one of the elements extending substantially normally (or perpendicular) with respect to the other elements when viewed in transversal cross-section. As a result a relatively strong structure can be obtained, capable of withstanding load/pressure from different directions.

According to a second aspect of the present invention, which can be combined with the above-described first aspect (but that is not required) a frame including an assembly of joined first elements and second elements is formed, the frame defining or surrounding at least one opening, particularly an opening to be closed by at least one panel.

For example, the resulting frame can be used in the construction of partitions, inner or outer walls, roof structures, buildings or differently. It allows the manufacturing of such structures providing limitless possibilities regarding shape, in a cost effective manner. Particularly, it allows building large structures having complex curvatures. Moreover, in case of using thermally insulation elements in the manufacturing process, proper thermally insulating frames can be obtained. A said panel can e.g. be an optically transparent panel, e.g. a glazing panel or glass sheet, preferably a thermally insulating panel (e.g. including two or three parallel glass sheets). The frame structure can support the panel after assembly. In a further, preferred embodiment, the panel as such can be curved or formed according to the shape of the frame, to fit into the frame.

The curving or forming of the panel can be achieved independently of the manufacturing of the respective frame that is to support that panel. For example, the panel can be curved or otherwise formed before it is joined with the curved frame structure, particularly to fit into that structure to close an opening defined by that structure.

Another embodiment involved shaping or bending the panel during assembly onto the frame, e.g. by pressing the panel onto the frame. In that case, particularly, the panel can be a plastically or elastically deformable panel (e.g. a panel including glass). The deforming or bending of the panel towards a curved shape, to be supported by the frame, can e.g. include a panel heat treatment step, wherein the panel is heated to a certain bending temperature higher than room temperature (e.g. to a temperature higher than about 100 °C), wherein the panel is deformed/bended when it has achieved the bending temperature.

Another embodiment involves at least a first step of partly curving or forming the panel before joining the panel to the frame structure, in combination with at least one step of shaping or bending the panel during assembly onto the frame, e.g. by pressing the panel onto the frame, to a final panel shape.

According to a third aspect of the invention, which aspect may be combined with the above-mentioned first aspect and/or with the above second aspect, more than two elements are curved in two directions, and combined to form a profile (e.g. a substantially T-shaped profile or a substantially L-shaped profile or a substantially H-shaped profile or a substantially U-shaped profile, or Z-shaped or a hollow beam having an angular, square or rectangular cross section).

Particularly, there is provided a method for manufacturing a support structure including:

-providing at least a third flat elongated element, to be joined with a said second element, spaced-apart from said first element,

the third element having a curvature in a third corresponding plane that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element;

-further curving both the first elongated element and a respective second element by bending the respective element out of the respective first and second plane such that they can be joined with a first side surface or lateral edge of the first element receiving a first lateral edge of the respective second element; and

- further curving the third elongated element out of the respective third plane such that it can be joined with a second lateral edge or a second side of the respective second element that is faced away from the first lateral edge of that second element; and

-joining at least the first element, respective second element and respective third element, for example (but not exclusively) to form a substantially T-shaped, L-shaped, U-shaped or H-shaped profile, or a Z- shaped profile, or a hollow beam having an angular, square or rectangular cross section. In this way, above-mentioned advantages can be achieved wherein a profile is formed from at least three elements. Particularly, the third element can act as a reinforcement or strengthening element of the respective profile. In a further embodiment, a plurality of thus formed profiles can be attached to each other to form a frame, e.g. a panel supporting frame.

A fourth aspect of the invention provides a method for

manufacturing a support structure, for example a method that can be combined with or include one or more of the first, second and third aspect of the invention. The support structure preferably includes at least a said first and second element, wherein the first element is made of metal or an alloy, wherein the second element is made of a thermally insulating material (e.g. a material as mentioned before). The first and second element can be connected to each other e.g. using an adhesive, a clamping connection, by application of dove-tail connections, or a combination thereof, and/or differently.

In the fourth aspect of the invention it is additionally advantageous when a third element is joined to the second element, wherein the second element forms or act as a thermally insulating connection between the first and third element. For example, the third element can be made of metal or an alloy, e.g. of the same material as the first element, particularly for reinforcement of the structure. Besides, the third element can be configured to widen the second element, wherein the third and second element are connected/attached to each other via opposite side edges. Also, in this case, the elements (i.e. third and second element) can be connected to each other e.g. using an adhesive, a clamping connection, by application of dove-tail connections, or a combination thereof, and/or differently.

