Field of the invention

[0001] The invention relates to a profiled beam element, a cellular element and a method for constructing the cellular element using plurality of profiled beam elements.

Background art

[0002] Cellular elements formed from profiled beam elements are already known from the prior art. They offer relatively cheap solutions for building objects with high degree of customization such as bridges or overpasses of different sizes and mechanical properties. The profiled beam elements can be transported to the installation location where the cellular element can be relatively easy assembled.

[0003] WO 2007/054608 A1 discloses a method for manufacturing cellular board, a cellular board, a method for producing cellular board element of steel plate strip, and a production line. A cellular board comprises a number of originally separate profiles of plate-like material, which have been fastened to each other.

[0004] US 2003/0110730 A1 discloses a profiled sheet comprising a web formation having first and second opposite ends; a first panel segment extending generally transversely from the web formation at or towards the first end thereof and a second panel segment, extending generally transversely from the web formation at or towards the second end thereof, wherein the first and second panel segments extend in opposite directions from the web.

[0005] However, cellular elements formed from profiled beam elements have poor structural integrity due to weak links between the profiled beam elements. This is especially the case with the cellular elements that need to sustain heavy loads. A solution for this problem is use of bolts or welding profiled beam elements together, which is both expensive and time consuming. Further, profiled beam elements are usually made of profiled metal sheets or casted metal resulting in relatively heavy and expensive profiled beams which are prone to corrosion. Thus, it would be advantageous to provide a profiled beam element that is light and inexpensive while allowing one to form cellular objects of high structural integrity.

Summary of the invention

[0006] Therefore, according to a first aspect of the invention, there is provided a profiled beam element according to claim 1 . The profiled beam element comprises a top flange, a bottom flange and a web. To describe these elements and relations between them, the following reference directions are used throughout the application. A direction along the profiled beam element is a longitudinal direction. A direction in which the flanges extend from the web is a transversal direction, and a direction in which the top flange and the bottom flange are displaced with respect to each other is a vertical direction. The top flange and the bottom flange extend in the same direction from the web and together with the web enclose an inner space configured to accommodate at least two further profiled beam elements placed in a sequence. Surfaces of the top flange, the bottom flange, and the web oriented towards the inner space are referred to as inner surfaces while the opposite surfaces of the mentioned elements are referred to as outer surfaces.

[0007] The profiled beam element according to the present invention is characterized in that at least one of the top flange or the bottom flange comprises at least three substantially flat portions interconnected and vertically (in the vertical direction) displaced with respect to each other by interconnecting regions comprising linear interlocking members. The flat portions and the interlocking members are configured to cooperate with the flat portions and the interlocking members of the further profiled beam elements placed in the sequence in order to fasten profiled beam elements together.

[0008] In an embodiment, both the top flange and the bottom flange, have at least three substantially flat portions vertically displaced with respect to each other by interconnecting regions. However, the top flange and/or the bottom flange of the profiled beam element according to the invention may have four or more flat portions. Furthermore, the number of flat portions of the top flange may differ from the number of flat portions of the bottom flange.

[0009] In an embodiment, vertical displacements between the successive flat portions of the top flange and/or the bottom flange are equal.

[0010] In a further embodiment, the flat portions and the interconnecting regions are integral parts of the top flange and/or the bottom flange arranged such that the flat portions are of the same or similar size and bound in the longitudinal direction by the interconnecting regions. “Similar” in this context means - of the same order. For example, the size of the flat portions in the transversal direction may be approximately A/-th part of the total size of the flange in the transversal direction, wherein N is a number of flat portions the flange is comprised of. However, one or more flat portions of the top flange and/or the bottom flange may have different sizes as well.

[0011] The interconnecting regions separate successive flat portions in the transversal direction. These regions are preferably substantially narrower than the flat portions and extend in the longitudinal direction.

[0012] In an embodiment, the interconnecting regions comprise interlocking members. The interlocking members may comprise a single or a plurality of linear protrusions and depressions. “Linear” in the context of this application means that the interlocking members are translationally invariant in the longitudinal direction. However, it may as well be that the interlocking members follow a pattern in the longitudinal direction. For example, it may be that the interlocking member comprises a series of depressions and protrusions that repeat in the longitudinal direction.

