Bar of a support structure for a false ceiling and working process for working the bar

Abstract

A bar of a support structure for a false ceiling is described. The bar has an elongated shape along a longitudinal direction and includes at least two sheet metal portions located side by side or overlapped, in contact or adherent, with each other along said longitudinal direction, or short side direction. In the bar a transverse direction, or short-side direction, extending transverse to, or intersecting, said longitudinal direction is defined. At least one of the sheet metal portions has cuts defining partially cut parts, wherein a partially cut part of said at least one of the sheet metal portions protrudes towards the other of said sheet metal portions in a thickness direction so as to determine an interference of parts in the thickness direction. The cuts are arranged, are directed, or extend along said transverse direction and the partially cut parts have, when viewed in perspective, an at least partially curvilinear or concave profile.

Claims

1. A bar for a support structure of a false ceiling, said bar being elongated in a longitudinal direction and including at least two sheet metal portions located side by side or overlapping, in contact, or adherent, with each other along said longitudinal direction, in a long-side direction, wherein, in said bar, a transverse direction, in a short-side direction, extending transverse to, or intersecting, said longitudinal direction, is defined, wherein both the sheet metal portions have cuts which are arranged, are directed, or extend, along said transverse direction, said cuts define partially cut parts wherein a single cut is common for two pairs of partially cut parts, pairs of partially cut parts of the sheet metal portions being overlapped and shifted in pairs in a thickness direction with respect to an adjacent area of the respective sheet metal portion, and wherein, of each pair of partially cut parts overlapped and shifted in the thickness direction, a part of a sheet metal portion is protruding outwards with respect to said thickness and defines a free zone in said thickness, and at least a concave or curved profile of the other partially cut part of the other of said sheet metal portions is arranged at least partially in said free zone of the thickness of the one sheet metal portion, creating an interference between the two sheet metal portions in the transverse direction, wherein said partially cut parts have along said transverse direction and, when viewed in perspective, a profile which is at least partially curvilinear or concave, and wherein each partial cut has an uncut central zone defining a central line intersecting said partial cuts.

2. The bar according to claim 1, wherein said curvilinear or concave profile is V-shaped or W shaped or with a concave C-shape or has a variety of said curvilinear shapes which are repeated in the transverse direction.

3. The bar according to claim 1, wherein said curvilinear or concave profile is symmetrical with respect to said central line.

4. The bar according to claim 1, wherein the central zone coincides with a zone of maximum concavity, or maximum bending or curvature, of the curvilinear or concave profile.

5. The bar according to claim 1, wherein the pairs of said partially cut parts alternate along said longitudinal direction, wherein a first pair of said partially cut parts is in a shifted condition towards the one sheet metal portion, and wherein a second pair of said partially cut parts is in a shifted condition towards the other sheet metal portion.

6. The bar according to claim 5, wherein the pairs of said partially cut parts are distributed along said longitudinal direction, wherein the first pair of said partially cut parts shifted towards the one sheet metal portion is adjacent and in contact with the second pair of said partially cut parts shifted towards the other sheet metal portion.

7. The bar according to claim 5, wherein at least two or four partially cut parts of the two sheet metal portions are arranged in sequence along the longitudinal direction.

8. The bar according to claim 5, wherein said cut parts are adjoining in sequence.

9. A support structure for a false ceiling including the metal bar according to claim 1.

10. The bar according to claim 1, wherein said cuts define sides extending along the transverse direction of the partially cut portion.