An example of a support structure that includes a first, second and third element is described in international patent application

PCT/NL2009/050396 (WO2010002258), wherein the support structure according to the present invention is highly suitable to be used to

manufacture a curved version of the system that is described in W0258 which is incorporated in the present application by reference in its entirety. Particularly, the known system is provided with panels, for instance glass sheets, and with elements which extend along edges of the panels, comprising in the wording of the present patent application:

- at least a first element which extends along a first edge of at least one panel, wherein the first element is manufactured from metal, and is of solid design;

- at least a further element (e.g. glazing bead) which extends along a second edge of the at least one panel, and

- a connection between said first and further element which connection comprises at least a third element (e.g. a solid metal, preferably steel connecting element), wherein said connection is also provided with second element being thermally insulating third part. The thermally insulating part (second element) is then preferably substantially located in a space located opposite an end face of the panel.

A fifth aspect of the invention provides a method for manufacturing a support structure, for example a method that can be combined with or include one or more of the first, second, third and fourth aspect of the invention. Also, in this case, the resulting support structure is highly suitable to be used to manufacture a curved version of the system that is described in W0258 which is incorporated in the present application by reference in its entirety. Particularly, the known system is provided with panels, for instance glass sheets, and with elements which extend along edges of the panels.

According to the fifth aspect, the method includes:

-providing a plurality of first flat elongated elements each having a respective curvature in a corresponding first plane that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element;

-providing a plurality of second flat elongated elements, to be joined with respective first elements, each second element having a curvature in a second corresponding plane that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element ;

-further curving both a said first elongated element and a respective second element by bending the respective element out of the respective first and second plane such that they can be joined with a first side surface of the first element receiving a first lateral edge of the respective second element; and

-joining corresponding pairs of first elements and respective second elements thereby forming respective profiles, for example T-shaped or L- shaped profiles,

wherein the elements are joined to form a curved frame that defines or surrounds at least one opening, wherein the opening is closed by at least one panel, particularly a panel that is curved or bended into the opening onto the frame during assembly.

The frame can be used as a tool or support during a bending or deformation process of the respective panel, as is mentioned before. To that aim, a flat panel-preform can be used, the preform having a predetermined contour that will match the shape of the curved support frame and fit into the frame after bending of the panel. The determining of the shape of the preform can be calculated beforehand using based e.g. on bending

parameters of the first and second elements, as will be appreciated by the skilled person. In this fifth aspect it is particularly preferred to additionally apply the option of providing a said third curved reinforcement element, the third element being joined to the second element, the second element forming or acting as a thermally insulating connection between the first and third element.

During a panel bending process, e.g., said second (and optional third) element can function as lateral guides for guiding the panel towards a supporting surface of a said first element, particularly in the case the elements together have a substantially T-shaped or L-shaped cross-section.

Further aspects of the invention provide a said a support structure as such, as well as a wall structure, for example an external structure of a building, the wall structure including at least one wall that consists of or includes a support structure manufactured by a method according to the invention.

Further advantageous embodiments are described in the dependent claims. The invention will now be elucidated referring to the embodiments shown in the drawings. Therein shows:

Figure 1 a perspective view of a first, second and third element, each still being flat in one respective plane;

Figure 2 a perspective view similar to Fig. 1, after bending of the elements;

Figure 3 a perspective view similar to Fig. 2, after joining the elements;

Figure 4 a perspective view of a first step of manufacturing an element: defining a preform of the element in a flat sheet;

Figure 5 a perspective view of a second step of manufacturing the element: the cutting out of the curved element from a flat sheet;

Figure 6 a perspective view of a third step of manufacturing the element, the further bending of the curved element;

Figure 7 a cross-section over line VII-VII of Figure 8, of a support structure; and

Figure 8 schematically a front view of a panel system, including a number of support structures. Corresponding or similar features are denoted by corresponding or similar reference signs in this patent application.

Figures 1-6 depict various steps for manufacturing a support structure S. A non-limiting example of such a support structure is shown in Figures 7-8, wherein Figure 8 shows four support structures (each having a respective first element 1, 101, 201, 301) that define an opening which is closed by a panel P. The support structure can have a relatively complex curved shape, and is preferably thermally insulating.

Referring to Figure 1, a preferred, efficient method for

manufacturing a support structure S includes providing at least a first flat elongated element 1 having a curvature in a corresponding first plane PI that is substantially in parallel with respect to faced-away longitudinal side surfaces la of that element 1. Said curvature of the first element 1 can include one or more bends, particularly each bend having a corresponding bending axis that extends normally with respect to the corresponding first plane P I. In this example, the first element has an S-shape (with two smooth bends in opposite directions) in the respective first plane PI.

