DESCRI PTI ON

The invention relates to a method for producing a reinforced prof ile element for supporting at least one wall partition , in particular at least one drywall plasterboard partition according to claim 1 , the use of a cut-out portion for reinforcing a prof ile element, and a prof ile element for supporting at least one wall partition , in particular at least one drywall plasterboard partition.

Prof ile elements as a carrier structure for the construction of walls, in particular walls consisting of gypsum plasterboards are known. Such prof ile elements are supporting components (e.g. studs) which absorb and transmit forces resulting, e.g. from adj acent wall partitions and/or forces resulting from external conditions, such as loadings, impacts, acoustics, etc. Profile elements should have a minimal weight and suff icient static properties, in particular a sufficient stiff ness and stability. I n order to improve stiffness and stability of the profile element, document WO 2008/087009 A1 suggests a prof ile element with a bridge region (web) comprising a plurality of support braces and connecting braces. The connecting braces are arranged between the support braces being oriented substantially in the longitudinal direction of the prof ile element. The structure of the bridge region of document WO 2008/087009 A1 allows the production of a comparatively low weighted profile element with suff icient static properties.

I t is an obj ect of the present invention to propose a method for producing a reinforced profile element for supporting at least one wall partition , in particular at least one drywall plasterboard partition with comparatively low costs, wherein the produced prof ile element should be of a low weight and suff icient stability and stiff ness. Moreover, it is an obj ect of the present invention to propose a corresponding reinforced prof ile element being light weighted and rigid, which can be produced with low costs.

According to the invention, a method for producing a reinforced prof ile element with a web and at least one f lange for supporting at least one wall partition, in particular at least one drywall plasterboard partition, comprises in particular the steps of : a) providing a preliminary prof ile element ;

b) forming at least one cut out within the preliminary prof ile element so that the preliminary prof ile element is subdivided in a prof ile element main body and at least one reinforcing element having at least one detached portion being detached f rom the profile element main body;

c) transferring at least a portion of the reinforcing element f rom a f irst

position to a second position ;

d) connecting, in the second position, at least the detached portion of the reinforcing element with the profile element main body in order to reinforce the prof ile element body.

A key aspect of the present invention is the formation of a cut out and the utilisation of the cut out (or a corresponding portion being detached or

detachable because of the cut out) as reinforcing structure. The cut out is preferably a service cut out for enabling a service person to access regions within the prof ile element. Preferably, the service cut out is used for leading (e.g. signal and/or power) lines into and/or through the prof ile element. Moreover, the service cut out may be used for inspections, e.g. endoscopic inspections. The use of a cut out , in particular a service cut out , as reinforcing member results in a very light , stiff and rigid prof ile element. I f the cut out is a service cut out , the same part of the prof ile element can be used in two completely different ways which f urther simplif ies the structure of the profile element . The cut out may have an area of at least 5 cm ² , preferably 1 0 cm ² , further preferably 20 cm ² . An upper limit of the area of the cut out may be 500 cm ² , preferably 300 cm ² , further preferably 1 00 cm ² . I n a preferred embodiment, the cut out has a four sided shape, in particular a rectangular shape. Other shapes (e.g. polygonal , circular, triangular or oval) are possible. The term "reinforcing" should preferably mean that a stiff ness, in particular bending stiff ness and/or the stability, in particular torsional stability and/or bending stability, of the prof ile element main body is enhanced.

The (gypsum) plasterboard is preferably a sandwich-type plasterboard with a gypsum layer between two sheets of paper and/or a fibre-reinforced

plasterboard. Preferably, after step b) , at least a portion of the reinforcing element is integrally connected with the profile element main body, in particular hinged, wherein the reinforcing element is preferably bent and/or folded for transferring at least a portion of the reinforcing element f rom the f irst position to the second position . I n this embodiment, reinforcing element and prof ile element main body preferably form (still) an integral body. Thereby, a stable prof ile element can be achieved via a simple production process.

I n an alternative embodiment, the reinforcing element is (completely) detached from the prof ile element main body (after step b) . Thereby, it is possible to handle (shape and/or process) the reinforcing element separately. For example, the reinforcing element can be cut out f rom the preliminary prof ile element and be, then, bent and/or folded in a certain shape for a reconnection with the profile element (or prof ile element main body) . This means that the complete structure can be precisely adapted to the requirements of the use of the prof ile element.