[0013] One interlocking member may form a linear protrusion on the inner surface of the flange while forming a linear depression on the outer surface of the same flange. The protrusion may be in a form of one or more of the following: a bump, an edge, a lip, a knob, a hook or similar. The depression may be in a form of one or more of the following: a recess, a groove, a dip, a concavity, a slit or similar. The protrusions are configured to cooperate with the depressions of the further profiled beam element placed in the sequence in order to fasten two profiled beam elements together.

[0014] In a further embodiment, the interlocking members are configured to form a snap-fit connections with the interlocking members of the further profiled beam element placed in the sequence. In the snap-fit lock, the protrusions or male parts of one profiled beam element are mechanically forced into the depressions or female parts of another profiled beam element in order to fasten the two profiled beam elements together.

[0015] Other locking mechanisms are conceivable as well. For example, two flat portions of the flange (the top and/or the bottom) may be separated by a vertical step, wherein the vertical step is configured to allow certain flat portions of a flange of the further profiled beam element to pass under when the further profiled beam element is placed in the sequence, while serving as a barrier for other flat portions of the same flange. In this manner, the further profiled beam element can only be partially fitted into the inner space of the profiled beam element. The two profiled beam elements may be then fastened together by means of bolts, clamps, glue and/or similar.

[0016] When placing the profiled beam elements in the sequence, a first successive profiled beam element is the element that is placed partially within the inner space of a current profiled beam element. The first successive profiled beam element may for example occupy approximately two-thirds of the inner space of the current profiled beam element. A second successive profiled beam element is placed simultaneously within the inner space of the current profiled beam element and the inner space of the first successive profiled beam element. The second successive profiled beam element occupies a smaller portion of the inner space of the current profiled beam element than the first successive profiled beam element. For example, the second successive profiled beam element may occupy approximately a third of the total inner space of the current profiled beam element and approximately two-thirds of the total inner space of the first successive profiled beam element. Any further profiled beam element placed in the sequence follows similar pattern.

[0017] In an embodiment, a vertical separation between the top flange and the bottom flange is the smallest between the flat portions that are closest to the web and increases with each successive flat portion away from the web. In other words, each successive flat portion of the top flange and/or the bottom flange is vertically displaced further away from the web.

[0018] In a further embodiment, the profiled beam element comprises a plurality of linear mating protrusions along at least one flat portion of at least one flange, wherein the linear mating protrusions are located away from the interconnecting regions and configured to cooperate with similar linear protrusions of the further profiled beam element placed in the sequence in order to fasten profiled beam elements together. The linear mating protrusions may have a zigzag, a sawtooth, a square wave or similar profile in the transversal direction. They may be placed symmetrically around the central axis of the flat portion in the longitudinal direction. Furthermore, the linear mating protrusions may be present on both, the inner surface and the outer surface of the flat portion, wherein the linear mating protrusions of the inner surface are configured to cooperate with the linear mating protrusions of the outer surface of the further profiled beam element placed in the sequence in order to fasten profiled beam elements together.

[0019] In an embodiment, the top flange and/or the bottom flange further comprise at least one linear protrusion along an edge in the longitudinal direction configured to cooperate with at least one linear depression located in the interconnecting region of the further profiled beam element placed in the sequence in order to fasten two profiled beam elements together. The protrusion along the edge may have a shape of a hook, a lip, a knob, or similar.

[0020] In an alternative embodiment, the top flange and/or the bottom flange comprise at least one linear protrusion and/or depression in the region between two consecutive flat portions configured to cooperate with at least one linear depression and/or protrusion of the further profiled beam element placed in the sequence.

[0021] In an embodiment, thicknesses of all flat portions of the top flange are equal and thicknesses of all flat portions of the bottom flange are equal as well. Additionally, thicknesses of all flat portions of the profiled beam element are equal.