Particularly, the first element 1 is an elongated strip, with said faced-away longitudinal side surfaces la extending in parallel, the element 1 also having two faced-away outer edge surfaces lb extending between the longitudinal edges of the side surfaces la (see also the cross-section in Fig. 7). The first element 1 may have a substantially rectangular cross -section as in this example, but that is not required.

Further, the manufacturing method includes providing at least a second flat elongated element 2, to be joined with a said first element 1, the second element 2 having a curvature in a second corresponding plane P2 that extends substantially in parallel with respect to faced-away

longitudinal side surfaces of that element 2. Similar to the first element, the curvature of the second element 2 can include one or more bends. In this example, the second element 2 has a arcuate C -shape (with a single smooth bend) in the respective second plane P2. Particularly, the second element 2 can be an elongated strip, with said faced-away longitudinal side surfaces 2a extending in parallel, the element 2 also having two faced-away outer edge surfaces 2b extending between the longitudinal edges of the side surfaces 2a (see also the cross-section in Fig. 7). Each second element 2 may have a substantially rectangular cross-section as in this example, but that is not required.

The present embodiment also includes the optional manufacturing of a respective third flat elongated element 3, to be joined with a first element 1 and second element 2.

The third element 3 has a curvature in a third corresponding plane P3 that extends substantially in parallel with respect to faced-away longitudinal side surfaces 3b of that element 3 (see also Fig. 7). Similar to the first and second element, the curvature of the third element 3 can include one or more bends. In this example, the third element 3 has a arcuate C-shape (with a single smooth bend) in the respective third plane P3, the third element 3 in particular having the same shape as the second element 2. The third element 3 can also be an elongated strip, with said faced-away longitudinal side surfaces 3a extending in parallel, the element 3 also having two faced-away outer edge surfaces 3b extending between the longitudinal edges of the side surfaces 3a (see also the cross-section in Fig. 7). Each third element 3 may have a substantially rectangular cross-section as in this example, but that is not required.

The thus provided initially flat (in respective flat planes PI, P2, P3), curved elements 1, 2, 3 are curved further, as is shown in Figure 2. Particularly, this involves curving the first elongated element 1 out of the respective first PI, and curving the respective second element 2 by bending that element 2 out of the respective second plane P2 such that they can be joined with a first side surface la of the first element 1 receiving a first lateral edge 2b of the respective second element 2 (as in Figure 3). As particularly follows from the drawings, this further curving step involves bending with each bend having a corresponding bending axis that extends in parallel with respect to corresponding lateral side surfaces la, 2a of the respective element 1, 2.

In this example, the third element 3 is further bended in substantially the same way as the second element 2 (i.e. out of a respective third plane P3), such that these two elements 2, 3 can be joined by connecting opposite lateral edges 2b, 3b (as in Fig. 3). In other words, this involves curving the third elongated element 3 out of the respective third plane P3 such that it can be joined with a second lateral edge or a second side of the respective second element 2 that is faced away from the first lateral edge of that second element 2 (the first lateral edge of the second element 2 is the edge side that connects to the first element 1 during joining).

In the example the resulting profile or structure of the three elements has a substantially T-shaped cross-section, wherein a said first element 1 forms an upper wing of the T and the mutually aligned second element 2 and third element 3 jointly form the normally extending center wing of the T.

Figures 4-6 show a process of providing one of such elements, in this case an alternatively shaped second element 2', in more detail. In the example, flat sheet material, e.g. a flat plate 50 is provided, the plate 50 defining a respective (second) flat plane P2'. As is shown in Figure 4, a contour (or flat outline F) of the curved element 2' is defined on/in the plate 50. The element 2' can be cut out from the plate 50, following the defined flat outline F, using for example a cutting tool, a laser, a water jet cutter, or different beam cutting device, or the-like (depending e.g. on the material). This is shown in Figure 5. In the example, the flat outline also defines a respective part of an alignment structure 12' of the element 2', to be used for engagement with an alignment structure of another element during joining (see below, and Figures 2-3). Referring to Figure 6, a next

manufacturing step is the further bending of the curved element 2', out of the respective plane P2'. Each of the first, second and third element 1, 2, 3 may be provided in this manner, wherein a preform of the element 1, 2 3 is cut out of a flat plate or sheet material. In another embodiment, for example, a curved element 2 or a curved elongated preform thereof may be made using e.g. a moulding process (e.g. injection moulding), or by an extrusion process, for example in case the element is made or substantially consists of plastic.

