EP4467737A1

EP4467737A1 - A prefabricated system and a method

Info

Publication number: EP4467737A1
Application number: EP24177684.8A
Authority: EP
Inventors: Antoine ABREZOL
Original assignee: Balco Group AB
Current assignee: Balco Group AB
Priority date: 2023-05-26
Filing date: 2024-05-23
Publication date: 2024-11-27

Abstract

The present disclosure relates to a prefabricated system (100) comprising an elongated profile (1) and at least one first fastening element (30). The elongated profile (1), as seen in a transverse cross section, comprises: a groove (10) having an open end (16) into which the at least one fastening element (30) has been inserted into a desired position of the at least one first fastening element and at least one deformation portion (20) formed in an inner wall portion (12) of the groove. The at least one first fastening element, when slid to the desired position, has been subjected to a force towards the at least one deformation portion to thereby plastically deform the at least one deformation portion and restrict movement of the first fastening element. The present disclosure further relates to a method.

Description

Technical field

The present disclosure relates to a prefabricated system for assembling a balcony, a pergola, a screen, a railing, or a roof. The present disclosure further relates to a method for producing a prefabricated system.

Technical background

Profiles for fastening objects like railings serve multiple purposes in construction and engineering applications. Structurally, a profile's design distributes weight and stress across a larger area, providing greater load-bearing capacity and stability. Profiles can also be designed with specific load-bearing capabilities to meet project-specific requirements. In terms of installation, profiles may provide a stable and level surface for fastening the object. This is especially important when attaching railings to surfaces that may not be perfectly flat or level. Profiles can help ensure that fasteners are securely mounted and distribute the load evenly, thereby reducing the risk of failure or collapse.
Being able to position the fastener on different positions in the profile is an important factor because it provides flexibility in the installation process and allows for customization based on the specific requirements of the project. Certain projects may have unique design requirements that require flexibility in the positioning of the fasteners along the profile. For example, a project may require a specific spacing between fasteners, or the fasteners may need to be positioned in a particular pattern.
Therefore, profiles are often designed and hence tailormade to work with specific fasteners or attachment systems. Ensuring compatibility between the profile and the specific fastening system can be critical to the structural integrity and safety of the installation. However, the existing profiles and fasteners are not always cost-efficient, and the availability may be limited. Furthermore, the existing profile may have a complex design which is limited in its flexibility of use areas.
Therefore, there is a need for a more cost-efficient profile which provides better availability for the fastening arrangement while still allowing a reduced work effort during installation.

