CURTI, Stefano (Via Cavallotti 6, Mortara, I-26841, IT)
VIOLANTE, Vincenzo (Via Carlo Santor 73, Cava Dè Tirreni, I-84127, IT)
CURTI, Stefano (Via Cavallotti 6, Mortara, I-26841, IT)
CLAIMS
1. A metal board for scaffolding comprising a metal base sheet, at least one support member and means for connecting said at least one support member to said base sheet, characterised in that said connecting means comprise a plurality of tabs extending transversally from said base sheet or respectively from said at least one support member, said tabs projecting through a plurality of apertures in said at least one support member or respectively in said base sheet and further extending along said at least one support member or respectively along said base sheet so as to be able to overlap said at least one support member or respectively said base sheet in a junction zone there between.
2. A metal board as claimed in claim 1 , characterised in that said at least one support member comprises an edge of said base sheet shaped to form said support member.
3. A metal board as claimed in any preceding claim, characterised in that said tabs are tapered.
4. A metal board as claimed in any preceding claim, characterised in that said base sheet comprises stiffening means.
5. A metal board as claimed in claim 4, characterised in that said stiffening means comprise elongated protrusions from said base sheet.
6. A metal board as claimed in any preceding claim, characterised in that said base sheet comprises anti-slip means.
7. A metal board as claimed in claim 6, characterised in that said anti-slip means comprise protrusions from said base sheet.
8. A metal board as claimed in any preceding claim, characterised in that said base sheet comprises means for liquid drainage.
9. A metal board as claimed in claim 8, characterised in that said drainage means comprise secondary apertures in said base sheet.
10. A metal board as claimed in any preceding claim, characterised in that said base sheet comprises retaining means.
11. A metal board as claimed in claim 10, characterised in that said retaining means comprise stacking protrusions in said base sheet.
12. A process for manufacturing a . metal board for scaffolding, said metal board comprising a metal base sheet, at least one support member and means for connecting said support member to said base sheet, characterised in that it comprises, along a single production line: a first step of unwinding a roll of said base sheet; a second step of creating a plurality of apertures, and placing a plurality of cuts, in said unwound base sheet; a third step of bending said base sheet at said cuts so as to create a plurality of tabs extending transversally there from; a fourth step of shaping at least one edge of said base sheet so as to form at least one support member, such that said tabs are aligned with and project through said apertures; a fifth step of bending said tabs such that they extend along said at least one support member or said base sheet so as to overlap said at least one support member or respectively said base sheet in a junction zone there between; a sixth step of cutting said base sheet into sections of desired length.
13. A process as claimed in claim 12, characterised in that said cuts are tapered.
14. A process as claimed in claims 12 or 13, characterised in that said bending of said tabs is by means of compression rollers.
15. A process as claimed in any of claims 12 to 14, characterised in that it comprises a further step of creating a plurality of elongated protrusions in said base sheet for stiffening.
16. A process as claimed in any of claims 12 to 15, characterised in that it comprises a further step of creating a plurality of protrusions in said base sheet for anti-slip.
17. A process as claimed in any of claims 12 to 16, characterised in that it comprises a further step of creating a plurality of secondary apertures in said base sheet for liquid drainage.
18. A process as claimed in any of claims 12 to 17, characterised in that it comprises a further step of creating a plurality of stacking protrusions in said base sheet for retaining. |
METAL BOARD FOR SCAFFOLDING AND METHOD OF MANUFACTURING THE SAME
The present invention relates to a metal board for scaffolding and a method of manufacturing the same.
Scaffolding metal boards known in the state of the art comprise a metal base sheet and at least one support member. The metal base sheet is usually made of steel, and it is usually connected to the support member by means of welding.
Current scaffolding metal boards have a number of drawbacks.
In particular, connecting the support to the base sheet by welding gives rise to the possibility of corrosion at the junction. Such corrosion can subsequently spread to other parts of the unit and clearly presents a serious safety hazard.
A further drawback of current metal boards is the high energy consumption for the production process including a welding phase.
The technical task proposed by the present invention is therefore that of providing a metal board for scaffolding and a method of manufacturing the same which overcome the noted technical drawbacks of the prior art.
Within the scope of this technical task, one object of the invention is that of providing a metal board for scaffolding with a metal base sheet and ^ at least one support member connected thereto, while minimising the risk of corrosion.
Another object of the invention is that of providing a metal board of simple, robust design for scaffolding.
A last but not least object of the invention is that of providing an energy-efficient method of manufacturing a metal board for scaffolding.
The technical task, as well as these and other objects, are achieved according to the present invention by a metal board for scaffolding, said metal board comprising a metal base sheet, at least one support member and means for connecting said at least one support member to said base sheet, characterised in that said connecting means comprise a plurality of tabs extending transversally from said base sheet or respectively from said at least one support member, said tabs projecting through a plurality of apertures in said at least one support member or respectively in said base sheet and further extending along said at least one support member or respectively along said base sheet so as to be able to overlap said at least one support member or respectively said base sheet in a junction zone there between.
The present invention also relates to a process for manufacturing a metal board for scaffolding, said metal board comprising a metal base sheet, at least one support member and means for connecting said support member to said base sheet, characterised in that it comprises, along a single production line: a) a first step of unwinding a roll of said base sheet; b) a second step of creating a plurality of apertures, and placing a plurality of cuts, in said unwound base sheet; c) a third step of bending said base sheet at said cuts so as to create a plurality of tabs extending transversally there from;
d) a fourth step of shaping at least one edge of said base sheet so as to form at least one support member, such that said tabs are aligned with and project through said apertures; e) a fifth step of bending said tabs such that they extend along said at least one support member or said base sheet so as to overlap said at least one support member or respectively said base sheet in a junction zone there between; f) a sixth step of cutting said base sheet into sections of desired length.