Referring to Figures 1-3 it is preferred that the first side surface of the first element 1 and the first lateral edge of the second element 2 are provided with a respective alignment structure 11, 12 for mutual alignment during joining. Such an alignment structure can have various

configurations, as has been explained before, for example, it can be an interlocking cam-groove structure, relief or other shape configured to cooperate and align the respective elements during joining. In the drawings, the alignment structure includes an array of holes or through -holes 11 in the first flat elongated element 1, as well as an array of engagement protrusions 12 on a first lateral edge 2b of the second element 2. The array of protrusions 12 is arranged for engaging the holes or through-holes 11 of the first flat elongated element 1 during the joining step. Optionally, the alignment structures 11, 12 can be configured to provide a clamping or clicking attachment of the respective elements 1, 2 during joining. Joining the elements 1, 2 can be carried out efficiently, swiftly, and accurately in this manner.

Similarly, opposite side edges 2b, 3b of the second and optional third element 2, 3 may include respective alignment structures for aligning those elements 2, 3 during joining.

The joining of the first and second element 1, 2 can include the alignment structure 11, 12 aligning the elements 1, 2 when they are moved onto each other, after which the elements 1, 2 can be irremovable attached using e.g. adhesive, clamping, glue, a thermal bonding process, welding, soldering, or a combination of such means, and depending e.g. on the material of those elements. For example in case both elements 1, 2 are made of metal or an alloy, welding the elements together might be preferred.

However, in case one of the elements 1, 2 is made of a material different than metal and alloy, another bonding process than welding might be preferred, e.g. a process using a curable adhesive (e.g. glue).

The at least two, for example three elements 1, 2, 3 that are joined to form a structure S can be made from various materials. In the present example, the first and third element 1, 3 can be made of metal or an alloy (e.g. aluminum or steel) , wherein the second element 2 is substantially made of a material that differs from the material of the first element 1, the second element 2 particularly having a non-metal composition. As an example, each second element 2 can be substantially made of plastic, and/or a fiber-reinforced material or compound. In case a sturdy structure S is desired, it is preferred that all of the elements 1, 2, 3 are substantially made of rigid material. For example, this can be achieved by the first and third element being made of an alloy or metal, and the intermediate second element being manufactured from a rigid fiber reinforced plastic or compound material. Moreover, it is preferred that the intermediate second element 2, is made of thermally insulating material, particularly a material having a thermal heat conductivity of at most 1 W/(m K), preferably at most 0.2 W/(m K). In that case, the other elements, for example the first and third element, can be have a thermal heat conductivity that is significantly higher than the thermal heat conductivity of the thermally insulating material, for example higher by a factor of at least 10 or 100. Thus, a strong, durable thermally insulating, curved support structure S can be achieved.

In a further embodiment, a non-limiting example being depicted in Figures 7 and 8, a frame K including an assembly of joined first elements 1 and second elements 2 is formed, the frame defining or surrounding at least one opening, particularly an opening to be closed by at least one panel P. Figure 7 shows a cross-section of one of the support frames, in a XY-plane, and figure 8 shows a front view of a panel system in a YZ plane that is orthogonal with respect to said XY plane (said planes XY and YZ being indicated by arrows in these drawings).

As follows from Figure 7 and 8, panels P (one shown in Figure 8) can be directly or indirectly supported on inner longitudinal sides la of the first elements 1, 101, 201, 301 of the four interconnected support structures.

The panel or panels P, to be used in the system, can include for example at least one curved panel of optically transparent material, for example a curved glass sheet. As follows from Figures 7-8, the first elements can extend along a front side Si of the panel P after assembly. Second elements 2 of the structure can extends along an lateral edge sides of the panel P.

The panel P can be held (e.g. clamped) in place by or via the third elements 3. In the example, third elements 3, 13 are connected to the second elements 2 of the support structures, wherein support parts 13 of the third elements, or support parts 1 connected to the third elements 3, extends along a back side S2 of the panel P that is faced away from said front side (said panel edge sides extending between said front sides Si and back sides S2 in this example). In the present example, said support parts 13 are shown as separate elements, that are attached (e.g. glued or welded) to longitudinal sides 3a of the third elements 3.

In the example, sealing means 8, 9 is provided between a said panel P and supporting elements 1, 13, for example a resilient structure and/or sealing kit.

Also, in the present example, the formed curved panel supporting structures S have substantially T-shaped cross-sections (as in Figures 3 and 7). It should be observed that in such form, the first element 1 and respective second element 2 (and optional third element 3) may extend perpendicularly with respect to each other as in the present drawings (with respective longitudinal center planes enclosing an angle of 90 degrees), however, that is not required. In an alternative embodiment, the first element 1 and second element 2 may be joined at an angle (that is, respective longitudinal center planes enclosing an angle in smaller than 90 degrees, for example an angle in the range of 45-90 degrees).

