TITLE OF THE INVENTION: A method of forming a closed metal frame unit and a thus produced metal frame unit

TECHNICAL FIELD

The present invention relates in general to a method of forming a closed metal frame unit, which, in a subsequent process step, may be put into use to form a complete flexurally rigid floor element.

Such a complete floor element thus consists of said metal frame unit whose surrounding metal frame parts constitute an outer mould for a concrete slab and where this concrete slab may advantageously support against a heat- and sound insulating layer, such as an insulating mat.

A metal frame unit according to the present invention will display a number, at least three, of coordinated metal frame parts, and with closely oriented metal profiles adapted to extend between and be fixedly connected to opposing metal frame parts, while the metal frame parts and the metal profiles rest against a supporting assembly table.

In addition, the present invention encompasses a metal frame unit, produced according to the method, and a floor element built up with the aid of the metal frame unit.

BACKGROUND ART

Methods, arrangements and constructions relating to the above disclosed technical field and with a function and a nature satisfying set requirements are previously known in the art in a plurality of different embodiments.

In general, it might be mentioned that it is previously known in the art to utilise an assembly table, to which are placed and fixedly clamped parts which are to be mechanically processed or treated, and it is also known in the art to clamp parts in a predetermined orientation where they are to be able to be welded together to one another to form a flexurally rigid fixed connection.

It is also previously known in the art that assembly tables of the type under consideration here display holes or the like distributed in rows and columns and each one of which being adapted to be able to retain and serve as a support for a part.

Taking into account the properties associated with the present invention, it might be mentioned that it is also per se previously known in the art to position, in a given sequential order, a number of parts on an assembly table, clamp them against the assembly table via supports and thereafter, in a flexurally rigid manner, weld together each one of formed connection points.

The present invention discloses a further development of these previously known principles and has for its object to realise an application for the production of a metal frame unit, directly adapted to be able to form part of the production of a floor element, with a relatively large surface extent, and intended to be able freely supporting to rest between support frames or support beams in a steel skeleton construction.

Two outer channel-shaped studs (10) and an inner channel shaped stud (12).

Studs (10 and 12) are positioned on a support surface (S), which must be level, and can be either a floor or, as preferred, a raised surface such as a platform or a table.

As oriented on support surface (S) studs (10, 12) each have an upper or concrete-side flange (20), a lower or insulation-side flange (22), and a web (24) extending between upper flange (20) and lower flange (22).

The flanges (20 and 22) of outermost studs (10) must be directed inwardly towards each other, while the flanks (20 and 22) of inner stud (12) must be directed towards one or the other of outermost studs (10).

Studs (10 and 12) preferably are disposed with their webs two feet apart, so that the distance between the outer surfaces of outermost studs (10) is four feet, the preferred width of the completed modular building panel.

Further, additional inner studs (12) can be inserted at two foot or other intervals to create d building panel that is, for example, six feet or eight feet in width. When additional inner studs (12) are inserted, their flanges should also be directed towards one of the outermost studs (10).

Additional structural strength is provided by beams (30).

Beams (30) are also channel-shaped, each beam (30) having an upper or concrete- side flange (32), a lower or insulations-side flange (34), and a web (36) connecting flanges (32 and 34).

Beams (30) are disposed perpendicular to studs (10 and 12) at the ends of studs (10 and 12) and with their flanges (32 and 34) directed inwardly and enclosing the ends offlanges (20 and 22).

Once studs (10 and 12) and beams (30) have been properly positioned on support surface (S) the joints between studs (10 and 12) and beams (30) are welded together to provide additional rigidity and strength to the resulting frame (40).

The three studs (10 and 12) and beams (30) define two interior chambers (42) in frame (40) into which insulation panels (50) are placed.

The proper alignment of studs (10 and 12) and beams (30 ) can in fact be determined by positioning insulation panels (50) between studs (10 and 12) and then adjusting

the positions of studs (10 and 12) until their webs (24 and 36) lie against the side edges of panels (50). Beams (30) can then be placed at the ends of studs (10 and 12) and welded into place.

Insulation panels (50) preferably are formed of fibreglass or styrofoam, or any other insulating material which is fire-resistant and suitable for construction purposes.