The use of connecting means that do not involve welding helps to avoid the risk of corrosion.
The connecting means of the present invention comprise a form of "mechanical stitching" by passing tabs from either the base sheet or the support member through corresponding apertures in the other member, and subsequently folding the tabs such that they overlap this member. The design of the unit and the method of manufacturing it on a single production line provide a simple, robust connection and can be accomplished without the high energy requirements of welding.
Advantageously, the process of manufacturing the metal boards on a single production line prevents lateral displacement and thus ensures perfect alignment of the support member with the base sheet.
As the step of cutting the base sheet into metal boards is the last in the process, this process allows great flexibility of choice of the length of the metal boards.
Other characteristics of the present invention are moreover defined in the subsequent claims. Further characteristics and advantages of the present invention will be more evident from the description of a preferred, but not exclusive embodiment of the metal board for scaffolding and the method for producing the same according to the finding, illustrated in the attached non-limiting drawings, wherein:
Figure 1 shows a schematic perspective view of the metal board in accordance with one embodiment of the invention.
Figure 2 shows a top view of a section of the metal board.
Figure 3 shows a cross-sectional side view of the metal board along line A-A of figure 2.
Figure 4 shows a cross-sectional view of the connecting means along line B-B of figure 2 during processing.
Figure 5 shows a top view of a section of the metal base sheet during processing.
With reference to the above figures, the metal board (1 ) comprises a metal base sheet (2), at least one support member (3A) (3B) (3C) 1 and connecting means (4) for connecting the at least one support member to the base sheet.
The connecting means (4) comprise a plurality of tabs (5) projecting from either the base sheet (2) or the support member (3A) (3B) (3C), extending through apertures (6) in the support member or the base sheet, respectively, and then extending along - and overlapping - the support member or base sheet, respectively.
Preferably, the tabs (5) are tapered so as to facilitate insertion into the apertures (6).
The support member (3A) (3B) (3C) can optionally be formed integrally with the base sheet (2) by folding an edge (2A) of said base sheet: for instance in the embodiment shown in the above figures, two support members (3A) (3B) are integrally formed with said base sheet (2) and one support member (3C) is individual.
The metal board can optionally also comprise stiffening means. These can be in a variety of forms, preferably in the form of elongated protrusions (7) extending from said base sheet.
Similarly, the metal board can optionally comprise anti-slip means. These can be in a variety of forms, preferably in the form of protrusions (8) extending from said base sheet.
Furthermore, the metal board can comprise liquid drainage means, preferably in the form of secondary apertures (9) in said base sheet. These allow the run-off of liquid from the surface of the unit.
The metal board may optionally also comprise retaining means, preferably in the form of a stacking protrusion (not shown) along the each of the front and rear edges of the base sheet (2) which, when metal boards are stacked, align beneath one another so as to help prevent lateral displacement of the metal boards.
The following is a non-limiting example of the manufacture of the metal board of the present invention.
The metal board (1) for scaffolding is manufactured on a single production line.
This involves a first step of unwinding a roll of metal base sheet (2). In a second step, a plurality of apertures (6) are created and a plurality of cuts (10) are made in the unwound base sheet. Preferably, the cuts (10) are tapered and the apertures (6) are elongated in nature and are at least as wide as the widest section of the tapered cuts. In a third step, the base sheet (2) is bent at said cuts (10) so as to create a plurality of tabs (5) extending transversally therefrom.
In a fourth step, at least one edge (2A) of the base sheet (2) is shaped so as to form at least one support member (3A) (3B), such that the tabs (5) are aligned with, and project through, the apertures (6), as shown in figure 4. The production along a single line prevents lateral displacement and thus ensures that this alignment is very precise. The tapered nature of the tabs (5) resulting from the tapered cuts (10) also facilitate insertion into the apertures (6).
In figure 5, the tabs (5) are located close to the centre of the base sheet (2) and the apertures (6) are shown as being along the edge (2A) of the base sheet and therefore becoming part of the support members (3A) (3B). However, it will be appreciated that the apertures can alternatively be created closer to the centre of the base sheet and the tabs be located along the edge, such that the tabs instead become part of the support members.
In a fifth step, as shown in figure 4, the tabs (5) are then bent such that they extend along the support member (3A) (3B), or respectively the base sheet (2), so as to
overlap this in a junction zone (11) therebetween. This is preferably carried out by use of compression rollers.
In a sixth and final step, the base sheet is cut into sections of desired length. This being the last step helps to prevent lateral displacement of the base sheet during processing and provides flexibility in choosing any desired length of unit.
Optional additional steps in the process include creating a plurality of elongated protrusions (7) in the base sheet (2) for stiffening, creating a plurality of protrusions (8) in the base sheet for anti-slip, creating a plurality of secondary apertures (9) in the base sheet for liquid drainage, and creating a plurality of stacking protrusions in the base sheet for preventing lateral movement of the metal boards when stacked. Preferably, these steps precede step four described above.
The metal board and the method of manufacturing the . same thus conceived is susceptible to numerous modifications and variations, all falling within the scope of the inventive concept; furthermore, all details may be substituted by technically equivalent elements. In practice, any material type or size may be used, according to needs and the state of the art.