Besides, one or more of the formed curved panel supporting structures S may be arranged to have a L-shaped cross-section. In that case, also, the first element 1 and respective second element 2 (and optional third element 3) may extend perpendicularly with respect to each other, but that is not required.

The system shown in Figure 8 can be a wall or window, or part thereof. During assembly, a pre-bended panel P can be installed, which matches the shape of the curved supporting frame 1, 101, 201, 301.

Alternatively, the panel P may be initially flat, to be pressed or deformed during assembly with the curved frame 1, 101, 201, 301.

Referring to Figure 7, more particularly, each panel P may be is a thermal insulation panel which is provided with two parallel glass sheets ("double glazing"). In addition, a panel P can for instance comprise only one sheet (for instance of glass) or more than two (for instance three spaced apart parallel glass sheets). In Fig. 1, end faces of neighbouring panels P bound a space H. The system shown in Figures 7-8 can be positioned in different manners, for instance vertically, horizontally or at an inclination (with respect to a horizontal plane).

As shown in Fig. 7, 8 the system comprises curved first elements 1, 101, 201, 301 which extend along first edges of the panel P, and for example along two first edges of two neighbouring panels P. Each first element 1, 101, 201, 301 can cover the edges of the panel(s), viewed in front view. Each first element 1, 101, 201, 301 can be of particularly slim design, having a (transversal) width LI, measured in a cross direction (according to arrow Y) with regard to a respective panel edge (i.e., measured in a direction parallel to the panels P), which is less than approximately 5 cm. Preferably, each first element 1, 101, 201, 301 has a maximum width LI of 4 cm, preferably 3 cm, measured in a direction transverse to the

longitudinal edges mentioned. Alternatively, the first element can have a width LI of 5 cm or more.

Each curved first element 1, 101, 201, 301 has a very simple configuration, and is preferably designed in solid metal, having, for instance, a substantially rectangular cross section. In this case, the first elements 1, 101, 201, 301 preferably extends parallel to the front surfaces of the panel P. More preferred, each first element 1, 101, 201, 301 can be is a solid element, made from steel (in particular stainless steel) or aluminum. The first elements 1, 101, 201, 301 can for instance provide the system with a certain rigidity and strength, so that relatively large panels P can durably be held in position. As further shown in the drawing, the first elements 1, 101, 201, 301 can be located completely outside a panel front surface Si.

A thickness L2 of each first element 1, 101, 201, 301 can for instance be greater than 1 mm, in particular greater than 2 mm, for instance a thickness in the range of approximately 2 - 15 mm. A ratio between the width LI and thickness L2 of the first element 1, i.e. L1:L2 can for instance be in the range of 10: 1-2: 1, in particular 6: 1 - 3: 1.

A length of the first element 1, measured orthogonally with respect to the width LI and thickness L2, can be significantly larger than said width L3, for example at least 10 times larger, particularly at least 30 times larger. In an embodiment, the element's length can be at least 0.5 meter, for example 1 meter or more.

Similarly, each curved second element 2 of the system shown in Figures 7, 8 can also be of particularly slim design, having a (transversal) width, measured in a cross direction which is less than approximately 5 cm. A thickness of each second element 2 can for instance be greater than 1 mm, in particular greater than 2 mm, for instance a thickness in the range of approximately 2 - 15 mm. A ratio between the width and thickness of the second element 2, can for instance be in the range of 10:1-2:1, in particular 6: 1 - 3:1.

In addition, each curved third element 3 of the system shown in Figures 7, 8 can be of particularly slim design, having a (transversal) width, measured in a cross direction which is less than approximately 5 cm. A thickness of each third element 3 can for instance be greater than 1 mm, in particular greater than 2 mm, for instance a thickness in the range of approximately 2 - 15 mm. A ratio between the width and thickness of the third element 3, can for instance be in the range of 10: 1-2:1, in particular 6:1 - 3: 1.

Preferably, first thermally insulating means 8 are provided between the first elements 1, 101, 201, 301 and the panel(s) P, for instance sealing means or plastic strips 8. The thermally insulating means (which are preferably manufactured from resilient material, for instance rubber, an elastomer or the hke), are preferably also designed for forming a watertight seal between panel outsides and an opposite inside of the first elements 1, 101, 201, 301. Preferably, an inside of the first element 1, 101, 201, 301 is at a relatively short distance L3 of opposite panel outside(s), for instance a distance L3 which is approximately equal to a thickness L2 of this element 1, 101, 201, 301 , or a smaller distance.