Summary

It is an object of the present disclosure to provide a prefabricated system for assembling a balcony, a pergola, a screen, a railing, or a roof that addresses at least some of the problems mentioned in the technical background, namely, to increase the number of possible use areas for a specific profile and to provide a profile that is less complex and more cost-efficient. Another object is to provide a profile where it is easy to position the fastener along the profile. Yet another object is to provide a profile that allows a reduced installation time at the work site.
These and other objects are met by a prefabricated system for assembling a balcony, a pergola, a screen, a railing, or a roof. The prefabricated system comprises an elongated profile and at least one first fastening element. The elongated profile, as seen in a transverse cross section, comprises: a groove having an open end into which the at least one fastening element has been inserted and wherein the at least one fastening element has been slid along a longitudinal extension of the groove into a desired position of the at least one first fastening element in view of the longitudinal extension of the groove, and at least one deformation portion formed in an inner wall portion of the groove. The at least one first fastening element, when slid to the desired position, has been subjected to a force in a direction transverse the longitudinal extension of the groove and towards the at least one deformation portion to thereby plastically deform the at least one deformation portion and restrict movement of the first fastening element, whereby the at least one first fastening element is fixedly secured in the groove of the elongated profile.
The prefabricated system offers the possibility to prepare the elongated profile off-site, allowing for faster construction timelines compared to traditional on-site installation methods. Further, the assembly of the prefabricated system is performed in controlled environments which allows for stricter controls and hence a higher-quality end product. This may result in a product with fewer defects while still achieving a faster installation time. Since the assembly is performed off-site the prefabricated system can reduce the project completion time and also minimize the disruption to the surroundings as less time is spent on-site. Prefabricated systems are engineered and tested for performance, ensuring consistent results and reliability across projects. This may lead to better long-term performance and durability of the building element.
The groove allows the first fastening element to move freely along the elongated profile, which allows the first fastening element to be positioned at a desired location along the elongated profile before fixation. Thereby, a flexibility is provided as to where the first fastening element can be positioned along the profile. Depending on the design of the elongated profile, the groove may have at least one point of entry. The at least one deformation portion allows the first fastening element to be locked from moving by applying a force to the first fastening element such that it moves from the groove into engagement with the at least one deformation portion. Thereby, the first fastening element can be positioned into the desired position along the interior of the groove and then be secured in that position by generating a plastic deformation when the first fastening element is forced into the at least one deformation portion. This is advantageous as it allows the first fastening element to be pre-mounted in the desired position before the elongated profile is transported to the work site.
In the context of the present patent application, the term "plastic deformation" is to be understood as an intentional deformation of material that is caused by actively forcing the first fastening element in a direction towards the at least one deformation portion, where the applied force is sufficiently high to cause a permanent re-shaping of the material in the at least one deformation portion.
When the first fastening element is forced into the deformation portion, the deformation portion is plastically deformed which secures the first fastening element such that the movement is restricted. The plastic deformation occurs due to the first fastening element forcing the material in the deformation portion to plastically deform. The force on the first fastening element causes it to penetrate into the deformation portion, which results in a permanent change in the shape of the deformation portion. When the first fastening element is positioned in the deformation portion, the plastically deformed portions of the deformation portion will secure the first fastening element through friction, such that first fastening element is not allowed to easily move back to the groove. When the first fastening element is in position in the deformation portions and the pulling or pushing force that is applied to the first fastening element is released, areas around the first fastening element will elastically rebound. This will tighten the deformation portions around the first fastening element. As the deformation portion extend along the longitudinal extension of the elongated profile it is not possible for the first fastening element to move in the longitudinal extension either. Hence, the first fastening element is prevented from movement in both the rotational direction and the transversal direction. This facilitates the installation process as the fastening element will neither rotate nor move along the elongated profiled when installing a system to the fastening element and hence to the elongated profile.
Furthermore, the elongated profile may provide a less complex design. As the deformation portion secures the first fastening element, there is no need of any specific designed element or tool to move a fastening element along the groove or to secure the fastening element in the desired position. The first fastening element may be a nut that is moved along the groove and secured in the deformation portion. The first fastening element may be a bolt, or a screw, that is moved along the groove and where the head is secured in the deformation portion. Nuts, bolts, and screws are stock goods and as different kinds of first fastening element may be used, the use of the elongated profile is not restricted by the availability of a specific fastening element.
