NZ280692A - Forming and deforming apparatus and method of forming a member with an at least partially reduced end part such as a fascia member facilitating an overlapping joint thereof - Google Patents

Description

2806 92 Patents Form No. 5 Our Ref: PT501016 NEW ZEALAND PATENTS ACT 1 953 Complete After Provisional No. 280692 Filed: 18 December 1995 COMPLETE SPECIFICATION BUILDING ELEMENT JOINT STRUCTURE AND METHOD We, MARLEY NEW ZEALAND LIMITED, a New Zealand company of 32 Mahia Road, Manurewa, Auckland, New Zealand hereby declare the invention, for which We pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: PT0529289 280 6 92 INTRODUCTION This invention relates to a building element joint structure and a method of forming the elements and/or the joint.

PRIOR ART DISCUSSION Traditionally, the joining of building elements, especially example elongate building elements for use in a building structure has presented difficulties, for example where the elements to be joined are formed in sheetmetal, such as fascia boarding, cladding, frieze boarding and the like.

Prior art methods and apparatus for element joining has generally incorporated a "joiner member" fitable in association with adjacent ends of similar elements to span a joint created therebetween. Such assemblies are often secured by fixing means such as adhesives and/or fastenings (such as blind rivets), screws and the like. Alternatively, adjacent ends of the joint structure can in certain instances be overlaid however, this is often I unacceptable for aesthetic reasons owing to the "stepped" nature of the resultant joint.

Recently attempts have been made to reduce the "step" effect of joint structures by providing a substantially "spigot and socket" assembly however, with sheetmetal building elements, such as panel sections (particularly narrow panel sections and other non-uniformly shaped products) significant difficulties can be experienced in appropriately spigoting or socketing the ends for joining. In the main such spigot and socket assemblies have been limited to annular members such as pipes, ducts and the like. 280 692 OBJECTS OF THE INVENTION It is an object of this invention to come some way in overcoming the abovementioned problems or at least provide the public with a useful choice. Other objects of this invention will come apparent from the following description.

BROAD DESCRIPTION OF THE INVENTION According to one aspect of this invention there is provided a method of progressively forming an elongate element including the steps of forming a portion of said element into a predetermined first shape, reforming a part of said element portion to a predetermined at least partially reduced shape and size prior to continuing to form a remainder of said element in said first shape.

According to one aspect of this invention there is provided a method of progressively forming an elongate element including the steps of forming a portion of said element into a predetermined first shape, reforming a part of said element portion to a predetermined at least partially reduced shape and/ or size prior to continuing to form a remainder of said element in said first shape.

According to a further aspect of this invention there is provided apparatus for producing elongate elements of a first predetermined shape and having a second at least partially reduced shape and/or size portion thereon, including a forming means arranged to form the element in the first predetermined shape, reforming means positioned adjacent an output end said forming means to reform a leading end portion of said element output to 280 692 - 3a - said predetermined second shape and/or size prior to completion of remaining - 4 2806 92.

According to a still further aspect of this invention there is provided a building element formed by the apparatus described hereinbefore.

Other aspects of this invention we come apparent from the following description.

DESCRIPTION OF PREFERRED EMBODIMENT The preferred form of the invention will now be described as reference to the accompanying drawings in which: Figure 1: Is a perspective view of a swaged end of a building element, in this case a building fascia member which is engageable with similar fascia members to provide a longitudinal fascia for a building roof, to trim the lower termination of the building roof; Figure 2: Is a cross sectional view through a typical joint between a spigoted portion of a fascia element and a similar non spigoted end of a similar fascia member in the orientation of arrows A of Figure 1; Figure 3: Is a substantially diagrammatic assembly view of a building element formation means incorporating roll forming for the building element of Figures 1 and 2; 28 0 6 92 Figure 4: Is a substantially diagrammatic enlarged view of the formation means of the invention in the orientation of arrow B of Figure 3; The preferred embodiment of the invention is described with reference to the formation of a building element in the form of an elongate fascia member provided by roll forming methods and incorporating a predetermined length of element. Each building element has one end thereof swaged or reformed into a spigot to facilitate operation of the joint assembly of the invention.

