DESCRI PTION

The invention relates to a support structure comprising:

- a first elongate structural element having at least four sides and a hollow interior, and

- a second elongate structural element having at least four sides and a hollow interior.

The invention further relates to a method of manufacturing a support structure.

A support structure is known using tubular members having a rectangular cross section. The tubular members are made of metal. In these tubular members, a section is removed from each of two tubular members for making for example a cross joint or a X-joint. The section removed corresponds to the width of the tubular member and to one-half of the height or depth of the tubular member wherein the members are fitted together by aligning the removed sections of each member with respect to each other to provide a support structure. The members are fixated to each other by means of a bolt and a nut.

A drawback of this know support structure is that the distance between the walls to be connected to each other is relatively large. Hence, the bolt for fixating the tubular members to each other has to extend through an outer side wall of the first tubular member and through an opposing outer side wall of the second tubular member. This relatively large distance between the walls to be fixated may negatively affect the fixation or complicate the fixation process of the tubular members to each other. In addition, the bolt and the nut will most likely protrude from both opposing side walls of the tubular member. Hence, the bolt and the nut may not only adversely affect the aesthetics of the support structure, but likely more importantly may also limit the design freedom as the bolt and the nut require space outside the support structure on two opposing sides to provide the fixation between the tubular members.

It is an object of the support structure of the present invention to provide an improved support structure.

This object is achieved with the support structure as defined in claim 1 . The support structure comprises: - a first elongate structural element having at least four sides and a hollow interior, and

- a second elongate structural element having at least four sides and a hollow interior. The first and the second elongate structural element comprise two spaced apart slots and each slot extends in three of the four sides of the first and the second elongate structural element, and one of the sides in the first or in the second elongate structural element is provided without a side wall portion between the two spaced apart slots, and/or the sides of the first and the second elongate structural element provide a male and female connection. The slots and/or the male and female connection are provided for connecting the first and second structural element to each other in a cross-shaped, X-shaped, L-shaped or T-shaped configuration, wherein an outer surface of one side of the first structural element abuts against an inner surface of one side of the second structural element for providing a connection between them.

The first elongate structural element and the second elongate structural element are designed and constructed such that in the connection one side of the first elongate structural element is adapted to lie in a contacting manner, i.e. without any room or minimal room there between, against one side of the second elongate structural element. During manufacturing/assembling of the support structure the outer surface of the first elongate structural element can be pushed against or slided over the inner surface of the second elongate structural element. After establishing the abutting sides the desired cross-shaped, X-shaped, L-shaped or T-shaped configuration of the support structure is provided by means of the first elongate structural element and the second elongate structural element. The abutting side portions can be used to provide a strong connection or fixation between the first elongate structural element and the second elongate structural element.

A fastener can be used for connecting the two abutting sides of the first and the second elongate structural element. Preferably, a clamping force fixates the two abutting sides of the elongate structural elements. For example, it is possible that the abutting side wall portions of the sides are provided with through holes to connect the sides with a non-permanent joint; that is, a joint that can be removed or dismantled without damaging the joined elongate structural elements. The non-permanent joint is for example a screw joint or a bolted joint, which is able to provide a clamping force to fixate the sides directly to each other. In addition, a relatively short bolt/screw can be used to fixate the sides to each other, because the bolt/screw does no longer need to extend through the hollow interior to an opposing side of the elongate structural elements to provide a manually undetachable joint connection. "Manually undetachable" means herein that a (normal) user requires tools to remove the clamping force holding the elongate structural elements together. Further, as a result of the abutting sides of the structural elements it is possible to provide a stronger fixation and/or it is possible to reduce the number of bolts/nuts to be used for fixating the sides of the structural elements.

It is also possible to connect the sides of the structural elements with a rivet or with a weld or adhesives.

Further, it is possible to connect the sides of the structural elements without any external elements (bolts, rivets, welds, etc.), for example by a form closed connection. In such a support structure no holes are required for bolts, screws or rivets. Hence, it is possible to design a support structure in which the use of a fastener can be avoided completely.

The support structure as described also increases the design freedom, as the connection between the first elongate structural element and the second elongate structural element can be made from one outer side of the support structure only. This facilitates the assembling process of the support structure which may be beneficial for a support structure being used for example in a frame for temporary building structures or in any type of structure (house, glasshouse, industrial warehouse) or as part of a supporting frame for tents and the like. The increased design freedom may also be particularly advantageous if the support structure is being used in a (design) furniture. The design of the support structure makes it simpler, easier and faster to assemble elements together, such that it is possible to produce a cost effective support structure having an attractive appearance.