[0022] In a further embodiment of the profiled beam element, the flat portion of the top flange that is the furthest from the web in the transversal direction has a wear surface coating on its outer surface. Upon placing the profiled beam elements in the sequence, the outer surfaces of the flat portions of the top flange and the bottom flange that are placed within the inner spaces of neighbouring profiled beam elements are covered by the inner surfaces of the flat portions of the neighbouring profiled beam elements. The flat portions of the top flange and the bottom flange that are located furthest from the web in the transversal direction remain uncovered in the process to form a top flat surface and a bottom flat surface, respectively. The wear surface coating may be placed on flat portions that are intended to the top flat surface and/or the bottom flat surface to protect the profiled beam element from the mechanical damage caused when the profiled beam element is in use. The wear surface coating may comprise a slurry filled with stone grit wherein the slurry may be selected from a group comprising an epoxy slurry, a methyl methacrylate slurry, a polyurethane slurry or similar, and the wear surface coating may have thickness in a range between 1 and 5 mm.

[0023] The profiled beam element according to the invention may comprise a recessed region of relatively reduced thickness on the top flange and/or the bottom flange configured to cooperate with the top flange and/or the bottom flange of the further profiled beam element placed in the sequence in order to form a recess for an adhesive. The profiled beam element may have a plurality of the recesses for the adhesive at different flat portions of one or both flanges. It may be that the flat portions have regions of reduced thickness only on the inner surface or the outer surface or, alternatively, the region of the reduced thickness may be formed on both surfaces of one or more flat portions. The recesses are configured to accommodate an amount of adhesive in order to provide an additional support to fastening profiled beam elements together. [0024] The top flange, the bottom flange, and the web of the profiled beam element according to the invention may be made from a continuous sheet of self-supporting material. Preferably, the profiled beam element is made of a plastic material, preferably a thermoplastic material, a composite such as plastic material with embedded fibres for reinforcement, i.e. fibre-reinforced polymers (FRP), aluminium or similar metallic materials.

[0025] In a further embodiment, the top flange and/or the bottom flange comprise a lip along the longitudinal edge of the top flange and/or the bottom flange and a slit, located at a distance from the longitudinal edge, configured to engage with the lip of the further profiled beam element placed in the sequence in order to fasten two profiled beam elements together. The lip and the slit may have any shape and/or dimension suitable to lock two profiled beam elements together. The lip and the slit may form a snap-fit lock.

[0026] The profiled beam element according to the invention may have the thickness of the flanges and/or the web in a range between 1 mm and 10 mm. It will be understood that a preferred thickness of the flange depends on type of the material used for manufacturing the flange. The flanges made of metal may have the thickness in a range between 1 and 3 mm. The flanges made of fibre-reinforced polymers may have the thickness in a range between 3 and 5 mm, while the flanges made of thermoplastic may have thickness in a range between 5 and 10 mm. The length of the flanges in the transversal direction may be in a range between 0.1 m and 5 m, preferably between 0.1 m and 3 m, and the length of the flanges in the longitudinal direction may be in a range of 1 m to 20 m. The length of the web in the vertical dimension may be in a range of 4 cm to 100 cm.

[0027] The profiled beam element may be curved in the longitudinal direction. Curved beams are suitable for constructing bridges as the curvature re-distributes the load from a mid-point of the bridge towards the edges. The profiled beam element is arch-shaped such that the mid-point of the profiled beam element is displaced vertically upwards with respect to end points of the profiled beam element. The extent of the curvature depends on the material and geometrical properties of the profiled beam element.

[0028] The profiled beam element may be produced using various moulding techniques such as injection moulding technique and a resin transfer moulding technique, or a 3D printing technique.

[0029] According to a second aspect of the invention, there is provided a method for constructing a cellular element comprising a plurality of profiled beam elements according to the first aspect of the invention, wherein the method comprises arranging the profiled beam elements in the sequence such that at least one profiled beam element has at least two further profiled beam elements partially accommodated within the space enclosed by the top and the bottom flange characterized in that the flat portions of the top flange and/or the bottom flange not enclosed within the space of the further profiled beam element placed in the sequence, form a substantially flat surface.