The invention is not limited to the described embodiment. It is to be appreciated that the method and resultant building element may be alternatively provided, for example downstream of an extrusion process and the like, without departing from the scope or spirit of the invention as defined in the appended claims.

Referring particularly to figures 1 and 2. In the preferred form of the invention the building element as generally indicated by arrow 1 is provided as a semi-enclosed cross-sectional element being of somewhat C-shaped configuration. Preferably an intended frontal face 2 to thereof is formed to be fluted or otherwise configured longitudinally to provide strength to the assembly as a whole and to reduce "oil canning", rippling and the like in the finished product.

The building element 1 is preferably provided in surface treated formable sheetmetal, for example mild steel, aluminium and the like. Usually 28 0 6 the sheet is protected with a coating of galvanising, paint or resin, such that the element may be formed preferably by a roll forming process (as is seen with reference to figure 3) from a suitably slitted roll of metal into predetermined lengths for use.

Each building element 1 is arranged of a similar first shape cross-section and has one end portion as generally indicated by arrow 3 formed of a substantially reduced dimension "second shape", an amount, in the preferred form of the invention substantially commensurate with a cross sectional thickness of first shape portions 4 of the building element 1.

It will be appreciated the swaged second shape end portions 3 of one element can in use be engaged within an opposite end "first shape" portion 5 of a similar building element so that an outer surface of the joined building elements is substantially in register, with the joint relatively securely held in a spigot and socket engagement.

With reference to figure 2, preferably a retaining means in the form of blind rivets and the like 6 is engaged between the overlapped "socket" and "spigot" portions 5 and 3 so that the joint may be held against dislodgement It will nevertheless be appreciated that fastening in this way is not essential to the invention.

Turning now to figure 3. In the preferred form of the invention, the method of formation of the building elements 1 is carried out in conjunction with a roll forming means or apparatus as generally indicated by arrow 10. The roll forming apparatus 10 is preferably "fed" from a roll 11 of suitable 2806 92 sheet material through rolls 12 of the former as shown diagrammatically in figure 3. An output end 13 of the apparatus 10 has associated therewith the swaging means 14 according to the invention for reforming or reshaping leading portions of the element 1 from the first shape to the second reformed shape.

Preferably the swaging or reforming means 14 is provided at the output 13 of the roll forming apparatus 10 and is coordinated to operate cooperatively therewith in a substantially sequenced manner. It should be appreciated that the roll forming process is in this form carried out preferably in a substantially "sequentially continuous" manner (ie start-run-stop start-run-stop....).

The reforming means 14 is also associated with suitable cut-off means 15, mounted preferably immediately downstream of the output end 13 of the roll forming apparatus 10 and adjacent the reforming means 14 such that the cut-off means 1 5 may be operated also sequentially in cooperation with the roll forming apparatus 10.

In the preferred form of the invention the cut-off means 1 5 is provided in the nature of a guillotine or shear, however this is in no way essential to the invention.

Downstream of the output 13 of the roll forming apparatus 10 is a carriageway as generally indicated by arrow 16. Preferably the carriageway 16 is provided with a plurality of mounted rollers 17, arranged to guide the output element 1 of said roll forming apparatus 10 to a stop means 18. 2806 9 2 Preferably the stop means 18 is provided in the path of the building element 1 as it exits from the output 13 and incorporates suitable sensing and switching means to control the operation of the roll forming apparatus 10 such that upon the leading end of a building element 1 portion contacting said stop means 18 the roll forming operation and associated activity is temporarily halted, to operate in the substantially continuous sequenced process, producing predetermined separate lengths of element 1 therefrom.