The first fastening element may have a shape such that it is restricted from rotational movement in the groove, thereby only allowing the first fastening element to be moved along the longitudinal extension of the groove. This would allow the first fastening element to be moved along the groove and then the first fastening element can be forced into the desired position by mounting it to a second fastening element.
The elongated profile may be configured to be delivered to an installation site with the at least one first fastening element fixedly secured in the desired position.
By preparing the elongated profile off-site and then transporting the elongated profile as a prefabricated system to the installation site, time savings during installation may be achieved. This allows the labourer to avoid mounting the first fastening element to the elongated profile at the installation site where the labour often is performed at heigh heights when installing for example a balcony fence. Hence, the safety of the labourer is improved. If it is a balcony fence that will be mounted to the elongated profile, there may for example be a fastening device for each balcony post and the fastening device are pre-mounted with a specific distance such that the balcony posts easily can be mounted at the installation site. When the first fastening element is fastened towards the balcony post, the force forcing the first fastening element towards the balcony post will further improve the fixedly secured position. For example, the nut and the bolt will be forced together, locking the first fastening element in the desired position.
Further, the deformation portion allows the labourer to force the first fastening element out from the deformation portion and to move the first fastening element to a new position. This may be advantageous if an error occurred during prefabrication and the first fastening element have to be moved to fit with the balcony post.
The desired position may be based on digital data of the balcony, the pergola, the screen, the railing, or the roof to be assembled.
For companies installing the same type of product repeatedly it may be advantageous the more streamlined the installations process is. By providing digital data, such as a CAD-model, of the product to be produced a more efficient production may be achieved. The digital data may provide where the desired position is for each fastening element, thereby allowing for an easy manufacturing of the prefabricated system. Further, with digital data the desired position is easily changed resulting in a prefabricated system that is easy to adapt to different types of applications. For example, one building may require a specific type of fence for the balcony which requires one type of distance between the fastening elements, while another building may require another distance between the posts, i.e., the fastening elements in the elongated profile. With digital data this can be easily marked and thereby a manuscript for how the fastening elements should be mounted could be produced. The digital data may also be used for producing the elongated profile.
The direction of the force to be applied to the first fastening element, may form an angle in the range of 60°-90° to the longitudinal direction of the elongated profile. The direction transverse to the longitudinal direction may be towards the prefabricator or away from the prefabricator. Thus, the first fastening may be configured to be either pushed or pulled to plastically deform the deformation portion. The force required may be applied directly by the prefabricator or through a tool, such as a pliers. A prefabricator is seen as a person working with producing the prefabricated system at the fabric.
The deformation portion may be defined by a portion having a smaller width than a width of the groove.
The force to the first fastening element may be applied in a direction orthogonally to the longitudinal extension of the elongated profile.
With the force being orthogonal, the precision of where in the groove the first fastening element is secured may be further increased.
The groove may comprise an opening that is configured to allow the first fastening element to be connected to a second fastening element by a portion of one of the first fastening element or the second fastening element extending through said opening.
It may be advantageous with the opening as it provides an easy way of connecting the first fastening element to the second fastening element and thereby securing a construction element to the elongated profile. The opening also further facilitates the positioning of the first fastening element in the groove as the access to the groove is facilitated. As an example, the first fastening element may be a bolt where the head is inserted in the groove, and where the threaded shaft extends through the opening. By holding the threaded shaft and moving the first fastening element to a desired position, the head of the bolt may slide in the groove to said desired position. At said desired position the head of the bolt is forced, either by pulling or pushing, into the deformation portion and the second fastening element, in this case a nut, is screwed onto the shaft of the bolt with the construction element in-between the first and the second fastening element. However, it should be noted that it may be the other way around as well. The nut may be the first fastening element and the second fastening element may be the bolt with its shaft extending through the opening.
Furthermore, the second fastening element may be used to force the first fastening element in the direction transverse to the longitudinal extension of the elongated profile. Thereby, the first fastening element is forced into engagement with the deformation portion.
The opening may have a width that is smaller than a maximum width of the first fastening element.
With the width of the opening being smaller than the maximum width of the first fastening element, the first fastening element may be supported by the walls defining the opening when connected with the second fastening element. Thereby, it may be ensured that the first fastening element is secured in its position and there is no risk that the first fastening element falls out from the opening.
The first fastening element may also be locked against the walls defining the opening by connecting the first fastening element to the second fastening element and forcing the two fastening elements together. As in the earlier discussed example, the head of the bolt may be pushed towards the walls defining the opening by threading the nut tighter towards the construction element and thereby pulling the head of the bolt tighter towards the walls defining the opening.