In one embodiment, the support structure comprises a third elongate structural element having at least four sides and a hollow interior, wherein the third elongate structural element is provided with two spaced apart slots and/or a male and/or a female connection portion. It may also be possible to use more than three elongate structural element. In particular, it is an advantage of the support structure that it is possible when using more than two elongate structural elements to combine the slots with the male and/or a female connection portion in one structural element. The support structure can be applied in various applications and the support structure is not restricted to the applications mentioned in this document.

The slots and/or the male and/or female connection portions may be provided for connecting the first, second and third structural element to each other in a cross-shaped or X-shaped or T-shaped configuration. In these configurations of the support structure the first elongate structural element may be provided with two spaced apart slots, the second elongate structural element may be provided with two spaced apart slots and at least one male/female connection portion, and the third elongate structural element may be provided with at least one male/female connection portion. In the known support structure it was not possible to combine two different connecting techniques for connecting three or more structural elements in a cross-shaped or X- shaped or T-shaped configuration.

The first or the second elongate structural element can be connected and/or fixated to each other such that at least two of the four corner edges of each elongate structural element contact each other without any gaps there between. In this way, it is possible to obtain a strong connection between the elongate structural elements, but it is also possible to obtain an attractive appearance of the support structure and the end product comprising the support structure.

It is a further object of the present invention to provide a method for manufacturing a support structure as described above in an accurate and efficient manner.

This object is achieved with the method as defined in the method claims. In this method slots and/or female/male connection portions in a first and a second elongate structural element of the support structure are provided by machining, moulding and/or additive manufacturing.

Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. Machining is also known as subtractive manufacturing. Machining is normally used on metal, but it can also be used on materials such as wood, plastic, ceramic, and composites.

For example, it is possible to cut the support structure as defined in this by means of a laser. However, it is also possible to use a machine for cutting, punching, folding and/or welding a sheet metal in the shape of an elongate element to be used in the support structure. Instead of machining or in addition to machining it is also possible to use moulding and/or processes of controlled material addition, which are known as additive manufacturing.

The method may be controlled by a processor which uses a computer program product, comprising a readable storage medium, comprising instructions which, when executed on at least one processor, cause the at least one processor to control the machining and/or the additive manufacturing process(es).

The invention will now be explained in more detail on basis of exemplary embodiments in the appended drawings, in which:

Figures 1 a-1 l show cross-shaped or X-shaped configuration of various embodiments of a support structure and/or a first elongate structural element and a second elongate structural element for forming a support structure;

Figures 2a-2f show a T-shaped configuration of a support structure and/or a first elongate structural element and a second elongate structural element for forming the support structure;

Figures 3a-3b show a cross-shaped configuration of a further embodiment of a support structure;

Figures 4a-4f show a T-shaped configuration of another embodiment of a support structure;

Figures 5a-5l show a T-shaped configuration of two embodiments of a support structure and/or a first elongate structural element and a second elongate structural element for forming a support structure;

Figures 6a and 6b show three other embodiments of the support structure with a T-shaped configuration.

Figures 7a-7f show a T-shaped configuration combined with a X-shaped configuration of a further embodiment of a support structure and/or a first elongate structural element, a second elongate structural element and a third elongate structural element for forming the support structure.

Like parts are indicated by the same numerals/signs in the various figures.

Figures 1 a-1 e, 1 g and 1 h show various embodiments of a cross-shaped configuration of a support structure 1 a-1 e. Figure 1 f shows a X-shaped configuration of a support structure 1 f. In addition, figures 1 i-1 l show a number of views of a first elongate structural element 2a and a second elongate structural element 3a for forming the support structure 1 a shown in figures 1 a, 1 g and 1 h.

The exemplary embodiments of the support structures as shown in the drawings all use a first elongate structural element and a second elongate structural element having four sides and a hollow interior. In other words, the elongate structural elements are hollow tubular members having a rectangular cross section. However, it is also possible to use other more complex shapes for a support structure (not shown) having at least four sides.

The four sides, see for example in figure 1 a the reference signs: 2a1 , 2a2, 2a3, 2a4; 3a1 , 3a2, 3a3, 3a4 (reference signs only indicated in figure 1 a, but all the structural elements shown have four sides without always identifying these sides in each drawing with reference signs) of the structural elements are four sides walls. These four side walls provide a rectangular-shaped cross section, see for example figure 1 d; second elongate structural element 3d, or a square shaped cross section, see for example figure 1 d; first elongate structural element 2d. The structural elements used in the support structures described in this specification are elongate, as the length dimension is larger than the width dimension and the depth dimension. Preferably the length dimension is at least five time larger than the second largest dimension (width or depth).