Insulation panels (50) are placed at a predetermined height above lower flanges (22), for example by resting them on a wood or metal formpiece (F) placed on the support surface (S).

Once bulkhead framework (B) and insulation panels (50) are in pace, a layer of concrete (60) is sprayed or foamed over insulation panels (50) using conventional equipment, completely filling the volume of interior chambers (42) above insulation panels (50) and extending over upper flanges (22) of studs (10 and 12) so that upper flanges (22) are embedded in the concrete layer (60).

BRIEF SUMMARY OF THE INVENTION TECHNICAL PROBLEM

Taking into account the circumstance that the technical considerations which a person skilled in the art must do in order to be able to offer a solution to one or more set technical problems is, on the one hand, initially a necessary insight into the measures and/or the sequence of measures to be implemented and, on the other hand, a necessary selection of the means required, in view hereof the following technical problems are likely to be relevant in the evolution of the subject matter of the present invention.

Taking into account the state of the art, as described above, it is probably therefore to be seen as a technical problem to realise the importance of, the advantages associated with and/or the technical measures and considerations which will be required in order, in a method for forming a closed metal frame unit with a number, at least

three, of coordinated metal frame parts, with metal profiles adapted to extend between and be fixedly connected to opposing metal frame parts, while the metal frame parts and the metal profiles rest against an assembly table, and where said closed metal frame unit, with fixedly connected metal profiles, is usable as a unit in order, in a subsequent process step, to make for the production of a floor element surrounded by the metal frame unit, with an upper fixed concrete slab and preferably a subjacent heat insulation layer, such as an insulating mat, to disclose the following sequence and pattern of action in order, in a simple manner, to create a fiexurally rigid metal frame unit, directly adapted to produce a floor element, by positioning one or more metal frame parts, of "L" or "U" configuration in cross section on the assembly table, with an orientation corresponding with a part of the periphery of said closed metal frame unit, and thereafter to position a number of coordinated metal profiles in a direction towards a metal frame part, or metal frame parts, where each one of these metal profiles is given a length which corresponds to a selected distance between opposing metal frame parts, and thereafter position one or more of the remaining metal frame parts against said assembly table for the formation of the closed metal frame unit and surround said metal profiles in order to fixedly unite the metal frame parts to one another and the metal profiles to their allocated metal frame parts.

There resides a technical problem in being able to realise the importance of, the advantages associated with and the technical considerations which may be referred to distributing, about the periphery of the assembly table, a number of force generating means and in such instance activate them simultaneously or in a sequence, said force generating means being able to urge the metal frame parts against the end surfaces of the metal profiles in order to form said closed metal frame unit and in addition make for the fixed connection of the diverging end surfaces of the metal profiles to corresponding surface portions of an adjacent metal frame part and fixedly connect the mutually facing end surfaces of the metal frame parts, or vice versa.

There resides a technical problem in being able to realise the importance of, the advantages associated with and/or the technical measures and considerations which

will be required in order to cause the end surfaces of said metal profiles, for example by means of welding or the like, to be fixedly and flexurally rigidly connected to adjacent metal frame part.

There resides a technical problem in being able to realise the importance of, the advantages associated with and/or the technical measures and considerations which will be required in order to cause a distance, adapted for welding, to be formed between the end surface of each respective metal profile and its proximal metal frame part.

There resides a technical problem in being able to realise the importance of, the advantages associated with and/or the technical measures and considerations which will be required in order to cause said distance to be formed, via a mechanical contact between the metal profile and the metal frame part, before the end surface of the metal profile directly abuts against the inner surface of the "U"-shaped frame part.

There resides a technical problem in being able to realise the importance of, the advantages associated with and/or the technical measures and considerations which will be required in order to cause an urging cooperation between the metal profile and the metal frame part to form said distance.

There resides a technical problem in being able to realise the importance of, the advantages associated with and/or the technical measures and considerations which will be required in order to cause the assembly table to display a number of distributed holes or other fixing points, in which or against which are placed one or more fixed supports, for fixedly retaining a metal profile between its allocated metal frame parts.