[0030] Alternatively, if the curved profiled beam elements have been used for construction of the cellular element, the formed surface is smooth enough to allow an unhinged passage of intended users such as passengers, cattle, vehicles, and similar. The cellular element may comprise support beams placed on each end in the longitudinal direction.

[0031] Additionally, the method may comprise a step of placing an adhesive in the recess(es) for the adhesive in order to additionally fasten profiled beam elements together. The adhesive comprises one or more of the following: an epoxy, a methyl methacrylate (MMA), a polyurethane, a urethane-acrylate, a silyl-modified polymer (SMP), a polyester such as a rubber toughened polyester, and a vinyl ester.

[0032] The method for constructing the cellular element may further comprise step of placing an adhesive in the recess for adhesive in order to fasten two profiled beam elements placed in the sequence.

[0033] According to a third aspect of the invention, a cellular element is provided, wherein the cellular element is constructed according to the method of the second aspect of the invention. The cellular element may be a bridge, a board, a floor, an overpass, or similar.

[0034] The cellular element may comprise a plurality of closing elements configured to close a plurality of longitudinal openings, wherein each opening is bound in the vertical direction by the top flange and the bottom flange of the profiled beam element and in the transversal direction by the webs of the profiled beam element and the further profiled element placed in the sequence, wherein the closing elements are placed at least at each end of the cellular element in the longitudinal direction.

Brief description of drawings

[0035] The present invention will be discussed in more detail below, with reference to the attached drawings, in which:

[0036] Fig. 1 depicts a perspective view of a cellular element comprising plurality of profiled beam elements according to the invention;

[0037] Fig. 2a depicts a perspective view of a profiled beam element according to the invention;

[0038] Fig. 2b depicts a side view of the profiled beam element of Fig. 2a;

[0039] Fig. 3a depicts a plurality of profiled beam elements of Figs 2a and 2b placed in a sequence;

[0040] Fig. 3b depicts a side view of the profiled beam arrangement of Fig 3a;

[0041] Fig. 4 depicts an enlarged area of a profiled beam element according to the invention having a recess for an adhesive;

[0042] Figs 5a and 5b depict alternative embodiments of a profiled beam element according to the invention;

[0043] Fig. 6 depicts a closing element for longitudinal openings;

Description of Embodiments [0044] The invention will be explained in more detail below with reference to drawings in which illustrative embodiments thereof are shown. The drawings are intended exclusively for illustrative purposes and not as a restriction of the inventive concept which is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention. The scope of the invention is only limited by the definitions presented in the appended claims.

[0045] In the following description and figures, the numbering of different features is assisted by using letters and accents. The letters a, b, c,... are used to indicate elements of the same kind appearing within a certain embodiment of the invention while the accents are used to indicate a plurality of embodiments of the same kind appearing within an embodiment of the invention of a different kind. When placing the embodiments in a sequence, accents before the number indicate that the embodiment is placed in the sequence before the current embodiment, while the accents after the number indicate that the embodiment is placed after the current embodiment.

[0046] Taking a random embodiment from the sequence as a current embodiment, we can use the above mentioned system to describe its position with respect to its neighbours as the following. The current embodiment 100 is placed between the first successive embodiment 100’ and the first preceding embodiment ‘100. The first successive embodiment 100’ is followed by the second successive embodiment 100” and the first preceding embodiment ‘100 is preceded by a second preceding embodiment “100.

[0047] Figure 1 illustrates in perspective view a cellular element 1 comprising a plurality of profiled beam elements 10 according to a first embodiment of the invention. The profiled beam elements are placed in a sequence such that a top flat surface 3 and a bottom flat surface 5 are formed. A direction along the profiled beam element 10 is a longitudinal direction X and a direction in which the profiled beam elements 10 are placed in the sequence is the transversal direction Y. A direction in which the bottom flat surface 5 is displaced with respect to the top flat surface 3 is a vertical direction Z.