The elongated profile may comprise two deformation portions, said two deformation portions being arranged in two opposing inner wall portions of the groove. It is to be understood that the elongated profile may have more than two deformation portions.
With two deformation portions, the first fastening element may plastically deform the two deformation portions at both opposing inner wall portions when forced into the deformation portions. When the first fastening element is in position between the two deformation portions and the pulling or pushing force that is applied to the first fastening element is released, areas around the first fastening element will elastically rebound from both of the opposing inner wall portions. This will tighten the deformation portions around the first fastening element. Thereby, the first fastening element may be secured in the deformation portions with a further increased friction force that secures the first fastening element in the deformation portion. Hence, a stronger force may be required to remove the first fastening element from the deformation portion.
Furthermore, the strength of each deformation portion may be reduced which may reduce the force needed to move the first fastening element in the direction transverse to the longitudinal extension of the groove, while still retaining a high friction force to the first fastening element, when in the deformation portion.
The at least one deformation portion may comprise a plurality of sub-portions that extend in parallel with each other.
The plurality of sub-portions may be designed so that the force that is needed to move the first fastening element into a locking engagement with the deformation portion is gradually increased in a stepwise manner. In other words, the plastic deformation may occur for one sub-portion at the time.
The plurality of sub-portions, as seen in the transverse cross section of the elongated profile, may have a gradually increasing height as seen in a direction from an inner wall of the groove opposite the opening towards the opening, or in a direction from the opening towards the inner wall of the groove opposite the opening. With a gradually increasing height, the sub-portions may further facilitate forcing the first fastening element into the deformation portion, by gradually increasing the amount of material that have to be plastically deformed. Thereby, the force needed to move the first fastening element is gradually increasing. In other words, the sub portions may have a gradually increasing height in the direction in which the first fastening element is subjected to a force when fixedly securing the first fastening element in the elongated profile.
The at least one deformation portion may have a barbed cross-sectional profile. The barbed cross-sectional profile may increase the force securing the first fastening element when the first fastening element is secured in the deformation portion. Thus, the barbs may grab the first fastening element.
A distance of the groove at the at least one deformation portion may be smaller than the maximum width of the first fastening element.
It may be advantageous with the smaller width at the at least one deformation portion as it may ensure that the deformation portion is plastically deformed when the first fastening element is forced into the deformation portion.
The first fastening element may have a portion with a polygonal cross section. Non-limiting examples of polygonal cross sections are a quadrangular or a hexagonal cross section. It may be advantageous with the non-rotation symmetry as the risk of the first fastening element rotating when secured in the deformation portion is reduced. The plastic deformation created by the non-rotation symmetry will be asymmetrical and therefore rotational movement may need to overcome the parts of the deformation portion that has not been subject to plastic deformation. The non-rotational symmetry may also restrict the first fastening element from rotating when the first fastening element is located in the groove.
The elongated profile may be an extruded profile. Extrusion is a cost-effective and automated method for producing profiles. The consistency may be advantageous when producing elongated profiles that need to meet specific requirements. The elongated profile may be made of aluminium or lightweight metal. Aluminium and lightweight metals are despite their light weight a strong material that can withstand significant loads and stresses which result in it being suitable materials for extrusion. Still, aluminium, or lightweight metal is typically fairly easy to deform plastically.
According to a second aspect of the present disclosure the prefabricated system of the first aspect may be used for assembling a balcony, a pergola, a screen, a railing, or a roof.
According to a third aspect of the present disclosure, a method for producing a prefabricated system is provided. The method comprises providing an elongated profile, wherein the elongated profile, as seen in a transverse cross section, comprises a groove configured to allow the at least one first fastening element to be received in the groove and to freely slide along the groove, and at least one deformation portion formed in an inner wall portion of the groove, inserting a first fastening element into the groove of the elongated profile; moving the first fastening element inside and along the groove into a desired position; and forcing the first fastening element in a direction transverse to the longitudinal extension of the elongated profile towards the at least one deformation portion and plastically deforming the at least one deformation portion, thereby restricting movement of the at least one first fastening element by fixedly securing the at least one first fastening element to the elongated profile.
The first fastening element may be forced in the direction transverse to the longitudinal extension of the elongated profile by lockingly engaging the first fastening element with a second fastening element.
The first fastening element may be a nut and the second fastening element may be a bolt; or the first fastening element may be a bolt and the second fastening element may be a nut.
The elongated profile and its advantages have been thoroughly discussed above. These are equally applicable for the second, third and fourth aspects.
A further scope of applicability of the present invention will become apparent from the detailed description given below. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the scope of the invention will become apparent to those skilled in the art from this detailed description.