There resides a technical problem in being able to realise the importance of, the advantages associated with and/or the technical measures and considerations which will be required in order to cause each one of, or in any event selected, metal frame

parts to be urged by external means to their peripheral position or an allocated bending.

There resides a technical problem in being able to realise the importance of, the advantages associated with and/or the technical measures and considerations which will be required in order to cause said external means to display a press plate rotatably disposed in a vertical plane, oriented over the assembly table or alternatively a magnet.

SOLUTION

In such instance, the present invention takes as its point of departure the prior art technology as disclosed by way of introduction as regards a method of forming a closed metal frame unit, with a number, at least three, of coordinated metal frame parts, with metal profiles adapted to extend between and be fixedly connected to opposing metal frame parts, while the metal frame parts and the metal profiles are to be able to rest against an assembly table, and where said closed metal frame with fixedly connected metal profiles is usable, as a unit, in a subsequent process step to make for the production of a floor element surrounding the metal frame unit, with an upper fixed concrete slab and preferably a subjacent thermal insulating mat as stated in the preamble of the succeeding claim 1.

In order to be able to solve one or more of the above-disclosed technical problems, the present invention more specifically discloses that the prior art technology is to be supplemented by positioning one or more metal frame parts formed with "L" or "U" cross section, on the assembly table, with an orientation corresponding to a part of the periphery of said closed metal frame unit and positioning a number of metal profiles, in a direction towards a metal frame part, or metal frame parts, where each one of these metal profiles is given a length which corresponds to a distance between opposing metal frame parts, and positioning one or more of the remaining metal frame parts against said assembly table for the formation of the closed metal frame unit and surround said metal profiles.

In addition, the present invention discloses the utilisation of force generating means as well as a control unit or control units for activating one or more of one or more force generating means, in order to be able to urge the metal frame parts against the end surfaces of the metal profiles, in order to form said closed metal frame unit.

It is further proposed according to the present invention to fixedly connect the diverging end surfaces of the metal profiles to adjacent metal frame part and fixedly connect the mutually facing end surfaces of the metal frame parts, or vice versa.

It is further disclosed that the end surfaces of said metal profiles should, by means of welding, be fixedly united to adjacent metal frame part.

A suitably adapted distance for welding is formed between the end surface of each respective metal profile and the metal frame part, where said distance may be formed via a mechanical contact between the metal profile and the metal frame part, before the end surface of the metal profile abuts against the inner surface of the "U"-shaped metal frame part.

An urging cooperation between the metal profile and the metal frame part forms said distance.

The assembly table displays a number of distributed holes or corresponding fixing points, in which there may be positioned or allocated one or more fixed supports for fixedly retaining a metal profile, between its allocated metal frame parts.

Each one of, or in any event selected, metal frame parts are urged by external means to their peripheral position or their allocated bending.

Said external means may display a press plate rotatably disposed in a vertical plane, oriented over the assembly table and where this press plate may be magnetic.

ADVANTAGES

That which may principally be deemed to be characteristic of the present invention and the specific significative characterising features disclosed thereby are that there have hereby been created or caused the preconditions in order, in a method for forming a closed metal frame unit, with a number, at least three, of coordinated metal frame parts, with metal profiles adapted to extend between and be fixedly connected to opposing metal frame parts, while the metal frame parts and the metal profiles rest against an assembly table, and where said closed metal frame unit with fixedly connected metal profiles is usable, as a unit, in order in a subsequent process step, to make for the production of a floor element surrounding and reinforcing the metal frame unit, with an upper fixed concrete slab and preferably a subjacent heat and sound insulating mat, to be able to create a simplification which is offered with a pattern of action implying positioning in sequence one or more metal frame parts of "L" or "U" configuration in cross section, on the assembly table with an orientation corresponding to a part of the periphery of said closed metal frame unit and position a number of metal profiles in a direction towards a metal frame part, or metal frame parts, where each one of these metal profiles is given a length which corresponds to a selected distance between opposing metal frame parts, and positioning one or more of the remaining metal frame parts against said assembly table for the formation of the closed metal frame unit and surround said metal profiles.