11. Working process for working a metal bar, wherein the process comprises the steps of: providing a bar elongated along a longitudinal direction or long side and including at least two sheet metal portions located side by side in contact with each other along said longitudinal direction, cutting at least partially at least one of said sheet metal portions in a transverse direction, or short side, transverse with respect to, or intersecting, said longitudinal direction, so as to define a partially cut part along said transverse direction, wherein a single cut is common for two pairs of partially cut parts, wherein both said sheet metal portions are cut, such that pairs of partially cut parts of the sheet metal portions are overlapped and shifted in pairs in the thickness direction with respect to an adjacent zone of the respective sheet metal portion, and so that, of each pair of partially cut parts overlapped and shifted in pairs in the thickness direction, a part of a sheet metal portion projects outwardly with respect to said thickness and defines a free zone in said thickness and at least a concave or curved profile of the other partially cut part of the other of said sheet metal portions is arranged at least partially in said free zone of the thickness of the one sheet metal portion, creating an interference between the two sheet metal portions in the transverse direction; wherein the partially cut parts have along said transverse direction and, when viewed in perspective, a profile which is at least partially curvilinear or concave, and wherein the parts are partially cut by a partial cut so as to have an uncut central zone defining a central line intersecting said partial cuts.

12. Process according to claim 11, wherein the parts are partially cut by means of a punch with a head having a profile which is curvilinear, V-shaped, W-shaped or with a concave C-shape or has a variety of said curvilinear shapes which are repeated in the transverse direction.

13. Process according to claim 11, wherein the central joining line extends parallel to said longitudinal direction.

14. Process according to claim 11, wherein a first pair of cuts is made on a first sheet metal portion so as to form a first pair of partially cut parts and a second pair of cuts is made on the other sheet metal portion so as to form a second pair of partially cut parts, so that said first pair and said second pair of partially cut parts alternate and are adjacent in the longitudinal direction and shifted alternately towards the one of said of said sheet metal portions and towards the other of said sheet metal portions.

15. Process according to claim 11, wherein said cuts define sides extending along the transverse direction of the partially cut portion.

Description

(1) Reference will be made to the figures of the annexed drawings, wherein:

(2) FIG. 1 shows a perspective view of a bar of a support structure for false ceilings, according to one embodiment of the present disclosure;

(3) FIG. 2 shows a view of a detail II of FIG. 1;

(4) FIG. 3 shows a side view of a bar of a support structure for false ceilings, according to one embodiment of the present disclosure;

(5) FIG. 4A shows a longitudinal section along the line IVA-IVA of FIG. 3;

(6) FIG. 4B shows a longitudinal section along the line IVB-IVB of FIG. 3;

(7) FIG. 4C shows a longitudinal section along the line IVC-IVC of FIG. 3;

(8) FIG. 5 shows a vertically sectioned view of a bar of a support structure for false ceilings, according to an embodiment of the present disclosure;

(9) FIG. 6 shows a perspective view of a bar of a support structure for false ceilings, according to a further embodiment of the present disclosure;

(10) FIG. 7 shows a perspective view of a bar of a support structure for false ceilings according to a further embodiment of the present disclosure;

(11) FIG. 8 shows a perspective view of a bar of a support structure for false ceilings according to a further embodiment of the present disclosure;

(12) FIG. 9 shows a perspective view of a bar of a support structure for false ceilings according to a further embodiment of the present disclosure;

(13) FIG. 10 shows a view, on a larger scale, of a detail X of FIG. 9;

(14) FIG. 11 shows a view, on a larger scale, of a detail of a bar according to an embodiment of the present disclosure, which is an alternative to the detail in FIG. 10;

(15) FIG. 12 shows a perspective view of a bar of a support structure for false ceilings according to a further embodiment of the present disclosure;

(16) FIG. 13 shows a longitudinally sectioned view of the bar shown in FIG. 12;

(17) FIG. 14 shows a perspective view of a bar of a support structure for false ceilings according to a further embodiment of the present disclosure;

(18) FIGS. 15-17 show longitudinally sectioned views of a bar according to a corresponding number of embodiments of the present disclosure;

(19) FIGS. 18-23 show respective perspective views of bars for a support structure for false ceilings, according to further embodiments of the present disclosure.