In this preferred form, the building element 1 is produced and run out of the roll forming apparatus 10 through the output 13. At an initial phase, the leading end of the first shaped element is swaged at the swaging or reforming station 14, (as will be described hereinafter) to reform the exposed leading end portion of the building element 1 portion into the second or reformed shape and reduced dimension as described hereinbefore.

The roll forming process subsequently continues and the formed building element 1 passes out along the support rollers 17 until such time as the element 1 leading end contacts the stop 18 and the roll forming process again temporarily ceases.

The swaging or reforming station 14 operates as the element 1 is stationery in the output 13, preferably in conjunction with the cutting means 1 5. This achieves a simultaneous swage or reform of portions of the roll formation projecting beyond the output end 13 and through the reforming jaws 14 upstream of the cutting means 1 5, into the reformed or second shape and reduced dimension; the cutting means 15 also shears the adjacent portion of the output downstream of the reformed portion to complete the 2806 92 element for removal. The roll forming apparatus 10 then reactivates to extend the output out along the rolls 17 and against the stop 18 where the jaws 14 and cut off means 15 again operate to complete the next element 1 for removal and so on.

Preferably sensors sense the removal of any completely formed element 1 from the rollers 17 and the roll forming process recommences to extend the next building element having the reduced second shape leading end 3 thereon across the rollers 17 and against the stop 18 for the process to again temporarily halt and the swaging and cut-off actions to again operate. It will be appreciated that by this method and apparatus, a substantially sequenced continuous process of formation of predetermined length building elements 1 can be achieved.

Whilst reference has been made in the preferred form to simultaneous cutting or shearing and reformation of the roll formation, it is to be appreciated that this is no way essential to the invention.

Referring now to figures 3 and 4, in this form of the invention the swaging or reforming station 14 incorporates a robust frame work 19 (see figure 3) mounted with suitable base frame work 20 of the roll forming apparatus 10 adjacent to the output 13.

The frame work 19 mounts suitable hydraulic rams 21 which are able to, under hydraulic pressure, reciprocate a plurality of reformation jaws 22 into and out of a swaging position relative to the mandrel 23 (see figure 4). 2806 Jaws 22 and mandrel 23 are provided with operative faces which substantially correspond with one another in a predetermined shape, less a tolerance substantially similar to the thickness of sheet material from which the building element 1 is provided.

Referring particularly to figure 4, preferably the jaws 22 are provided in the cross section of the building element 1 described to each move inwardly under swaging operation on the effort of hydraulic rams to reform or compress adjacent portions of the building element against the mandrel 23 and create the second or reformed shape therein.

The mandrel 23 is provided internally within the plane of operation of the jaws 22 and of a size that the jaws 22 can compress portions of the building element 1 sandwiched between the mandrel 23 and jaws 22 to reduce the shape and dimension of those portions a predetermined extent and sufficiently to enable unswaged opposite end portions of similar building elements 1 to slide over and engage with swaged end portions 3, as previously described with reference to figures 1 and 2.

Owing to the mandrel 2 being positioned adjacent the output end of the roll forming apparatus 10, as the roll forming process recommences (on removal of a formed building element from the support roller 17; (the jaws 1 2 having already retracted after a swaging or reforming operation) the swaged leading end portion 3 of the building element 1 is slid from adjacent said mandrel 23 and any frictional engagement with the end portion 3 at recommencement of roll forming operation. Unswaged portions of the 2806 building element pass over the mandrel 23 with clearance between, thus avoiding undue friction.

The positioning of the mandrel 23 and reformation jaws upstream of the stop 18, conveniently facilitates the continuous sequenced production of the building elements, with minimal friction, and avoidance of the need for a reverse flow of the overall process, as has hitherto been generally necessary.

The mandrel 23 and the jaws 22 are arranged to swage or reform the portions of the building element to a size such that when the jaws 22 retract, sufficient latent bias remains in the adjacent sheetmetal forming the reformed leading end portion 3, to create sufficient clearance for a relatively load free removal of the portion 3 from the mandrel 23.

