The present invention relates to a profile element for supporting at least one wall partition, in particular at least one drywall plasterboard partition, a method for producing a profile element and a system comprising a profile element and at least one wall section, in particular plasterboard.

Document WO 2008/087009 A1 describes a profile element being used for the construction of, e.g. light weight double partition walls. Such profile elements may be (vertically oriented) supporting components (studs) which absorb and transmit forces (mainly) in the direction of the longitudinal axis. Conventional profile elements have a C- or U-shape comprising two flange sections which are connected by a web. Wall sections, e.g. gypsum plasterboards are usually fixed to the flange regions (screwed, riveted, nailed or fastened by some other means).

In some situations, it is necessary to strengthen a wall system, e.g. where a noggin or pattress is required (within a partition) in order to support fixings (for example, a fixing for flat screen TV and/or cupboards). The adaption of partition boards, in particular drywall plasterboard partitions to such requirements is - at present - very cumbersome and complicated. Document EP1083267 A2 shows a profile element with the possibility of fastening further boards.

Document US4364212 A1 describes a metal stud, wherein the web has a plurality of small tabs, which are cut out and folded out of the metal sheet of the web.

Document FR2883895 A1 describes a H-profile with branches, wherein plates can be arranged in between these branches.

Document DE202013004213U1 describes a C- or U-profile, wherein different lower and/or upper end portions are possible.

It is an object of the present invention to propose a simple structure for adapting a wall partition, in particular a drywall plasterboard partition to the requirement of supporting fixations for heavy weight interiors such as TVs or cupboards. According to the invention, a profile element for supporting at least one board partition, in particular at least one drywall plasterboard partition, comprises a web, a first flange and a second flange, wherein at least one first additional fastening surface is provided on the web for fastening a (secondary) wall section, in particular for fastening a (secondary) plasterboard and at least one second additional fastening surface is provided at a distal end of the first flange and/or the second flange for fastening a (secondary) wall section, in particular for fastening a (secondary) plasterboard, wherein the first and second additional surfaces are flush-aligned.

A core idea of the invention is the use of the profile element itself to provide a further possibility for supporting a wall partition. In conventional profile elements, the flanges define the fastening surface. According to the invention, there is provided a separate (additional) fastening surface in addition to the flanges of the profile element. Thereby, it is possible (in a simple manner) to strengthen a wall partition, in particular a drywall plasterboard partition, e.g. by inserting a plywood or comparatively hard plasterboard into the construction. Precisely, this enforcing means (e.g. plywood or hard plasterboard) is fastened to the additional fastening surface. Specifically, a border area of the enforcing structure (e.g. a border area of an enforcing plate) can be fastened to the additional fastening surface (e.g. via screws, bolts or the like). Since the fastening surface is part of the profile element, there is no need for any additional bracketry or notching in order to fasten sections of supporting plates (e.g. a plywood or a gypsum board). Preferably, the fastening surface is planar. Thereby, it is very easy to fix a support structure for any interior (e.g. TV or high level cupboard) to the profile element. Preferably an offset is provided between the first flange and the additional fastening surface. The first flange and the additional fastening surface may be (structurally) separated, in particular by a step and/or a further surface having an angle of 45° to 135° (e.g. 90°) with respect to the first flange and/or the additional fastening surface.

At least one additional fastening surface is provided on the web. In addition, at least one additional fastening surface is provided at a distal end of the first flange. Alternatively or in addition, at least one additional fastening surface may be provided at a distal end of the second flange. Preferably, at least two additional fastening surfaces are provided on the web (or the first or second flange). The at least two additional fastening surfaces are aligned in parallel and flushing with each other. For example, it is preferred to have two fastening surfaces on the web, wherein the two fastening surfaces are arranged at different locations with respect to a width direction of the profile element (= with respect to a direction defined by the width of the web). Thereby, it is possible to provide two supporting structures on both sides of the profile element.

In preferred embodiments, the fastening surface is planar. The fastening surface is preferably parallel to the first and/or second flange and/or perpendicular to the web. The terms "parallel" and "perpendicular" may be understood as a degree of 0° or 90°. However, a deviation of 10° from an angle of 0° or 90° is acceptable in certain embodiments. Thus, the supporting (secondary) board can easily be fastened.

In different embodiments, the profile element has a C-shape, a U-shape or an I-shape. Other geometric structures are possible.