Brief description of the drawings

The present disclosure will by way of example be described in more detail with reference to the appended drawings, which show example embodiments of the disclosure.

Fig. 1: illustrates a balcony where the fence posts are mounted with a prefabricated system.
Fig. 2: illustrates a perspective cross-sectional view of an elongated profile.
Fig. 3A-3C: illustrate a transverse cross-sectional view of three different embodiments of an elongated profile.
Fig. 4A-4D: illustrate a sequence of assembling the prefabricated system for two different embodiments.
Fig. 5: illustrates a fifth embodiment of an elongated profile.
Fig. 6: illustrates a method for mounting assembling a prefabricated system.

Detailed description

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and to fully convey the scope of the invention to the skilled person.
Turning to Fig. 1, a balcony 5 that is mounted to a wall 2 of a building is illustrated. The balcony 5 has a railing 4 that is mounted with a plurality of fence posts 3 to an elongated profile 1 that forms part of a construction element 6 of the balcony 5. The construction element 6 may by way of example be a bottom plate of the balcony 5. The balcony 5 will be used as an example but it should be noted that the elongate profile may be used in other construction elements as well, for example as a prefabricated system 100 for assembling a pergola, a screen, a railing, or a roof. The prefabricated system 100 comprises an elongated profile 1 and a first fastening element 30 and may be used for suspending for example a railing.
The disclosed elongated profile 1 comprises two grooves 10 that extend along the extended profile 1. Each side of the balcony 5 that is equipped with a railing 4 has elongated profiles 1 to facilitate the installation of the railing 4. The fence posts 3 are mounted with a respective first fastening element 30 that is located inside the groove 10 and that protrudes out from an opening 14 of the groove 10.
A second fastening element 40 is used to clamp the fence post 3 toward the first fastening element 30 and thereby towards a side wall of the bottom plate 6 of the balcony 5. The two grooves 10 allow each fence post 3 to be mounted in two points towards the bottom plate 6 which further secures the fence post 3 and thereby the railing 4 to the balcony 5. However, it should be noted that it may with remained functionality be the second fastening element 40 that protrudes into the opening 14 and that the first fastening element 30 is mounted in the groove 10 and receives the second fastening element 40 when the second fastening element 40 extends into the groove 10.
Turning to Fig. 2, one embodiment of the elongated profile 1 is illustrated in a perspective cross-sectional view. The elongated profile 1 may be an extruded profile. The profile may, as a non-limiting example, be made of aluminium or light metal.
The elongated profile 1 comprises the two grooves 10 that are configured to allow the first fastening element 30 that is received in the groove 10 to freely slide along the groove 10. The first fastening element 30 is configured to be inserted to the groove 10 from one open end 16 of the groove 10. The fastening element 30 may be allowed to be inserted from either only one of the ends 16 of the groove 10 or both of the ends. The groove 10 allows the first fastening element 30 to move freely along the elongated profile 1. Thereby, the first fastening element 30 may be positioned by a sliding movement into a desired location along the elongated profile 1.
The first fastening element 30 may be a nut that is moved along the groove 10. Alternatively, the first fastening element 30 may be the head of a bolt, or a screw, that is moved along the groove 10. In Fig. 2 the first fastening element 30 is a nut and the second fastening element 40 is a bolt. A threaded portion 32 of the second fastening element 40 extends through the opening 14 and allows the second fastening element 40 to be mounted to the first fastening element 30.
The skilled person realises that in the event the first fastening element 30 is a bolt, the bolt head will be received in the groove 10 and its threaded shaft will extend through the opening 14 and allow the second fastening element 40 in the form of a nut to be mounted by threading to the first fastening element 30.
The groove 10 has two deformation portions 20 that are formed in a respective inner wall portion 12a, 12b of the groove 10. The two deformation portions 20 are configured to be plastically deformed to thereby restrict movement of the first fastening element 30. The deformation allows a restriction of the movement of the first fastening element 30 along the longitudinal extension of the groove 10 but also in a direction transverse the longitudinal extension of the groove 10.
The plastic deformation is the result of the first fastening element 30 being forced in a direction towards the deformation portion 20 when a force is applied to the first fastening element 30 in a direction transverse the longitudinal extension L of the elongated profile 1. The force is generated by tensioning the threaded engagement between the first and second fastening elements 30, 40. As the engagement is tensioned, the fastening element 30, contained in the groove 10, no matter if it is a nut or a bolt head, will cause a plastic deformation of the deformation portion 20 in a direction transverse the longitudinal extension of the groove 10. This deformation will restrict/prevent a sliding/rotational movement of the first fastening element 30 inside the groove 10. Alternatively, the first fastening element 30 may be pulled by a prefabricator or through a tool into the deformation portion 20. Furthermore, when the first fastening element 30 is in position between the two deformation portions 20 and the force that is pulling or pushing the first fastening element 30 is released, areas around the plastically deformed portions 20 will at least to some extent elastically rebound. This will tighten the deformation portions 20 around the first fastening element 30.
In other words, the first fastening element 30 contained in the groove 10 may be positioned in a sliding manner in the groove 10, where it is allowed to slide freely along the groove 10. Alternatively, the first fastening element 30 may be arranged in a secured position in the groove 10, in which secured position it has plastically deformed the deformation portions 20 whereby it is restricted/prevented from moving, both in terms of a rotational movement and a longitudinal movement. This will be further described in connection to Fig. 4A-4D. This applies no matter if the first fastening element 30 is a nut or a bolt head.
This facilitates the installation process as the first fastening element 30 will neither rotate nor move along the elongated profile when installing a system to the first fastening element 30 and hence to the elongated profile 1.