The support structures 1 a-1 g shown in figures 1 a-1 g all use a first elongate structural element 2a-f comprising slits or slots 14a, 14b (reference signs only shown in figure 1 i) and a second elongate structural element 3a-3f comprising slots 15a, 15b (reference signs of the slots only shown in figure 1 i). These slots 14a, 14b, 15a, 15b are used to provide a connection between the first elongate structural element and the second elongate structural element. The slots 14a, 14b, 15a, 15b will be explained in more detail below.

The embodiments shown in figures 1 a-1 l differ from each other because these figures show combinations of elongate structural elements with different cross sections. See for example, the first elongate structural element 2d having a square- shaped cross section and the second elongate structural element 3d having a rectangular-shaped cross section. However, the figures 1 a-1 l also show combinations with identical structural elements. The combination for identical structural elements with a rectangular-shaped cross section can also be different by combining the structural element under a different orientation with respect to each other. See for example, figures 1 a and 1 b showing a first elongate structural element 2a, 2b having an identical shape and dimension as the second elongate structural element 3a, 3b, but the structural elements used in these support structures 1 a; 1 b have a different orientation with respect to each other.

In the support structures 1 e, 1 f shown in figures 1 e and 1 f the only difference is the angle α, β, Θ between the first elongate structural element 2e; 2f and the second elongate structural element 3e; 3f. In figure 1 e showing a cross-shaped configuration the angle a is 90 degrees, whereas in figure 1f showing a X-shaped configuration the angle β is larger than 90 degrees and the angle Θ is smaller than 90 degrees.

The slots 14a, 14b, 15a, 15b are provided by machining, moulding and/or additive manufacturing. The machining and/or additive manufacturing process is preferably controlled by a computer program product. The process may for example use a laser. The computer program product, comprising a readable storage medium, comprising instructions which, when executed on at least one processor, cause the at least one processor to control the laser. In this way it is possible to cut the structural elements in the most accurate manner and/or efficient manner. Each structural element 2a-2f, 3a-3f comprises at least one pair of slots 14a, 14b which mates/cooperates with a pair of slots 15a, 15b made in the other structural element. Each pair of slots has two spaced apart slots 14a, 14b, 15a, 15b and each slot 14a, 14b, 15a, 15b extends in three of the four sides of the first and the second elongate structural element (see for example structural element 2a in figure 1j). In each of the three sides of each elongate structural element the distance (see figure 1j the distance is indicated with A) between the two slots of a pair of slots is identical. In the two opposing sides 3a1 , 3a3 of the second structural element 3a the length of the slot 15a, 15b corresponds to a half of the smallest (depth) dimension of the first/second structural element 2a/3a, wherein the length of the slot 15a, 15b in side 3a4 corresponds/is equal to the smallest (depth) dimension of the first structural element 2a. The first structural element 2a comprises a pair of slots 14a, 14b to be used in combination with the pair of slots 15a, 15b of the second structural element 3a. The slots 14a, 14b have a length in the two opposing sides 2a2, 2a4 corresponding to a half of the smallest (depth) dimension of the first/second structural element 2a/3a, wherein the length of the slot 14a, 14b in side 2a3 corresponds to the width dimension of the first/second structural element 2a/2b. As can be seen in the figures 1 a, 1 g-l, the width dimension of the structural elements 2a, 3a is larger than the depth dimension of the structural elements 2a, 3a. In the embodiments shown the width dimension is at least two times larger than the depth dimension. The length of each slot 14a, 14b, 15a, 15b is also longer than the depth/smallest dimension of the structural elements 2a, 3a. The width of the slots 14a, 14b, 15a, 15b is relatively small. The width of the slots 14a, 14b, 15a, 15b is configured to receive the side walls of the structural elements 2a, 2b in a tight fitting manner. In other words, the width of the slots is minimally larger than the thickness of the side walls of the structural elements 2a, 3a. In addition, one 2a3 of the sides in the first structural element 2a is provided without a side wall portion as indicated by arrow 8 in figure 1 k between the two spaced apart slots 14a, 14b. With the slots 14a, 14b, 15a, 15b and the removed side wall portion (see arrow 8), it is possible that an outer surface of one side 3a4 of the second structural element 3a abuts against an inner surface 9 (see figure 1j) of one side 2a1 of the first structural element 2a for providing a connection between the two sides 3a4, 2a1 . During manufacturing/assembling of the support structure 1 a the outer surface of the side 3a4 of the second structural element 3a is pushed against the inner surface 9 of the side 2a1 of the first structural element 2a.