There are further disclosed a plurality of force generating means which, via control units, are to be able to activate these means in order to be able to urge the metal frame parts against the end surfaces of the metal profiles, in order to form said closed metal frame unit and make for the fixed connection of the diverging (or end surfaces facing away from an intermediate profile section) end surfaces of the metal profiles to adjacent metal frame part and fixedly connect the mutually facing end surfaces of the metal frame parts, or vice versa.

That which may principally be deemed to be characteristic of a method, according to the present invention is disclosed in the characterising clause of appended Claim 1. A thus produced metal frame unit is disclosed in appended Claim 10 and a floor element, produced with such a metal frame unit, is disclosed in appended Claim 11.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

One currently proposed embodiment of a metal frame unit, displaying the significative characterising features associated with the present invention, will now be described in greater detail hereinbelow for purposes of exemplification, with reference to the accompanying Drawings, where:

Fig. 1 is a top plan view of an assembly table, on which a ready-produced metal frame unit lies and where the assembly table may form part of an assembly production line and is now ready to be transported to an adjacent (not shown) production station, in order there to position a subjacent insulating mat and cast the upper portion with a fresh concrete mass, which is allowed to set;

Fig. 2 shows a cooperation between a metal frame part and a metal profile specifically disclosed for the present invention;

Fig. 3 is a section through a floor element, in association with a metal profile; Fig. 4 is intended to illustrate a selected sequence, within the method or process associated with the present invention;

Fig. 5 is a side elevation of a fixedly retaining means or a support for a metal profile;

Fig. 6 is intended to illustrate a selected sequence within the method associated with the present invention and with a practical application to a closed metal frame unit of a nature which differs from that illustrated in Fig. 4; and

Fig. 7 is a side elevation of a press plate, cooperating with external means (not shown) for a reciprocal movement.

DESCRIPTION OF CURRENTLY PROPOSED EMBODIMENT By way of introduction, it should be emphasised that in the subsequent description of one currently proposed embodiment displaying the significative characterising features associated with the present invention and which has been clarified by means

of the figures shown in the accompanying Drawings, we have selected terms and a specific terminology with the intention in such instance principally of clarifying the inventive concept.

However, in this context it should be taken into consideration that expressions selected here should not be seen as restrictive exclusively to the terms selected and utilised here, but that it should be understood that every such selected term is to be interpreted so that in addition it encompasses all technical equivalents which function in the same or substantially the same manner in order in such instance to be able to attain the same or substantially the same object and/or technical effect.

With reference to the accompanying Drawings, there are thus shown schematically and in detail not only the basic preconditions of the present invention, but also the significative properties associated with the present invention have been given concrete form as a result of the currently proposed embodiment described in greater detail hereinbelow.

Thus, Fig. 1 is a top plan view of an assembly table 1 on which a ready-produced metal frame unit 2 lies and where the assembly table may be included in an assembly production line and is then in Fig. 1 shown as ready to be transported to an adjacent production station (not shown) in order, in the metal frame unit 2, to make for the positioning of an insulating mat 7 and cast the upper portion with a fresh concrete mass 6, which is allowed to set. (See Fig. 3.)

The invention relates to a method of forming a closed metal frame unit 2, with a number, at least three, of coordinated metal frame pars 4a, 4b, 4c and 4d, with a number of metal profiles 5, for example 5a, 5b, 5c, adapted to extend between and be fixedly connected with opposing metal frame parts 4a, 4c, while the frame parts 4 (4a, 4b, 4c and 4d) and the metal profiles 5 (5a, 5b, 5c) rest against the upper surface Ia of the assembly table 1, and where said closed metal frame unit 4, with fixedly connected metal profiles 5, is usable, as a unit, in order in a subsequent process step to make for the production of a floor element, surrounded by the metal

frame unit 4 and reinforced by using metal profiles 5 of the metal frame unit 4, with an upper fixed concrete slab 6 (Fig. 3) and preferably a subjacent thermal insulation mat 7.

Fig. 2 illustrates a cooperation between a metal profile 5a and a metal frame part 4a with a "U"-shaped cross section. In particular, Fig. 2 is intended to illustrate that the metal profile 5a is in its upper and lower edges 5a' adapted for a metal contact with each one of the flanges, 4a', 4a", of the frame part in order thereby to form a free space 8 adapted for welding.