Preferably, the shape of the reinforcing element is changed (during step c) . The shaping may imply a bending and/or folding and/or cutting and/or thermal treatment (preferably, the reinforcing element is not heated in step c) . I t is, hence, possible to adapt the reinforcing element synergetically to the profile element main body in order to improve the stability thereof . As an alternative, the shape of the reinforcing element may be kept constant. For example, it is possible to simply turn or rotate the reinforcing element f rom the first to the second position . Moreover, it is possible to completely remove the reinforcing element and to reconnect the same reinforcing element to the prof ile element main body without changing the shape thereof . I n any case, the production process is very simple and excellent static properties are achieved.

I t is preferred to arrest a reinforcing element with the profile element main body in step d) via an arresting mechanism. I n an embodiment, the arresting mechanism is a snap-in mechanism . The arresting mechanism ( in particular snap- in mechanism) may comprise at least a recess and/or at least one proj ection being provided at the reinforcing element and/or the profile element main body. I n a first embodiment, the prof ile element main body comprises a proj ection which may be urged backwards by an edge of the reinforcing element, wherein the proj ection of the prof ile element main body snaps in its original position when the edge of the reinforcing element exceeds a certain point (e.g. a tip of the proj ection) . Alternatively or in addition , a proj ection is arranged on the

reinforcing element. I n general , the prof ile element main body and the

reinforcing element can be formed and arranged so that a movement ( rotation) of the reinforcing element widens the profile element main body until the prof ile element main body snaps back in its original position . A "widening" of the prof ile element main body is preferably an enlargement of an angle between two f langes or one flange and a web of the profile element main body. I n another

embodiment, the reinforcing element comprises one or two recesses

corresponding (e.g.) with edges of the prof ile element main body. I n any case, the connection between the reinforcing element and the profile element main body is very simple and reliable.

I n preferred embodiments, the method comprises the steps of providing a plurality (e.g. at least two, at least three, at least five or at least ten) cut-outs, wherein the cut-outs are preferably positioned at regular intervals and/or preferably formed so that their alignment alternates. Hence, the stability of the prof ile element may be improved in a simple manner.

The profile element may be a Z-, C- , T- or I - profile element . Other geometric structures are possible (e.g. a CT-stud) . I n any case, it is preferred that the cutout is provided in a web (bridge section) of the prof ile element. As an alternative, the cut-out may be provided on a f lange section. For example, the reinforcing element being made of the cut-out can connect a web with a flange section or a web with two flange sections or one flange section with another f lange section . Through these measures, the stability of the prof ile element is f urther improved.

At least a portion of the reinforcing element may be rotatable. A rotation axis is preferably perpendicular or parallel to a longitudinal axis of the profile element . I n particular, if the profile element is a Z-profile element , the rotation axis is parallel to the prof ile element. I f the prof ile element is a U- or C-profile element, it is preferred to have the rotation axis perpendicular to the longitudinal axis of the prof ile element.

The reinforcing element may comprise a clip member. The clip member has preferably a U-shape (in cross section) and/or at least one recess. Such a clip member can realiably be reconnected with the prof ile element main body in order to obtain a rigid and reinforced prof ile element.

I t is preferred that the cut-out is a service cut-out. Then , the cut-out serves two functions resulting in a simple and light weighted reinforced profile element .

Preferably, the reinforcing element engages and/or locks the f langes of the prof ile element. Alternatively, the reinforcing element may engage and/or lock a flange of the prof ile element with the web.

The profile element and/or profile element main body and/or reinforcing element can be made of a (metal) sheet . The prof ile element and/or prof ile element main body and/or reinforcing element can be formed by bending and/or folding and/or cutting and/or thermal conversion .

The abovementioned problem is solved by the use of a portion of a preliminary prof ile element being (at least partially) cut-out of the preliminary prof ile element for reinforcing a prof ile element main body originating f rom the preliminary prof ile element . Thereby, a reinforced prof ile element is achieved.

Moreover, the obj ected problem is solved by use of a prof ile element of the above-described kind for producing a reinforced profile element for supporting at least one wall partition, in particular at least one drywall plasterboard partition .

Moreover, the above-identif ied problem is solved by a prof ile element produced by the above-described method.

Moreover, the above-identif ied problem is solved by a profile element for supporting at least one wall partition , in particular at least one drywall

plasterboard partition, comprising a reinforcing element being hinged on a prof ile element main body so that it is rotatable from a first position to a second

(reinforcing) position . I n addition or as an alternative, the reinforcing element may be connected or connectable to a profile element main body via an arresting mechanism, in particular a snap-in mechanism . The reinforcing element may be a clip, e.g. made of a (shaped) metal sheet (e.g. with a U- , C-, I - , T- , CT- , L- cross section) . The snap-in mechanism may comprise a recess and/or a (corresponding) proj ection and/or edge. Moreover, the snap-in mechanism may comprise an edge, on the one hand, and a proj ection , on the other hand. Said edge and/or proj ection and/or recess may be part of the reinforcing element or the prof ile element main body. As a f urther alternative or in addition, the reinforcing element and the profile element main body can be made of the same material , in particular made f rom the same preliminary profile element by forming a cut-out within the preliminary prof ile element. Preferably, the preliminary prof ile element is a (metal) sheet being planar or preformed (e.g. having a U- , C- , Z- , I - or T- shape) .