Further, after assembly, the system is provided with the support parts 13, functioning, for instance, as glazing beads which extend along inner second edges of the panel(s) P (these second panel edges are parallel to the first edges, and are located at the same panel end faces arranged opposite each other as the first edges). In the elaboration of Figures 7-8, second thermally insulating means 9 are provided between each support part 13 and an opposite panel side, for instance sealing means or plastic strips 9. A support part 13 can be designed in various ways, and may comprise, for instance, a tube, tubular profile, a U-shaped profile, a glazing bead or the like. A support part may be also manufactured from steel (in particular stainless steel). Alternatively, a second element can be

manufactured from a metal (for instance aluminum) wood or plastic or a different material.

In addition, each inner panel support part 13 may be manufactured in the same ways as the above-described steps for manufacturing a said first element 1 or second element 2 as such (as in Figures 4-6), wherein an initially flat curved support part 13 (e.g. cut out of a flat sheet material) is further bended out of its plane, particularly to match the curved shape of an opposite inner side la of a respective first element 1, to hold the panel P there-between after assembly.

Also, for example, a number of curved elements 1, 2, 3, 13 can be manufactured to be joined to form an H-profile (i.e. having an H-shape viewed in transversal cross-section), or a U-profile (i.e. having a U-shape viewed in transversal cross-section), or a Z-shaped or O-shaped profile, or a hollow beam having an angular, square or rectangular cross section, as will be appreciated by the skilled person.

A width LI of a first element 1 can for instance be approximately equal to or even be less than a panel width L5. Alternatively the width LI mentioned of a first element 1 may be greater than a panel width L5.

In a further embodiment, each third element 3 can be of a particularly simple design. The element 3 may consists of an elongated solid metal or steel connecting element (for instance a supporting beam), preferably with a thickness (measured in a direction Y parallel to a panel front face Si) which is greater than 1 mm, in particular greater than 2 mm, for instance a thickness in the range of approximately 2 - 15 mm. In the examples, the third elements 3 do not have recesses or passages, however, that is not required. As follows from the drawing, in this case, the third elements 3 extends at substantially right angles to the first elements 1. The third elements may reaches along the end face of the panel (into the intermediate space H), but that is not required. After assembly, a said third element 3 may also extend entirely outside the space H that lies opposite the panel edge.

In the example, the third elements 3 do not touch the panel (s) P, and are indirectly connected to the respective first elements 1, 101, 201, 301 by means of intermediate thermal insulating parts 2.

As follows from the Figures, the second elements 2 can be located substantially (for instance for over 50%, for instance volume%, mass% or both, as is the case in this example) in the system inner space H (i.e. the space that is located opposite the panel edge).

It is preferred that each second curved element 2 is manufactured from, for instance, plastic, rubber, an elastomer or another suitable, thermally insulating material. The second curved element 2 is preferably designed for substantially preventing heat transfer through the system. Preferably, after assembly, the second curved elements 2 doe not touch the panel(s) P; in the example, relatively narrow slits are present between the second curved elements 2 and panel end faces.

It should be clear to the person skilled in the art that the invention is not limited to the embodiments described above. Many alternatives are possible within the scope of protection as formulated in the claims hereafter.

In this application, the term "a" should be construed broadly since it is not limited to "only one" but can also mean "at least one" or "one or more". For example, a said initially flat element 1, 2, 3 may have one or more curvatures, viewed in a corresponding plane.

The resulting system, shown in Figure 8, is durable and strong. In this particular example, the third elements 3 are particularly arranged for substantially absorbing forces in a direction perpendicular to the panel front surface S 1 (in the X-direction), for the purpose of preventing the system from bending under the influence of such forces (e.g. a wind force). In addition, the respective first elements 1 are arranged for substantially absorbing forces in directions in parallel with the panel front surface Si (in X-direction and/or Z-direction), for the purpose of preventing the system from bending under the influence of such forces (e.g. gravity in case the YZ plane is a substantially vertical plane).

In this specification, the term "solid element" means for instance that this element is not a tubular section and does for instance not enclose a space in itself. In particular, the solid element in itself has no inside surfaces extending opposite to each other (but for instance only a continuous outside surface).

For instance, a connection between certain parts of the system may comprise a glue connection, or a different connection, for instance a mechanical connection, a snap connection and/or a clamping connection. A clamping connection can for instance form integral part of the respective parts to be clamped together, by being manufactured in one piece with those parts, and is preferably provided with a sealing means (for instance glue or sealant).

Furthermore, a said first element 1, second element 2 or further

(e.g. third) element 3 may have various curvatures. A said element 1, 2, 3 may also be deformed in one or more additional deformation steps around an axial center line, leading to torsional deformation.