Turning to Fig. 3A-3C, three different embodiments of the elongated profile 1 are illustrated as transverse cross-sectional views. It is mainly the deformation portions 20 in the three embodiments that differ from each other. The deformation portions 20 of the three embodiments have in common that the deformation portions 20 protrude out from the two opposing inner wall 12a, 12b and into the void volume of the groove 10. Thus, a distance d3 as measured between the tips of two opposing deformation portions 20 is comparably smaller than a distance d4 of the groove 10 as measured on at least one side of the two opposing deformation portions 20 and preferably on both sides of the two opposing deformation portions 20. The two opposing deformation portions 20 are further defined by that the distance d3 as measured between the tips of two opposing deformation portions 20 is comparably larger than a width d1 of the opening 14 of the groove 10.
In Fig. 3A, each deformation portion 20 is a portion 22 that protrudes out from the inner wall 12a, 12b and forms a bulge in the groove 10. Each deformation portion 20 extends along the longitudinal extension L of the elongated profile 1 as a result of the elongated profile preferably being an extruded profile. The deformation portions 20 are located in the groove 10 and adjacent to the opening 14.
In Fig. 3B, the deformation portions 20 are a plurality of sub-portions 22a, 22b that extend in parallel with each other along the longitudinal extension L of the elongated profile 1. The sub-portions 22a, 22b have a pointy shape and are positioned in the groove 10 adjacent to an inner wall 18 opposite to the opening 14. Two sub-portions 22a, 22b are disclosed. The skilled person realises that more than two sub-portions may be provided.
In Fig. 3C, the deformation portions 20 are a plurality of sub-portions 22c, 22d. The sub-portions 22c, 22d have substantially uniform cross-sectional size and height. The deformation portions do together form a barbed cross-sectional profile. As an alternative to the sub-portions having the same cross-sectional size and height, the skilled person realises that the sub-portions may have a gradually increasing cross-sectional size and height as seen in a direction towards the opening 14 or even have a gradually decreasing cross-sectional size and height.
The sub-portions 22c, 22d extend along the longitudinally extension of the elongated profile 1. The sub-portions 22c, 22d are located adjacent to the opening 14. The principle is equally applicable if the deformation portions instead would be arranged adjacent to a wall opposite the opening 14 as in Fig. 3B.
As can be understood from the three embodiments, the deformation portions 20 may be designed in a plurality of ways. How the deformation portions 20 are designed is dependent of what functions are desired to achieve and which requirements that are set on the construction. For example, the sub-portions 22a-d may be designed such that the force that is needed to move the first fastening element 30 into a locking engagement with the deformation portions 20 is gradually increased in a stepwise manner. In other words, the plastic deformation may occur for one sub-portion 22a-d at the time. With a gradually increasing cross-sectional size the sub-portions 22c, 22d may further facilitate forcing the first fastening element 30 into engagement with the respective deformation portion 20, by gradually increasing the amount of material that have to be plastically deformed. In other words, the plurality of sub-portions 22a-d may have a gradually increasing height as seen in a direction from the groove 10 where the first fastening element 30 is allowed to freely slide and towards the deformation portion 20.
Thereby, the force needed to move the first fastening element 30 is gradually increased. A barbed cross-sectional profile may increase the force that secures the first fastening element 30 when the first fastening element 30 is secured in the deformation portion 20. Thus, the barbs may grab the first fastening element. Furthermore, the distance d3 as measured between the tips of two opposing deformation portion 20 may be designed based on the required strength of the construction element. A comparably smaller distance d3 equals a comparably larger plastic deformation, which may increase the strength holding the first fastening element 30. As is understood by the skilled person, the design of the deformation portion is not limiting for the invention.
Turning to Fig. 4A-4D, where a sequence assembling the prefabricated system 100 and to mounting the first fastening element 30 to the second fastening element 40 is illustrated. Each figure illustrates two embodiments of the elongated profile 1. In the figures to the left, constituting the first embodiment, the deformation portion 20 is positioned adjacent to the opening 14 and a bolt is used as the first fastening element 30 and a nut is used as the second fastening element 40. In the figures to the right, constituting the second embodiment, the deformation portion 20 is positioned adjacent to the inner wall 18 opposite to the opening 14 and the first fastening element 30 is a nut and the second fastening element 40 is a bolt.
In Fig. 4A, the first fastening element 30 have been positioned at the desired longitudinal position in the groove 10. In the first embodiment the first fastening element 30 has been moved to the desired longitudinal position by holding the portion 32 that protrudes out from the opening 14. The second fastening element 40 is loosely mounted to the first fastening element 30. In the second embodiment the first fastening element 30 has been located in the groove 10 by holding and moving the second fastening element 40 to the desired position. A width d2 of a portion 34 of the first fastening element 30 is comparably larger than the distance d3 as measured between the tips of two opposing deformation portions 20 and also comparably larger than the width d1 of the opening 14.
In Fig. 4B, the first fastening element 30 is pushed or pulled into engagement with the deformation portions 20, thereby plastically deforming the deformation portions 20. The force to move the first fastening element 30 may be applied by hand or through a tool. In the first embodiment, the first fastening element 30 may also be locked against the walls defining the opening 14 by connecting the first fastening element 30 to the second fastening element 40 and threading the two fastening elements together. Thereby, the first fastening element 30 is forced into the deformation portion 20.
The direction of the force to be applied to the first fastening element 30, may form an angle in the range of 60°-90° to the longitudinal direction L of the elongated profile 1. This may be performed by pulling or pushing the first fastening element 30 with an angle into the deformation portions 20. The angle is measured between the force applied and the longitudinal direction of the elongated profile 1.
To enhance the precision when the first fastening element 30 is forced into the deformation portion 20, the force to the first fastening element 30 may be applied in a direction orthogonally to the longitudinal extension L of the elongated profile 1.