A key aspect of the present invention is in general the utilisation of an existing (service) cut-out to reinforce a prof ile element. Another key aspect is the utilisation of an additional reinforcement clip or a plurality of additional reinforcement clips.

The term "Z- profile" shall mean a prof ile having two (substantially) parallel flanges and a bridge section ( "web") linking both f langes and being arranged diagonally f rom one flange to the other.

I f several cut-outs are provided, a ( regular) interval between the cut-outs may be 200 to 400 mm ( in particular 300 mm) or 500 to 700 mm (in particular 600 mm) .

The enclosed figures show embodiments of the present invention :

Fig. 1 : A first cross-section (along line I - I in Fig. 7) of a first embodiment of a reinforced prof ile element ;

Fig. 2: a second cross-section (along line l l - l l in Fig. 7) of the embodiment of Fig. 1 in a f irst state;

Fig. 3: the cross-section of Fig. 2 in a second state;

Fig. 4: the cross-section of Figs. 2 and 3 in a third state;

Fig. 5: a third cross-section (along line V-V in Fig. 7) of the embodiment of

Fig. 1 in a first state;

Fig. 6: the cross-section of Fig. 5 in a second state;

Fig. 7: a web of the profile element of Fig. 1 ;

Fig. 8: an oblique view of the profile element of Fig. 1 ;

Fig. 9: a preliminary prof ile element according to a second embodiment ;

Fig. 1 0: a profile element of the second embodiment according to the

preliminary prof ile element of Fig. 9, in a f irst state; Fig. 11 : the profile element of Fig. 10 in a second state;

Fig. 12: a side view of the embodiment of the reinforced profile

element according to Fig. 10;

Fig. 13: the side view of the profile element of Fig. 10 in a second state; Fig. 14: a top view of a part of the web of the second

embodiment of Fig. 10;

Fig. 15: a side view of a third embodiment of the reinforced profile element; Fig. 16: a cross-section along line XVI -XVI in Fig. 15.

Figure 1 shows a first embodiment of a reinforced profile element (compare Figs. 7 and 8). The reinforced profile element comprises a first flange 10, a second flange 11 and a web (bridge section) 12. The web 12 connects the first flange 10 and the second flange 11. The first and second flanges 10, 11 are arranged in parallel. The bridge section 12 has an angle (of about 45°) with respect to the first and second flanges 10, 11. The angle may be different (e.g. in a range of 20 to 70°, preferably 40 to 60°), depending on the ratio of the width of the web 12 and the width of the flange 10 and/or 11. I n essence, the profile element of Fig. 1 has a Z-shaped cross-section so that it may be called "Z-profile element". Fig.2 shows a second cross-section of the profile element of Fig. 1 in a first state. The cross-section of Fig. 2 shows the profile element of Fig. 1 in a cross-section along line I l-l I in Fig.7.

Fig. 7 shows altogether three cut-outs 13 (the number may be different) consisting of three cut lines 14, 15 and 16. Together with a knuckle line 17, the cut lines 14, 15 and 16 form a rectangular structure. The knuckle line 17 is (in Fig. 7) shown as a dotted line. The cut lines 14, 15 and 16 are shown as solid lines.

The respective knuckle line 17 defines a rotational axis about which a reinforcing element 18 surrounded by cut lines 14, 15 and 16 and knuckle line 17 is rotatable.

Referring to Fig.2, there is shown a state of the reinforcing element 18, where a distal end 19 of the reinforcing element 18 is still very close to a neighbouring edge 20 of a profile element main body 21 which consists of all parts of the reinforced profile element except of the reinforcing element 18. Fig. 3 shows the cross-section of Fig. 2 in a second state of the profile element. The distal end 19 has been moved in the direction of an arrow 22 so that the distal end 19 comes close to a projection 23 provided on the profile element main body 21,

specifically on the first flange 10. A further movement of the distal end 19 of the reinforcing element 18 in the direction of arrow 22 urges the first flange 10 in the direction of an arrow 24 so that the distal end 19 can pass the projection 23. A final state of the reinforced profile element is shown in Fig.4. There, the distal end 19 has passed the projection 23 and the flange 10 has snapped back into its original position. In essence, there is provided a snap-in mechanism 25 for arresting the distal end 19 with the first flange 10 (the profile element main body).