(20) With reference to the attached figures, a bar for forming a frame of a support structure of a false ceiling according to some embodiments of the present disclosure is denoted by the reference number 1. The bar is adapted to be joined to another metal bar 1 by means of a clip 2 fixed to one end of the metal bar 1. For example, more particularly, the clip 2 may be inserted into a slot (not shown) of a second metal bar 1 to be engaged with an edge that defines the slot in the metal bar 1 so as to create a join between two metal bars 1.

(21) In the example, the metal bar 1 has a T-shaped section and is obtained by folding a metal sheet, so as to obtain overlapping of at least two sheet metal portions 5, 6. The metal bar 1 may be different from the one illustrated, for example, with a different section, such as for example a C-shaped or U-shaped section, or even with a further different section/T-shape.

(22) What is important in the scope of the present disclosure is that the metal bar 1 should include at least two sheet metal portions 5, 6, or walls, located side by side and/or overlapped, as shown for example in FIG. 5. The two sheet metal portions 5, 6 may be adherent, i.e. in contact, with one another.

(23) The metal bar 1 extends in a prevailing direction, also called longitudinal direction, which is indicated by a broken line in FIG. 3 and denoted by the reference letter L. In other words, the metal bar is an elongated body wherein a long side, extending in said longitudinal direction, and a short side, extending transversely with respect to the long side, are distinguished.

(24) With respect to this longitudinal direction L, in the metal bar 1 it is possible to identify a transverse direction T (extending from a long side to the other long side of the bar, when viewing FIGS. 3 and 8) which traverses, crosses or intersects the longitudinal direction and which consequently extends from a base area 8 (first long side) of the metal bar 1 to a top area 7 (second long side) of the metal bar 1.

(25) Such a transverse direction T may be understood as being a direction orthogonal to the longitudinal direction L or also be understood as being a direction extending obliquely and therefore forming an acute angle with the longitudinal direction L, in a short-side direction of the bar. The transverse direction T may be partially curved or completely curved.

(26) According to one aspect of the present disclosure, at least one of the two sheet metal portions 5, 6 includes one or more half-cut areas, i.e. incomplete cut areas (such as to leave a joining zone), wherein the half-cut extends in the transverse direction T of the metal bar 1. More particularly, at least one of the two sheet metal portions 5, 6 includes one or more parts 10, 10A, 11, 11A partially sheared by means of a partial cut, i.e. by one or more cuts 9 which determines a shifting, with bending, of that part 10, 10A, 11, 11A of a sheet metal portion 5, 6 towards the other sheet metal portion 5, 6. Such a part 10, 10A, 11, 11A of a sheet metal portion 5, 6 is shifted so as to protrude and interfere with the other sheet metal portion 5.6. In other words, the partially cut part 10, 10A, 11, 11A of a sheet metal portion 6 is shifted so as to occupy a thickness zone of the other sheet metal portion 5, 6. In particular, the cuts 9 carried out in the transverse direction T are such as to determine a shifting or bending of the partially cut part 10, 10A, 11, 11A of at least one of the sheet metal portions 5, 6 towards the other sheet metal portion 5, 6, and a consequent projection towards the other sheet metal portion 5, 6.

(27) It should be noted that the interference of a half-cut part with respect to the other sheet metal portion may occur along the whole of the cut 9, or only in a bending zone, for example in a corner zone of the half-cut part.

(28) In practice, one of the two sheet metal portions 5, 6 includes a part 10, 10A, 11, 11A, which being partially cut, is shifted towards the other sheet metal portion 5, 6. It follows that the partially cut part 10, 10A, 11, 11A of one of the sheet metal portions 5, 6 is able to interfere with the other sheet metal portion 5, 6, and such interference occurs, or extends, mainly in a transverse direction T.

(29) It is pointed out moreover that, in addition to the bending zone 12, each half-cut part 10, 10A, 11, 11A has an uncut central zone 13 joined to the remaining part of the metal sheet 5, 6. The central zone 13 of all the partially cut parts 10, 10A, 11, 11A defines a central line, which is a line of symmetry, for the partially cut parts 10, 10A, 11, 11A and which extends parallel to the longitudinal direction L.