When the first fastening element 30 is forced into the deformation portion 20, the plastic deformation will occur due to the larger width d2 of the first fastening element 30. To be able to move the first fastening element 30 into the deformation portions 20, the force is required to be large enough for the plastic deformation to occur. The plastic deformation occurs due to the first fastening element 30 forcing the material in the deformation portions 20 to plastically deform. The force on the first fastening element 30 causes it to penetrate into the deformation portion 20, which results in a permanent change in the shape of the deformation portions 20. When the first fastening element 30 is positioned in the deformation portions 20, the plastically deformed portions of the deformation portions 20 will secure the first fastening element 30 through friction, such that first fastening element is not allowed to move back to the groove.
It may be advantageous with the non-rotational cross section of the first fastening element 30 as the risk of the first fastening element 30 rotating when secured in the deformation portion 20 is reduced. The plastic deformation created by the non-rotational cross section will result in a non-rotational geometry for the plastically deformed deformation portion 20 as well. Therefore, the first fastening element 30 may be restricted from rotational movement in the deformation portion 20. The non-rotational cross section may also restrict the first fastening element 30 from rotating when the first fastening element 30 is located in the groove 10.
In Fig. 4C, the second fastening element 40 has been removed. The elongated profile 1 may be prepared until the position in Fig. 4C before the elongated profile 1 is transported to the installation site where it will be used. Fig. 4C provides an example of how the prefabricated system 100 is prepared off-site before being sent to the installation site.
In Fig. 4D, a building element 7 is mounted between the first fastening element 30 and the second fastening element 40 of the prefabricated system 100. In the first embodiment a hole of the building element 7 is positioned at the threaded portion 32 that extends out from the opening 14 of the elongated profile 1, such that the threaded portion 32 extends through the hole of the building element 7 as well. Thereafter, the second fastening element 40 is threaded onto the first fastening element 30 to secure the building element 7 to the elongated profile 1.
In the second embodiment, the second fastening element 40 is positioned through the hole of the building element 7. Thereafter, the building element 7 is positioned such that the threaded portion 32 of the second fastening element 40 extends through the opening 14 whereafter it is threaded onto the first fastening element 30. In the second embodiment, the deformation portion 20 may have the required strength to hold the building element 7. In other embodiments, the first fastening element 30 may be threaded back towards the walls of the opening and thereby locking the building element 7 in position.
The steps in Fig 3A to 3C may be prepared off-site during production such that an elongated profile 1 with first fastening elements 30 already mounted is delivered to the installation site, such that the labourer directly can mount building element 7 with the second fastening element 40.
Turning to Fig. 5, a fifth embodiment of an elongated profile 1 is illustrated. The first fastening element 30 may, in the fifth embodiment, be positioned anywhere along the groove 10. The first fastening element 30 is positioned into the groove while producing the prefabricated system 100. A hole 50 may be provided at a desired position in the inner wall 18 opposite the opening 14. The hole 50 allows the second fastening element 40 to be connected to the first fastening element 30 that is located in the deformation portion 20. This allows the prefabricator to provide the hole 50 at the desired position and thereafter position the first fastening element 30 in the deformation portions 20 at the desired position before the elongated profile 1 leaves the fabric. The first fastening element 30 may be forced into the deformation portions 20 by attaching the second fastening element 40 and force the first fastening element 30 to plastically deform the deformation portions 20 by tightening the second fastening element 40 to the first fastening element 30. Thereby, the first fastening element 30 is forced towards the inner wall 18. Thereafter, the second fastening element 40 may be removed until the prefabricated system 100 should be mounted. However, it should be noted that the first fastening element 30 may be forced into the deformation portion by a prefabricator or a tool as well.
Turning to Fig. 6, a method 200 for producing a prefabricated system by mounting a fastening system to an elongated profile 1 is provided. The method 200 comprises, providing 210 an elongated profile 1, inserting 220 a first fastening element 30 into the groove 10 of the elongated profile 1, moving 230 the first fastening element 30 inside and along the groove 10 into a desired position and forcing 240 the first fastening element 40 in a direction transverse to the longitudinal extension of the elongated profile 1 towards the at least one deformation portion 20 and plastically deforming the at least one deformation portion 20, thereby restricting movement of the at least one first fastening element 30 by fixedly securing the at least one first fastening element to the elongated profile.
The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims.
By way of example, the exemplified embodiments disclose a groove with two or more opposing deformation portions. The skilled person realises that the same principle is equally applicable with one or more deformation portions on only one of two opposing inner wall portions of the groove. Also, the skilled person realises that the same principle is applicable with one or more deformation portions on the two opposing inner wall portions of the groove and where the deformation portions on one inner wall portion are laterally displaced in view of the deformation portions on the opposing inner wall portion.
Also, the skilled person realises that the deformation portions may have other cross-sectional geometries than those disclosed. The exemplified geometries are non-binding examples only.
The first and second fastening elements have been exemplified as nuts and bolts. The skilled person realises that other fastening elements may be applicable.
Although two grooves 10 are disclosed in the embodiment of Fig. 1, the skilled person realises that the number of grooves may be adapted to the actual design. Hence, it may be one or more grooves. Also, the skilled person realises that the longitudinal extension, or the cross-sectional shape of the respective groove may vary. An individual groove may have a straight extension or a curved extension.
Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