[0048] The profiled beam element according to the first embodiment of the invention is illustrated in Fig. 2a in perspective view. The profiled beam element 10 extends in the longitudinal direction X and comprises a top flange 11 , a bottom flange 12 and a web 13 which are made as integral parts of the profiled beam element 10. The top flange 11 and the bottom flange 12 extend from the web 13 in the same direction. The web 13 is substantially perpendicular to the top flange 11 and the bottom flange 12 and together, these three elements enclose an inner space 17. The top flange has three top flat portions, generally marked 14, which are bound in the transversal direction Y by top interconnecting regions, generally marked 23. A first top flat portion 14a is the closest to the web 13. A second top flat portion 14b is in the middle and a third top flat portion 14c is the furthest from the web 13. Similarly, the bottom flange 12 has three bottom flat portions, generally marked 15: a first bottom flat portion 15a, a second bottom flat portion 15b, and a third bottom flat portion 15c. All flat portions have same thicknesses. They are bound in the transversal direction by bottom interconnecting regions, generally marked 25. The top flat portions 14 are separated vertically by the web 13 from the bottom flat portions 15. Each top flat portion 14 is substantially parallel to the bottom flat portion 15 located under it. A wear surface coating 16 is placed only on the top flat portion 14c and the bottom flat portion 15c (not visible). The wear surface coating 16 is placed on the side of flange that is not facing the inner space 17.

[0049] Fig. 2b illustrates a side view of the profiled beam element 10 of Fig. 2a. The successive flat portions of the top flange 11 and the bottom flange 12 are vertically displaced by the interconnecting regions 23, 25. This means that the profiled beam element 10 widens away from the web 13 as a vertical distance Za, Zb, Zc between the top flange 11 and the bottom flange 12 incrementally increases for a double the value of a vertical step dZ with each flat portion away from the web 13. The vertical steps dZ between the successive flat portions are all equal. This simplifies significantly placing the profiled beam elements 10 in the sequence. The wear surface coatings 16 are present on both flanges at flat portions 14c, 15c that are the furthest from the web 13.

[0050] Figure 3a illustrates the perspective view of a plurality of profiled beam elements 10, 10’, 10” placed in the sequence. That is: All profiled beam elements are identical and are placed such that a first successive profiled beam element 10’ is placed within the inner space 17 of the current profiled beam element 10. A second successive profiled beam element 10” is placed simultaneously within the inner space 17’ of the first successive profiled beam element 10’ and the inner space 17 of the current profiled beam element 10. In this manner, longitudinal openings 18, 18’, 18” are formed. Each longitudinal opening 18 is bound by the top flat portion 14a, the bottom flat portion 15a, the web 13 of the current profiled beam element 10 and the web 13’ of the first successive profiled beam element 10’ placed in the sequence.

[0051] Fig. 3b illustrates the side view of the profiled beam elements placed in the sequence. Particularly, relations between interconnecting parts of the neighbouring profiled beam elements placed in the sequence are shown. Flat portions 14, 15 of the neighbouring profiled beam elements are stacked on top of each other such that the top flat surface 3 and the bottom flat surface 5 are formed. The flat portions are stacked such that the first flat portion 14a for the current profiled beam element 10 is the closest to the longitudinal opening 18. The second flat portion ‘14b of the first preceding profiled beam element ’10 is placed above it and the third flat portion “14c of the second preceding profiled beam element “10 is placed on the top. Additionally, the third flat portion “14c has the wear surface coating 16 placed on top of it. Thus, the thickness of the top flat surface 3 equals the sum of the thicknesses of stacked flat portions and the thickness of the wear surface coating 16. Similar can be stated for the bottom flat surface 5 with the exception that the third bottom flat portion “15c in this particular embodiment does not have the wear surface coating 16 on its outer side.