In alternative forms of the invention, for example where relatively complex shapes are provided, it is envisaged that additional lubrication means may be needed for initial removal of the reformed leading end portion 3 from the mandrel 23, for example the use of compressed air or other "lubrication" providing a friction reducing film between opposing mandrel 23 and reformed leading end portion 3.

Thus by this invention there is provided a method and apparatus for forming joint assemblies for building elements and a building element so formed. 280 69 2

Claims (14)

WHAT WE CLAIM IS

1. A method of progressively forming an elongate element including the steps of forming a portion of said element into a predetermined first shape, reforming a part of said element portion to a predetermined at least partially reduced shape and/or size prior to continuing to form a remainder of said element in said first shape.

2. A method as claimed in Claim 1 including the steps of positioning a reforming means downstream of a first element shape output, reforming the element part positioned in said reforming means as a leading end portion of said element prior to further first shape forming of said element.

3. A method of forming an elongate element as claimed in claim 2 including the step of moving said formed element portions in said first shape past portions of said reforming means subsequent to reformation of the element part into said second shape.

4. A method of forming an elongate element as claimed in claim 2 or claim 3 including the steps of, upon disengagement of said reforming means, continuing formation of said element in said first shape, until the leading end portion reaches a predetermined position, defining the element by severing said element portion output at a portion remote from said reformed part. - 13 - 280 69 2

5. A method of forming an elongate element as claimed in claim 4 including the step of reforming the upstream end part of said first shape output to create the leading end of the next element, during a phase for severing the previously formed element from said element portion output.

6. Apparatus for producing elongate elements of a first predetermined shape and having a second at least partially reduced shape and/or size portion thereon, including a forming means arranged to form the element in the first predetermined shape, reforming means positioned adjacent an output end said forming means to reform a leading end portion of said element output to said predetermined second shape and/or size prior to completion of remaining portions of said element in said forming means.

7. Apparatus for producing an elongate element as claimed in claim 6 wherein said reforming means is positioned downstream of said forming means and is arranged to coact with said forming means to operate upstream of a severing means for severing elements of predetermined length from the apparatus output.

8. Apparatus for producing an elongate element as claimed in claim 7 wherein the reforming means is adapted to operate during a phase for operation of said severing means. N-Z. PAiT.KiT' OFFICE f 2 MAR 1997 - 14 - 280 6

9. Apparatus for producing an elongate element as claimed in any one of claims 5 to 7 wherein said element is of a predetermined semi-enclosed configuration and wherein the reforming means include jaws positioned outwardly of a mandrel and arranged to coact with said mandrel to, upon operation, reform portions of said element sandwiched therebetween to the second predetermined shape, said reforming means arranged that upon release from the reforming means those portions and subsequent element portions are capable of movement relative to said reforming means with said mandrel remaining within said portions during at least part of said movement.

10. Apparatus for producing an elongate element as claimed in claim 9 wherein said mandrel is arranged of a predetermined shape such that when said element portions are reformed thereabout, sufficient latent bias remains in said reformed portions, after formation, to space said reformed portions from said mandrel sufficiently to enable dislodgement of said reformed portions from said mandrel on further operation of said apparatus.

11. Apparatus for producing an elongate element as claimed in claim 10 wherein a lubrication means is provided to assist dislodgement of said reformed portions from said mandrel.

12. A building element formed according to the method claimed in any one of the preceding claims 1 to 5. t 2 MAR 1997 - 15 - 280 69 2

13. A method as hereinbefore described with reference to the accompanying drawings

14. Apparatus as hereinbefore described with reference to the accompanying drawings. 1 5. An element produced according to the method and apparatus as hereinbefore described with reference to the accompanying drawings. MARLEY NEW ZEALAND LIMITED By Their Attorneys kj/holdback/CSPEC29298 END OF CLAIMS n.z. "nt office; I 2 MAR 199?