Figs.5 and 6 show a second cross-section of the profile element of Fig. 1 in a first and a second state. In Fig. 5, the reinforcing element 18 has already been moved a certain distance in the direction of an arrow 26; in Fig.6, the reinforcing element 18 has passed a projection 27 provided on the second flange 11.

The projections 23 and 27 of the embodiment of Figs. 1 to 7 may extend along the whole length of the profile element or maybe interrupted (wherein the first option is preferred). It is advantageous (as shown in Fig. 1 to 6) that the projections 23 and 27 comprise a sloped surface 28 so that the distal end 19 of the respective reinforcing element 18 forces the first flange 10 or second flange 11 in a radial direction. In its final state (compare Figs.4 and 6), it is preferred that the reinforcing element 18 is in tight contact with an (inner) surface 29 of the projections 23, 27, wherein a reset force acts in the direction of an arrow 30 (= radially inwards). Thereby, the distal end 19 and the complete reinforcing element 18 is securely arrested.

Figs.9 to 14 show a second embodiment of the reinforced profile element. The profile element of the second embodiment is a C-profile element with a first flange 10, a second flange 11 and a web 12. Distal ends 31 of the flanges 10 and 11 are bent inwardly. Fig. 10 shows a first state of the profile element. Fig. 11 shows a second state of the profile element. I n the state of Fig. 11 , a reinforcing element 18 has been rotated upwards so that it forms an angle of (about) 90° with the web 12. Alternatively, the angle between the reinforcing element 18 and the web 12 can be (in its final state, shown in Fig. 9) between 20° and 160° preferably between 60° to 120°. Fig. 14 shows a part of a web 12 of the reinforced profile element of the second embodiment. The reinforcing element 18 is surrounded by cut lines 14, 15 and 16 (solid lines) and a knuckle line 17 (dotted line). The cut lines 14 and 15 define each a recess 32 in which the corresponding distal end 31 of flanges 10, 11 can be arrested (as shown in Fig. 13). Distal corners 33 of the reinforcing element 18 are rounded so that a movement of the corners 33 against the distal ends 31 of the flanges 10, 11 urge the flanges 10, 11 in a radial direction. When the distal ends 31 engage with the recesses 32 of the reinforcing element 18, the flanges 10, 11 snap back in their original position. Therefore, also the embodiment of Figs. 9 to 14 comprises a snap-in mechanism 25.

Fig. 15 shows a side view of a third embodiment of the present invention. In the first embodiment (Figs. 1 to 8) and the second embodiment (Figs.9 to 14), the reinforcing element 18 is (still) an integral part of the whole profile element because they are hinged on one side. The third embodiment of Figs. 15 and 16 has a reinforcing element 18 being completely separated from the profile element main body 21. The profile element main body 21 comprises (similar to the embodiment of Figs. 9 to 14) a web 12, a first flange 10 and a second flange 11. However, the first flange 10 is longer than the second flange 11. The reinforcing element 18 comprises a recess 34 corresponding with a distal end 36 of the first flange 10 and a recess 35 corresponding to a distal end 37 of the second flange 11.

Fig. 16 shows a cross-section along line XVI -XVI in Fig. 15. The reinforcing element 18 has a U-shaped cross-section. This means, recesses 34 and 35 consist preferably each of a pair of recesses. One recess of the pair of recesses is provided on each flange 38, 39 of the reinforcing element 18.

The reinforcing element 18 is formed as a clip so that it connects first flange 10 and second flange 11 of the profile element main body 21. Rounded corners 40, 41 (facing toward an interior of the profile element) simplify the mounting process of reinforcing element 18. Similar to the first and second embodiment, the profile element main body 21 widens when the reinforcing element 18 is approached to the distal ends 36 and 37 of the flanges 10, 11. Thereby, the reinforcing element 18 can snap into the profile element main body 21. In general (concerning all embodiments and irrespective of the presence of other specific features), the reinforced profile element can be made of a metal sheet, preferably with a thickness of at least 0.3 or 0.4 mm. An upper limit of the thickness of the metal sheet may be 1.5 mm or 1.0 mm. Preferred materials are metal, aluminium or an aluminium alloy or steel. Alternatives are wood or plastics.

Reference numerals

10 first flange

11 second flange

12 web (bridge section)

13 cut-out

14 cut-out

15 cut line

16 cut line

17 cut line

18 knuckle line

19 reinforcing element

20 distal end

21 profile element main body

22 arrow

23 projection

24 arrow

25 snap-in mechanism

26 arrow

27 projection

28 sloped surface

29 surface

30 arrow

31 distal end

32 recess

33 distal corner

34 recess

35 recess distal end distal end flange flange corner corner