(30) According to one aspect of the present disclosure, the partially cut part 10, 10A, 11, 11A has, when viewed from a thickness side, or in perspective, or in vertical section, of the bar 1, a curvilinear profile, namely a profile which is not straight, for example V-shaped, as shown in FIG. 5. In other embodiments, the partially cut part 10, 10A, 11, 11A has a W-shaped or concave C-shaped profile, or a variety of such profiles repeated in the transverse direction.

(31) It can be seen that, in one embodiment of the present disclosure, such as the embodiment shown in the drawings, the central zone 13 coincides with a zone of maximum concavity, or curved zone, of the profile of the partially cut part 10, 10A, 11, 11A, for example with the tip zone of the V shape.

(32) Owing to an interference in this transverse direction T, together with the aforementioned curvilinear profile, it is possible to minimize the possibility of torsion of the metal bar 1 about an axis parallel to the longitudinal direction L, compared to metal bars made of the same material and with the same thickness of sheet metal or other characteristics, such as the elastic limit and tensile strength. In other words, the extension of the cuts 9 in the transverse direction of the metal bar 1, together with the aforementioned curvilinear profile, determines the formation of half-sheared parts protruding, with a maximum interference owing to the curvilinear profile, in said transverse direction.

(33) Such half-sheared parts therefore create projections, which are V-shaped and have a similar curvature, in the transverse direction and a consequent interference that is able to create an effective obstacle to relative slipping of the two sheet metal portions 5, 6, and consequently an effective impediment to torsion of the bar about an axis parallel to the longitudinal direction L (anti-torsion effect).

(34) This interference, in addition to preventing relative slipping of the two sheet metal portions 5, 6, results in clinching together of the two sheet metal portions 5, 6 (anti-disengagement effect) such as to prevent also fortuitous disengagement of the sheet metal portions 5, 6.

(35) In some embodiments, such as, by way of example, the one shown in FIGS. 1-5, each of the two sheet metal portions 5, 6 comprises the aforementioned cuts 9 defining the partially sheared parts 10, 10A, 11, 11A, i.e. obtained by means of a partial cut.

(36) In particular, each sheet metal portion 5, 6 has pairs of adjacent cuts 9, wherein each of said pairs of cuts 9 defines the part 10, 10A, 11, 11A (half-sheared or half-cut part 10, 10A, 11, 11A).

(37) In the example of embodiment in FIGS. 1-5, the pairs of cuts 9 of one of the two sheet metal portions 5, 6 alternate (are staggered) with respect to the pair of cuts of the other of the two sheet metal portions. In other words, the cuts 9 are made in pairs, alternatively on one side and on the other side of the bar, so as to form pairs of staggered cuts. In practice, in some embodiments, such as those illustrated, the two sheet metal portions 5, 6 have pairs of adjacent/staggered cuts in said longitudinal direction L and on opposite sides. Such cuts 9 determine an alternate shifting in opposite directions of overlapped pairs of partially cut parts, as can be seen in FIG. 2 and FIG. 5. This alternate shifting enables an increased interference between the parts to be obtained.

(38) It follows that, with reference to FIGS. 4A, 4B, 4C and 5, according to some aspects of the present disclosure, each of said sheet metal portions 5, 6 has a thickness S such that a direction which crosses the thickness S is a thickness direction DS. The partially cut parts 10, 10A, 11, 11A of FIG. 4c are overlapped in said thickness direction DS and are shifted in pairs in the thickness direction DS with respect to an adjacent area of the respective sheet metal portion 5, 6. In particular, the partially cut parts 10, 10A, 11, 11A are shifted in pairs in the thickness direction DS and one of the partially shifted parts 10A, 11A is protruding towards the outside with respect to said thickness S and defines a free area in said thickness S. The other of said partially cut parts 10, 11, with the respective curved profile, is arranged at least partially in the free area of the thickness S of the one sheet metal portion 5, 6, so as to create the interference in the longitudinal direction and in the transverse direction. Such interference allows a satisfactory anti-torsion action to be obtained.