[0052] The successive flat portions of the profiled beam element 10 are vertically displaced by the interconnecting regions 23, 25. The vertical displacement dZ between the successive flat portions is constant and approximately matches the thickness of the flat portion. Thus, when the second successive profiled beam element 10” is placed within the inner space 17’ of the first successive profiled beam element 10’, the first interconnecting region 23”a, 25”a of this element engages with the second interlocking region 23’b, 25’b of the first successive profiled beam element 10’. The first interlocking region 23”a, 25”a is slanted such that it fits into a complementary slated second interlocking region 23’b, 25’b. The second interlocking region 23’b, 25’b has a linear protrusion 22’b, 26’b facing the inner space 1 T and a linear depression 24’b, 28’b facing the second flange 14b, 15b of the current profiled beam element 10. The linear depression 24’b, 28’b is configured to form a snap-fit lock with the linear protrusion 22c, 26c of the current profiled beam element 10 in order to fasten profiled beam elements together. The current profiled beam element 10 has the linear depression 24c, 28c on the opposite surface from the linear protrusion 22c, 26c. The linear depression 24c, 28c is configured to form a snap-fit lock with the linear protrusion ‘22d, ‘26d of the first preceding profiled beam element ’10 in order to fasten these two profiled beam elements together.

[0053] In this manner the profiled beam elements are fasten together to form a cellular element 1.

[0054] To additionally fasten profiled beam elements placed in the sequence, a recess for adhesive 41 can be formed as illustrated in Fig. 4. The recesses 41 are formed by reducing the thickness of the flat portions 14a, ’14b; ‘14b, ”14c such that when the profiled beam elements are placed in the sequence the reduced thickness regions align to form the recesses 41 .

[0055] Fig. 5a illustrates an alternative embodiment of the profiled beam element 10 where the linear depressions and the linear protrusions are replaced with a slit, generally marked 35, and a lip, generally marked 33, configuration. The lip 33 is configured to fit within the slit 35 in order to fasten profiled beam elements together. This configuration provides better grip between the profiled beam elements placed in the sequence as it forms a tighter lock between the connecting members. A top flange lip 33a is extending outwards from the top flange 11 and the top flange slit 35a is located on the surface of the top flange 11 lying opposite to the inner space 17. On the other hand, a bottom flange lip 33b extends inwards, towards the web 13, and a bottom flange slit 35b is located on the surface of the bottom flange 12 lying opposite to the inner space 17. The interconnecting regions 23, 25 are much wider compared to the previous embodiment due to more prominent interlocking members they comprise.

[0056] Fig. 5b illustrates another embodiment of the profiled beam element 10 according to the invention wherein the interconnecting regions 23, 25 have rather simple interlocking members in a form of slanted regions. However, the flat portions 14, 15 additionally have a plurality of linear mating protrusions, generally marked 37, on each side of each flat portion 14, 15 that is in contact with a flat portion 14, 15 of another profiled beam element 10 placed in the sequence. Inner linear mating protrusions 37b are on the surface of the flat portion 14, 15 which faces the inner region 17 while outer linear mating protrusions 37a are on the surface of the flat portion 14, 15 that is opposite to the inner space 17. Both the inner linear mating protrusions 37b and the outer linear mating protrusions 37a have a sawtooth profile in a transversal direction with the difference that the teeth are tilted in opposite directions. The inner linear mating protrusions 37b have the teeth tilted towards the web 13 while the teeth of the outer linear mating protrusions 37a are tilted away from the web 13. In this way, when the profiled beam elements are placed in the sequence, the teeth of the inner linear mating protrusions 37b of one profiled beam element interlock with the teeth of the outer linear mating protrusions 37a of another profiled beam element and fasten two profiled beam elements together.

[0057] Fig. 6 illustrates the cellular element 1 wherein the longitudinal openings 18 are closed by closing elements 51 that match with the dimensions of the longitudinal openings. The closing elements 51 are placed on each longitudinal opening 18 at both ends of the cellular element 1 in the longitudinal direction X. This increases the strength of the cellular element 1 and also prevents accumulation of dirt, water, and other unwanted objects within the longitudinal openings 18.

[0058] The present invention may be embodied in other specific forms without departing from its essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive to the inventive concept. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. It will be apparent to the person skilled in the art that alternative and equivalent embodiments of the invention can be conceived and reduced to practice. In addition, many modifications may be made to adapt a particular configuration or material to the teachings of the invention without departing from the essential scope thereof.

[0059] All modifications which come within the meaning and range of equivalency of the claims are to be embraced within their scope.