Besides, it is preferred that a said first elongated element 1 is bended out of the respective first plane PI, using cold deformation (e.g. bending without substantially heating up that element, such as bending at ambient or room temperature). The same holds for the bending of a said second element 2 out of the respective second plane P2,and the bending of a said third element 3 out of a respective third plane P3. Similarly, it is preferred that a deformation of a panel P is carried out without substantially heating up that panel P, such as bending at ambient or room temperature (cold bending).

In this application, the term "flat elongated" regarding an element 1, 2, 3 particularly means that the element' s length is significantly larger than the element's width, and that the element's width is significantly larger than the element's thickness. Herein, the length, width and thickness of the element can be orthogonal dimensions of the element. For example, a length of the element 1, 2, 3 can be at least 30x its width. A length of the element 1, 2, 3 can be at least 0.5 meter, particularly at least 1 meter. Also, a thickness of the element 1, 2, 3can be at most half the width of that element 1, 2, 3.

It will be appreciated that a length of the second element 2 can be substantially the same as the length of a respective first element 1, so that they can be joined along substantially their entire lengths. In an alternative embodiment, a plurality of first elements 1 is joined to a single second element 2, or vice-versa, in which case the elements do not have to be of the same length. This also holds for further (e.g. third) elements of the system. For example, a said third element can have substantially the same length of a said second element to which it is joined, but that is not required.

Besides, in a further embodiment two or more second elements 2 can be joined in parallel with/to a side surface of a said first element 1, particularly in a spaced-apart configuration. In that case, optionally, the first element 1 and respective parallel second elements 2 can be provided with an alignment structure configured for alignment of the second elements 2 with respect to the single first element 1 during joining.

According to a further embodiment, the alignment structure can consist of or include a longitudinal groove or slit, extending longitudinally in the first side surface of the first element 1. In that embodiment, the second element 2 can be simply engaged by the first element 1 by pushing or otherwise introducing the first lateral edge of the second element into that

longitudinal groove/slit. In that case, the later first lateral edge acts as part of the alignment structure.

For example, a said flat elongated element 1, 2, 3 can be a strip - like element. Preferably, that element has two smooth faced-away side surfaces that extend in parallel but that is not required. For example, the faced-away longitudinal sides of the flat element can extend along respective planes that include an angle >0 degrees with each other. The flat element may have a rectangular cross-section, a trapezoid cross-section, a parallelogram cross-section, an oval cross-section or differently. Each side surface of a said flat elongated element 1, 2, 3 may be entirely smooth or continuous/uninterrupted, or it may include a relief or structure, one or more apertures, one or more protrusions or other forms or configurations.

Claims

1. Method for manufacturing a support structure including:

-providing at least a first flat elongated element (1) having a curvature in a corresponding first plane (P I) that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1);

-providing at least a second flat elongated element (2), to be joined with a said first element (1), the second element (2) having a curvature in a second corresponding plane (P2) that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element (2);

-further curving both the first elongated element (1) and a respective second element (2) by bending the respective element (1, 2) out of the respective first and second plane (PI, P2) such that they can be joined with a first side surface of the first element (1) receiving a first lateral edge of the respective second element (2); and

-joining at least the first element (1) and respective second element (2);

wherein the first side surface of the first element (1) and the first lateral edge of the second element (2) are provided with an alignment structure (11, 12) for mutual alignment during joining.

2. Method according to claim 1, wherein the alignment structure include a cam-groove structure.

3. Method according to claim 1 or 2, including providing holes or through-holes in the first flat elongated element (1) to provide part of the alignment structure.

4. Method according to claim 3, including providing engagement protrusions on the first lateral edge of the second element (2) for engaging the holes or through-holes of the first flat elongated element (1) during joining.

5. Method according to any of the preceding claims, wherein at least one of the first and second flat elongated element, and preferably both, is/are provided by cutting out from flat sheet material.

6. Method according to any of the preceding claims, wherein at least one of the first and second flat elongated element, and preferably both, is/are provided by cutting using a beam cutting device, for example a laser.

7. Method according to any of the preceding claims, wherein each first element (2) is made of metal or an alloy, wherein each second element (2) is substantially made of a material that differs from the material of the first element (1), the second element (2) particularly having a non-metal composition.

8. Method according to any of the preceding claims, wherein one of the elements (2), particularly each second element (2), is substantially made of plastic.

9. Method according to any of the preceding claims, wherein one of the elements (2), particularly each second element (2), is substantially made of a fiber-reinforced material.

10. Method according to any of the preceding claims, wherein one of the elements (2), particularly each second element (2), is substantially made of a rigid composite material.

11. Method according to any of the preceding claims, wherein one of the elements (2), particularly each second element (2), is made of thermally insulating material, particularly a material having a thermal heat conductivity of at most 1 W/(m K), preferably at most 0.2 W/(m K).