(39) It may be noted that, in the exemplary embodiment of FIGS. 1-5, the pairs of parts 10, 11A and 11, 10A follow one another adjacent without interruption in the bar 1. In practice the cuts 9 are in each case common to two pairs of half-cut parts which are adjoining in the sequence.

(40) In some embodiments, such as those illustrated in FIGS. 12 and 13, only one of the two sheet metal portions 5, 6 includes the cuts 9 defining the partially cut parts 10 (sheared by a partial cut) which determine a shifting and possible cut of a corresponding part 11A of the other sheet metal portion.

(41) In particular, a single sheet metal portion 5, 6 has one or more, for example pairs of adjacent cuts 9, wherein each of said pairs of cuts 9 defines pairs of parts. For example, the pairs of cuts 9 of one of the two sheet metal portions 5, 6 are made at intervals along the longitudinal direction at a constant pitch, or with a given pitch, so as to define a plurality of pairs of cuts 9. In practice, it can be noted that the pairs of parts 10, 11A follow one another spaced at regular intervals. Owing to the geometry of the parts described above, the pairs of parts 10, 11A alternate with parts 110, 111 of the two sheet metal portions 5, 6 which are not cut, i.e. have not been worked.

(42) The spacing between successive pairs 10, 110, 11A, 111, denoted by I in FIG. 13 corresponds, for example, to the mutual distance d between the two cuts 9 of each pair. In other words, pairs of cuts 9 are made only on one side of the bar, at more or less regular intervals. In this embodiment, the cuts 9 determine a shift in the same direction of the parts 10, 11A.

(43) It follows that, with reference to FIG. 13, according to some aspects of the present disclosure, each of said sheet metal portions 5, 6 has a thickness S such that a direction which crosses the thickness S is a thickness direction DS. The partially cut parts 10, 11A of FIG. 13 are overlapped in said thickness direction DS and are shifted in pairs in the thickness direction DS with respect to an adjacent area of the respective sheet metal portion 5, 6. In particular, the partially cut parts 10, 11A are shifted in pairs in the thickness direction S and one of the partially shifted parts 11A is protruding towards the outside with respect to said thickness S and defines a free area in said thickness S. The other of said parts 10 is arranged at least partially in the free area of the thickness S, so as to create interference between the sheet metal portions 5, 6.

(44) In other embodiments, such as that shown in FIG. 14, it is also possible to provide a combination of the two preceding embodiments, wherein the pairs of cuts 9 may be made at intervals along the longitudinal direction at a constant pitch, or with a given pitch, as in the embodiment of FIG. 13 and, at the same time, alternatively on the one and on the other sheet metal portion 5, 6 as in the embodiment of FIGS. 1-5.

(45) It follows that, in some embodiments, the cuts 9 define a sequence or series of half-cut parts 10, 10A, 11, 11A, which alternate continuously or at intervals, so as to form a half-cut line. Such a half-cut line is also called, by analogy of ideas, a seam line or seam.

(46) The seam line 15 or half-cut line may be in turn continuous, as shown in FIG. 1, FIG. 7 and FIG. 8, or may be a discontinuous line, or a broken line, as shown in FIGS. 6 and 9 and FIGS. 18-20.

(47) Furthermore, according to further aspects of the present disclosure, the metal bar 1 may include two or more series or half-cut lines 15 arranged on two different levels in said transverse direction, comprised between the base area 8 and the top area 7, as shown by way of example in FIG. 17 or FIG. 18.

(48) Even more particularly, in order to adjust and control a degree of interference between the first sheet metal portion 5 and the second sheet metal portion 6, it is possible, for each of the embodiments of the present disclosure such as those described above or a combination thereof, to adjust the depth of cut 9 with respect to the thickness S or height of the sheet metal portion 5, 6 of the bar.