Each of the sides 3a4, 2a1 abutting against each other each comprises at least one through-hole 12, 13 (figure 1 i) to be aligned with a through hole 12, 13 of the abutting side 3a4, 2a1 for fixating the abutting sides 3a4, 2a1 to each other by means of a non-permanent joint, such as a bolt/screw(not shown). This way the first 2a and the second elongate structural element 3a can be fixated in a cross-shaped, X-shaped, L-shaped or T-shaped configuration. In addition, the bolt/screw may be relatively short for fixating the two abutting sides 3a4, 2a1 .

In the support structure 1 a-f the first 2a-f and the second elongate structural element 3a-f are connected to each other such that at least two of the four corner edges of each elongate structural element 2a-f, 3a-f contact each other or bound to each other without any gaps there between. For example, figure 1 d shows that two edges of the first elongate structural member 2d contact or bound two edges of the second elongate member 3d, and figure 1 f shows that each edge if the first elongate structural member 2f contacts or bounds two edges of the second elongate member 3f.

Figures 2a and 2b show a T-shaped configuration of a support structure 51 . Figures 2c-2f show various views of a first elongate structural element 52 and a second elongate structural element 53 for forming the support structure 51 shown in the figures 2a and 2b. The first elongate structural element 52 have sides 52a1 -52a4 providing a female connection portion 52a5 (see figure 2d) and the second elongate structural element 53 have sides 53a1 -53a4 providing a male connection portion 53a5 (see figure 2d). In the embodiment shown the first elongate structural element 52 is longer than the second elongate structural element 53, but their width and depth dimensions are identical. The female connection portion 52a5 and the male connection portion 53a5 are used in the support structure 51 to provide a connection between the structural elements 52, 53. The female connection portion 52a5 and the male connection portion 53a5 will now be explained in more detail.

The female/male connection 52a5/53a5 may be provided by machining, moulding and/or additive manufacturing and a computer program product as described above for the slots. For example, the recess for the female connection portion 52a5 is cut by means of a laser in the first elongate structural element 52. The second elongate structural element 53 may also be provided by using two hollow elongate rectangular members 71 , 72 that can be welded together for providing the second elongate structural element 53 with a male connection 53a5. The elongate rectangular member 72 is designed to fit in a tight fitting manner in the elongate rectangular member 71 , wherein member 72 protrudes in a longitudinal direction from member 71 such that the protruding portion of the sides 72a-d of the elongate rectangular member 72 provides the male connection portion 53a5. This male connection portion 53a5 can be slided in its longitudinal direction in the female connection portion 52a5 in a tight fitting manner with respect to the sides 52a1 -a3 of the first elongate structural element 52 to provide a male and female connection. During manufacturing/assembling of the support structure 51 the outer surface of the sides 72a, 72b of the male connection 53a5 are slid over the inner surface of the sides 52a1 , 52a3 of the first elongate structural element 52.

Each of the abutting sides 72a, 72b, 52a1 , 52a3 of the structural elements 52, 53 comprises at least one through-hole 62, 63 (figure 2f) to be aligned with a through hole 62, 63 of the abutting side 72a, 72b, 52a1 , 52a3 for fixating the abutting sides 72a, 72b, 52a1 , 52a3 to each other by means of a non-permanent joint, such as a bolt/screw (not shown). This way the first 52 and the second elongate structural element 53 can be fixated to each other in the in figures 2a, 2b shown T- shaped configuration. The bolt/screw can be relatively short for fixating the two abutting sides 72a, 72b, 52a1 , 52a3.

In the support structure 51 the first 52 and the second elongate structural element 53 are connected to each other such that at least two of the four corner edges of each elongate structural element 52, 53 contact each other or bound to each other without any gaps there between (see figures 2a and 2b).

In the support structure 51 , the sides 52a1 , 52a3, 53a1 , 53a3 of the first 52 and the second elongate structural element 53 adjacent the female/male connection portions 52a5, 53a5 comprise tongues 81 , 83 and grooves 85, 87 for providing additional tongue-groove connections. These connections may facilitate aligning the structural elements 52, 53 during assembling the support structure 51 . In the assembled state of the support structure 51 the additional tongue-groove connections provide additional stability.