Claims

A prefabricated system (100) for assembling a balcony, a pergola, a screen, a railing, or a roof, the prefabricated system comprising an elongated profile (1) and at least one first fastening element (30), wherein the elongated profile (1), as seen in a transverse cross section, comprises:
a groove (10) having an open end (16) into which the at least one fastening element (30) has been inserted and wherein the at least one fastening element (30) has been slid along a longitudinal extension of the groove (10) into a desired position of the at least one first fastening element (30) in view of the longitudinal extension of the groove (10), and

at least one deformation portion (20) formed in an inner wall portion (12) of the groove (10),

wherein the at least one first fastening element (30), when slid to the desired position, has been subjected to a force in a direction transverse the longitudinal extension of the groove (10) and towards the at least one deformation portion (20) to thereby plastically deform the at least one deformation portion and restrict movement of the first fastening element (30), whereby the at least one first fastening element is by fixedly secured in the groove of the elongated profile.
The prefabricated system (100) according to claim 1, wherein the elongated profile is configured to be delivered to an installation site with the at least one first fastening element fixedly secured in the desired position.
The prefabricated system (100) according to claim 1 or 2, wherein the desired position is based on digital data of the balcony, the pergola, the screen, the railing, or the roof to be assembled.
The prefabricated system (100) according to any one of the preceding claims, wherein the force to the first fastening element (30) is applied in a direction orthogonally to the longitudinal extension of the elongated profile (1).
The prefabricated system (100) according to any one of the preceding claims, wherein the groove (10) comprises an opening (14) that is configured to allow the first fastening element (30) to be connected to a second fastening element (40) by a portion (32) of one of the first fastening element (30) or the second fastening element (40) extending through said opening (14).
The prefabricated system (100) according to claim 5, wherein the opening (14) has a width (d1) that is smaller than a maximum width (d2) of the first fastening element (30).
The prefabricated system (100) according to any of the preceding claims, wherein the elongated profile (1) comprises two deformation portions (20), said two deformation portions (20) being arranged in two opposing inner wall portions (12a, 12b) of the groove (10).
The prefabricated system (100) according to any one of claims 5 to 7, wherein the at least one deformation portion (20) comprises a plurality of sub-portions (22a-d) that extend in parallel with each other.
The prefabricated system (100) according to claim 8, wherein the plurality of sub-portions (22c, 22d), as seen in the transverse cross section of the elongated profile, have a gradually increasing height as seen in a direction from an inner wall (18) of the groove (10) opposite the opening (14) towards the opening (14) or in a direction from the opening (14) towards the inner wall (18) of the groove (10) opposite the opening (14).
The prefabricated system (100) according to any one of the preceding claims, wherein a distance (d3) of the groove (10) at the at least one deformation portion (20) is smaller than the maximum width (d2) of the first fastening element.
The prefabricated system (100) according to any one of the preceding claims, wherein the first fastening element (30) is a nut or a bolt.
The prefabricated system (100) according to any one of the preceding claims, wherein the elongated profile (1) is an extruded profile.
Use of a prefabricated system (100) according to any one of the preceding claims for assembling a balcony, a pergola, a screen, a railing, or a roof.
A method (200) for producing a prefabricated system, the method (200) comprising:
providing (210) an elongated profile (1), wherein the elongated profile (1), as seen in a transverse cross section, comprises a groove (10) configured to allow the at least one first fastening element (30) to be received in the groove (10) and to freely slide along the groove (10), and at least one deformation portion (20) formed in an inner wall portion (12) of the groove (10),

inserting (220) a first fastening element (30) into the groove (10) of the elongated profile (1);

moving (230) the first fastening element (30) inside and along the groove (10) into a desired position; and

forcing (240) the first fastening element (30) in a direction transverse to the longitudinal extension of the elongated profile (1) towards the at least one deformation portion (20) and plastically deforming the at least one deformation portion (20), thereby restricting movement of the at least one first fastening element (30) by fixedly securing the at least one first fastening element to the elongated profile.
The method (200) of claim 14, wherein the first fastening element (30) is forced in the direction transverse to the longitudinal extension of the elongated profile (1) by lockingly engaging the first fastening element (30) with a second fastening element (40).
The method (200) of claim 15, wherein the first fastening element (30) is a nut, and the second fastening element (40) is a bolt; or wherein the first fastening element (30) is a bolt, and the second fastening element (40) is a nut.