(49) It is to be understood that the depth or penetration of the cut 9 with respect to the thickness is chosen according to the interference capacity (and therefore the anti-torsion capacity) of the two sheet metal portions 5, 6 which is to be obtained and depends on the thickness of each sheet metal portion 5, 6, on the material of the sheet metal portion 5, 6, on its elastic limit and on its tensile strength, or on the presence of possible surface machining on the faces of the sheet metal portions 5, 6.

(50) A working process for working a metal bar 1 according to an exemplary embodiment of the present disclosure is illustrated below. Such process may be used to make any of the bars described above.

(51) A metal bar 1 is provided with for example a T-shaped section or another section and is obtained by bending a metal sheet, so as to have a pair of portions or sheet metal walls 5, 6 which are overlapped.

(52) One, both, or more, portions or sheet metal walls 5, 6 are subjected to a partial cut by means of a device known to a person skilled in the art, suitable for making partial cuts in sheet metal. In particular, a punch with a head having a profile which is not straight, for example V-shaped or W-shaped or in the shape of a concave C, or a variety of these shapes which are repeated in the transverse direction, is used.

(53) The partial cut is performed so as to make staggered pairs of cuts 9 on opposite sides of the two sheet metal portions 5, on the one of the two sheet metal portions 5, 6 towards the other of the two sheet metal portions 5, 6, such as those visible in FIG. 5, or pairs of cuts 9 at regular distances on only one of the two sheet metal portions 5, 6, or cuts as in any one of the embodiments of FIGS. 12 and 13. These cuts 9 extend, i.e. are directed, in the transverse direction T of the metal bar 1. The half-cut parts, when viewed in the thickness direction DS, have a profile which is not straight, for example V-shaped or W-shaped or with a concave C-shape, or with a variety of such shapes which are repeated in the transverse direction.

(54) The curvilinear profile may also be a sinusoidal profile.

(55) More particularly, the half-cut is made so as to define pairs of half-cut parts 10, 10A, 11, 11A, which in the exemplary embodiment of FIGS. 1 to 5 alternate continuously in the longitudinal direction and pairs of parts 10, 11 which in the exemplary embodiment of FIG. 10 or 11 are arranged at regular intervals in the longitudinal direction. Owing to the half-cut in the transverse direction an intersection in the transverse direction and in the longitudinal direction between the two sheet metal portions 5, 6 is produced, thus preventing relative sliding of said portions.

(56) More particularly, with reference to FIGS. 9 to 11, it should be noted that, according to one aspect of the present disclosure, in order to obtain an effective interference between the sheet metal portions and the aforementioned anti-torsion effect and anti-disengagement effect between the metal portions, it is preferable to make at least three, or even better five, cuts 9 in succession along the bar so as to obtain at least two, or four, half-cut parts 10, 10A, 11, 11A in sequence along the bar 1.

(57) It should be noted, moreover, that the shape of the parts 10, 10A, 11, 11A, when viewed from one side of the bar 1 is substantially rectangular. This shape is not to be considered essential for the present disclosure. Many forms or different shapes of half-sheared parts may be provided. It is important that the half-cut is performed to art, making sure that any play resulting from machining is very small and that interference between the parts is ensured.

(58) In accordance with further embodiments, not shown, instead of the clip 2, the bar includes an integral engaging element located at one end of the bar and forming an integral part of the bar.

(59) The cuts 9 according to the present disclosure may be performed in the integral engaging element so as to connect together by means of mutual clinching the sheet metal portions which define the integral engaging element and prevent mutual separation and opening of the sheet metal portions, which would result in the integral engaging element being unutilizable.

(60) The subject-matter of the present disclosure has been described hitherto with reference to preferred embodiments thereof. It is understood that there may be other embodiments which relate to the same inventive concept, all falling within the protective scope of the claims set forth hereinafter.