Figure 3a shows a cross-shaped configuration of a further embodiment of a support structure 101 . Figure 3b shows a first elongate structural element 102, a second elongate structural element 103 and an auxiliary elongate structural element 106 for forming the support structure 101 shown in figure 3a. The structural elements 102, 103 also use a female 102a5 / male connection 103a5 in a similar manner as the female / male connection 52a5, 53a5 described above for the support structure 51 shown in figures 2a, b. The only difference is that the male connection portion 103a5 is longer, such that this portion is able to project through a recess 102a6 provided in side 102a4 of the first structural element 102 opposite the female connection portion 102a5, and into the interior of the auxiliary elongate structural element 106. Inside the auxiliary elongate structural element 106 the through hole 1 13 can be aligned with through hole 1 16 of the auxiliary elongate structural element 106 to fixate by means of a bolt/screw (not shown) the first elongate structural element 102, the second elongate structural element 103 and the auxiliary elongate structural element 106 in the cross-shaped configuration of the support structure 101 shown in figure 3a. Figures 4a-4f show a T-shaped configuration of another embodiment of a support structure 151 which is a modification of the support structure 51 shown in figure 2a-2f. The support structure 151 differs from the support structure 51 in that the angle φ between a first elongate structural element 152 and a second elongate structural element 153 is larger than 90 degrees, such that the support structure 151 has a deviant T shape. Like the support structure 51 , the support structure 151 also uses a female 152a5 / male connection 153a5.

Figures 5a, 5b; 5g and 5h show a T-shaped configuration of a support structure 201 a, 201 b, wherein figures 5c-f and 5i-5l show a first elongate structural element 202a, 203a and a second elongate structural element 202b, 203b for forming the support structures 201 a, 201 b. The first elongate structural element 202a, 203a and the second elongate structural element 202b, 203b comprise two spaced apart slots 214a, 214b, 215a, 215b; 214a', 214b', 215a', 215b'. These slots 214a, 214b, 215a, 215b; 214a', 214b', 215a', 215b' are used in a similar manner as explained above for the embodiments shown in figures 1 a-l to provide a connection between the first elongate structural element 202a, 203a and the second elongate structural element 202b, 203b.

Figures 6a and 6b show various embodiments of the support structures 251 a-c comprising structural elements which are or can be assembled in a T-shaped configuration.

Each of these support structures 251 a-c comprises a first elongate structural element 252a; 252b; 252c and a second elongate structural element 253a;

253b; 253c using a female 252a5; 252b5; 252c5 / male connection 253a5; 253b5;

253c5 for forming the support structures 251 a-c with a T-shaped configuration. The three support structures 251 a-c are different from each other, because they use different shaped/dimensioned sides 253a1 , 253a3; 253b1 , 253b3; 253c1 , 253c3; in combination with different shaped recesses of the female connection portions 252a5;

252b5; 252c5. Each male connection portion comprises two flanges 253a5; 253b5;

253c5 to be slid in in the groove shaped recesses of the female connection portions 252a5; 252b5; 252c5.

Figures 7a-7f show a support structure 301 combining a T-shaped configuration with a X-shaped configuration. The support structure 301 comprises a first elongate structural element 302, a second elongate structural element 303 and a third elongate structural element 304. The three elongate structural elements 302, 303, 304 have four sides and a hollow interior.

The third elongate structural element 304 is identical to the second elongate structural element 53 described above and shown in figures 2a-f.

The first elongate structural element 302 is identical to the first structural element 2a described above and shown in figures 1 a, 1 g-l.

The second elongate structural element 303 is provided with two spaced apart slots 315a, 315b extending inter alia through side 303a4 and with a female connection portion 303a5 provided inter alia in the side 303a2, i.e. the side 303a2 opposite to side 303a4 of the second elongate structural element 303.

The slots 314a, 314b, 315a, 315b, the male portion 304a5 and the female connection portion 303a5 are provided for connecting the first 302, the second 303 and the third structural element 304 to each other in a fashion as described above for other embodiments.

The first structural element 302 can be connected and/or fixated to the second structural element 303 to provide the cross-shaped configuration of the support structure 301 , wherein the third structural element 304 can be connected and/or fixated to the second structural element 303 to provide the T-shaped configuration of the support structure 301 .

The support structure 301 shown in figures 7a, 7b, may be projected in a Cartesian coordinate system, wherein the first structural element 302 extends parallel to the x-axis, the second structural element 303 extends parallel to the z-axis and the third structural element 304 extends parallel to the y-axis. In the support structure 303 the virtual center line of the first structural element 302 crosses the virtual center line of the third structural element 304 inside the interior of the second structural element 303.

The structural elements of the support structure are made of metal, wood, plastic, ceramic, and/or composites including fibre reinforced composites.

All the embodiments of the support structure described and shown in this specification provide two parallel extending sides of a first hollow elongate structural element and a second hollow elongate structural element, wherein at least an inner surface portion of one of the two sides is abutting an outer surface portion of the other one of the two sides for providing a connection between them.