Said free space 8 may also be formed by moving the metal profile 5a close to the metal frame part 4a and thereby displace the profile 5a and the part 4a from one another.

With direct reference to Fig. 4, the method according to the present invention is now illustrated.

In a first sequence, one or more "L" or "U" cross sectional shaped metal frame parts 4a, 4b are placed on the upper surface Ia of the assembly table 1 with an orientation corresponding to an angular part of the periphery 2a of said closed metal frame unit 2.

Thereafter, a number, a plurality, of metal profiles 5a', 5b', 5c' are placed in a direction towards a metal frame part 4a, or metal frame parts, where each one of these metal profiles is given a length which directly corresponds to the distance "Ll" between opposing frame parts 4a, 4c.

Fig. 4 illustrates a metal frame unit 2', where a number of metal profiles to the right in the figure are to be shorter "L2" than those to the left.

When all metal profiles 5 are placed out against the metal frame part 4a, one or more of the remaining metal frame parts 4e, 4f, 4g and 4h are placed out on said assembly

table 1 for the formation of the closed metal frame unit 2' and surrounding said metal profiles 5a', 5b' and 5c'.

The invention also discloses the utilisation of a number of controlled external means 90, 91 and 92 where a control unit (not shown) causes the activation of these power generating means 90, 91 and 92 in order to be able to urge the metal frame parts 4a, 4c; 4a, 4g; towards the end surfaces 5c'a and 5c'b of the metal profiles 5 in order to form said closed metal frame 4'.

Means 92 and 93 act against the short sides 4b, 4f and 4h.

In the next subsequent process step, action is taken in order, with a "robot weld" to be able fixedly and rigidly interconnect the divergent end surfaces 5c'a and 5c'b of the metal profiles to adjacent metal frame parts 4a and 4c or 4e and in addition to fixedly connect the mutually facing, end surfaces of the metal frame parts 4a, 4b, 4c, 4e, 4f, 4g, 4h to one another or vice versa.

The present invention in addition discloses that the end surfaces (5c'a and 5c'b, respectively) of said metal profiles 5 are by means of a welding strand within the gap or the distance 8 to be fixedly secured to an adjacent metal frame part. A distance adapted for the welding is to be formed between the end surface of each respective metal profile and the metal frame part and can be adapted to approx. 3 mm.

Said distance 8 may then simply be formed via a mechanical contact between the metal profile 5a and the metal frame part 4a before the end surface 5a', 5a" of the metal profile 5a abuts against the inner surface 4a', 4a" of the "U"-shaped frame part, according to Fig. 2.

In such instance, an urging cooperation between the metal profile 5c' and the metal frame part 4a and 4c (4e), respectively, may form said distance.

The upper surface Ia of the assembly table also displays a number of distributed holes 10 or corresponding fixing surface points, in which or to which are placed one or more fixed supports 11, for the fixed retention of a metal profile 5c' between its allocated metal frame parts.

Each one of, or in any event selected, metal frame parts 4c can be urged by external means 12 to their peripheral position or bending, according to Fig. 6.

Said external means 12 displays a press plate 12a rotatably disposed in a vertical plane, oriented over the assembly table 1 and where the press plate 12 may be permanently magnetic or electromagnetic.

Those principles which have been illustrated in Fig. 4 are correspondingly applicable to the embodiment illustrated in Fig. 6.

Falling within the scope of the present invention is a metal frame unit 4 produced according to the method or the process of the present invention with its united metal frame parts and metal profiles 5a', 5b' and 5c' as well as a floor element, produced under the utilisation of a metal frame unit 4' with a metal frame surrounding the floor element (6, 7) and with flexural resistance reinforcing metal profiles cast partly in the concrete slab 6.

The invention is naturally not restricted to the embodiment disclosed above by way of example, but may undergo modifications without departing from the scope of the inventive concept as illustrated in the appended Claims.

In particular, it should be observed that every illustrated unit and/or circuit may be combined with every other illustrated unit and/or circuit, within the scope in order to be able to attain the desired technical function.