12. Method according to any of claim 11, wherein one of the elements

(1) has a thermal heat conductivity that is significantly higher than the thermal heat conductivity of the thermally insulating material, for example higher by a factor of at least 10 or 100.

13. Method according to any of the preceding claims, wherein a frame including an assembly of joined first elements (1) and second elements (2) is formed, the frame defining or surrounding at least one opening, particularly an opening to be closed by at least one panel (P).

14. Method according to any of the preceding claims, including:

-providing at least a third flat elongated element (3), to be joined with a said second element (2), spaced-apart from said first element (2),

the third element (2) having a curvature in a third corresponding plane (P3) that extends substantially in parallel with respect to faced-away

longitudinal side surfaces of that element (3);

- curving the third elongated element (3) out of the respective third plane (P3) such that it can be joined with a second lateral edge or a second side of the respective second element (2) that is faced away from the first lateral edge of that second element (2); and

-joining the third element (3) to the second element (2).

15. Method according to any of the preceding claims, wherein the joined at least one first element (1) and the respective second element (2) are provided with at least one panel (P), for example at least one panel of optically transparent material, for example a glass sheet, for supporting that panel (P).

16. Method according to claim 15, wherein the first element (1) extends along a front side (Si) of the panel, and the second element (2) extends along an edge side (E) of the panel (P), wherein preferably at least a third element (3, 13) is connected to the second element (2), wherein the third element (3) or a further element (13) connected to the third element (3) is arranged to extend along a back side (S2) of the panel (P) that is faced away from said front side.

17. Method according to any of claims 15-16, wherein a sealing means is provided between a said panel (P) and element (1, 3), for example a resilient structure and/or sealing kit.

18. Method according to any of the preceding claims, wherein the first and respective second element (1, 2) are joined to form a curved profile having a substantially T-shaped or L-shaped cross-section.

19. Method according to any of the preceding claims, wherein the first and respective second element are attached to each other using adhesive and/or clamping.

20. Method for manufacturing a support structure, for example a method according to any of the preceding claims, the method including: -providing at least a first flat elongated element (1) having a curvature in a corresponding first plane (P I) that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1);

-providing at least a second flat elongated element (2), to be joined with a said first element (1), the second element (2) having a curvature in a second corresponding plane (P2) that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1);

-joining at least the first element (1) and respective second element (2); wherein the first element (1) is made of metal or an alloy, wherein the second element (2) is made of a thermally insulating material.

21. Method for manufacturing a support structure, for example a method according to any of the preceding claims, the method including:

-providing a plurality of first flat elongated elements (1) each having a respective curvature in a corresponding first plane (P I) that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1); -providing a plurality of second flat elongated elements (2), to be joined with respective first elements (1), each second element (2) having a curvature in a second corresponding plane (P2) that extends substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1); -further curving both a said first elongated element (1) and a respective second element (2) by bending the respective element (1, 2) out of the respective first and second plane (PI, P2) such that they can be joined with a first side surface of the first element (1) receiving a first lateral edge of the respective second element (2); and

-joining corresponding pairs of first elements (1) and respective second elements (2) thereby forming respective profiles, for example T-shaped or L- shaped profiles,

wherein the elements (1, 2) are joined to form a frame that defines or surrounds at least one opening, wherein the opening is closed by at least one panel (P) , particularly a panel that is curved or bended into the opening onto the frame during assembly.

22. Method for manufacturing a support structure including:

-providing at least a first flat elongated element (1) having a curvature in a corresponding first plane (PI) that is substantially in parallel with respect to faced-away longitudinal side surfaces of that element (1);

longitudinal side surfaces of that element (3); -further curving both the first elongated element (1) and a respective second element (2) by bending the respective element (1, 2) out of the respective first and second plane (PI, P2) such that they can be joined with a first side surface or lateral edge of the first element (1) receiving a first lateral edge of the respective second element (2); and

- further curving the third elongated element (3) out of the respective third plane (P3) such that it can be joined with a second lateral edge or a second side of the respective second element (2) that is faced away from the first lateral edge of that second element (2); and

-joining at least the first element (1), respective second element (2) and respective third element (2).

23. A method according to claim 22, wherein the first element (1) is arranged to substantially absorb external forces from a first direction (Y; Z), wherein the third element (3) is arranged to substantially absorb external forces from a second direction (X) that is substantially orthogonal to said first direction (Y; Z).

24. A support structure, particularly manufactured by a method according to any of the preceding claims.

25. A wall structure, for example an external structure of a building, the wall structure including at least one wall that consists of or includes a support structure manufactured by a method according to any of claims 1- 23.