At least one first and one second fastening surface is provided. The first fastening surface is provided on the web. The second fastening surface is provided at a distal end of the first and/or second flange. The at least one first and at least one second fastening surface pare parallel to each other, and flush-aligned. Thus, a supporting (secondary) board can be fixed between two neighbouring profile elements by utilisation of the fastening surfaces of the two neighbouring profile elements. This simplifies a fixation of a supporting (secondary) board.

In an embodiment, a portion of the profile element (in particular of the web) is cut out and folded out in a radial direction so that a tab portion defining at least one fastening surface is formed. In general, the fastening surface may be formed by a projection (e.g. rectangular). If a portion of the profile element is cut out and folded, it may be hinged from the profile element (in particular web), thereby providing a fixing point for a supporting (secondary) board. Such structure is easy to produce and provides a comparatively high stability. Preferably, the cut out portion is used as service cut out (e.g. for installations as signal and/or power lines). In such a case, the cut out portion serves two (completely) different functions, thereby simplifying the structure of the profile element. In general, the invention comprises (as independent aspects) the use of a cut-out of a profile element (in particular of the above described kind) for providing a fastening surface and, preferably, as service cut out and/or, preferably, for installations as (signal and/or power) lines.

In order to achieve a high degree of stability, a portion of the profile element (in particular, of the web) may be rolled so that a projection defining at least one fastening surface is formed. As a result, the projection may consist of two adjacent layers of the profile element being connected by a bent portion of the profile element. The fastening surface may extend along the whole length of the profile element. In any case, the structure providing the fastening surface is very stiff and can bear a substantial load (e.g. of TVs or cupboards).

In a preferred embodiment, the profile element is an integral body (formed of one piece, e.g. of one piece of sheet). Alternatively, the profile element may consist of two (or more) parts. If the profile element is an integral body, it is very simple to produce and allows a sufficient degree of stability. The profile element is preferably made of metal, in particular aluminium and/or aluminium alloy and/or steel. "Made of" shall preferably mean that the complete profile element consists of the respective material. However, in alternative embodiments, it is sufficient if only a part of the profile element (e.g. at least 50% of the overall weight) is made of the respective material.

A distance of at least one fastening surface and a first or second flange may be 5 to 30 mm, preferably 10 to 20 mm, further preferably 12.5 mm. The profile element may have a length of 15 cm to 400 cm. The profile element may have a maximum width (e.g. being defined by the maximum width of the web and/or the first and/or the second flange) of 30 to 250 mm, preferably 50 to 100 mm. At least one fastening surface may have a maximum width of 15 to 40 mm, in particular 20 to 30 mm, preferably 25 mm. The profile element may have an (average) thickness of 0.3 mm to 2 mm.

As an independent aspect of the present invention, a method for producing a profile element (in particular of the above-described kind) is proposed, comprising the steps:

1. a) providing a preliminary profile element comprising preliminary flanges and a preliminary web;
2. b) forming at least one additional fastening surface on the web of the preliminary profile element and at least one additional fastening surface at a distal end of at least one flange of the preliminary profile element, wherein the first and second additional surfaces are flush-aligned.

Step b) may comprise rolling a portion of the preliminary profile element, in particular the preliminary web in order to form at least one fastening surface. Alternatively or in addition, step b) may comprise cutting out a portion of the preliminary profile element, in particular the preliminary web and folding out the cut out portion in order to form a fastening surface. In general, the profile element may be formed (at least in part) by rolling and/or cutting.

According to an independent aspect of the present invention, a system is proposed comprising a profile element (of the above-described kind) and/or a profile element produced by the method of the above-described kind, and at least one wall section, in particular plasterboard, fastened to at least one fastening surface and/or the first and/or second flange. A distance between the at least one fastening surface and the first or second flange may correspond with the thickness of the wall section, in particular the thickness of the plasterboard.

In the following, preferred embodiments of the present invention are described with reference to the drawings.

These show:

Fig. 1

A plane view of a first embodiment of the present invention;

Fig. 2

an oblique view of the embodiment of Fig. 1;

Fig. 3

a cross-section along line III-III of Fig. 1;

Fig. 4

a side view of the embodiment of Fig. 1;

Fig. 5

a cross-section along line V-V in Fig. 1;

Fig. 6

an oblique view of the second embodiment of the present invention;

Fig. 7

a side view of the embodiment of Fig. 6;

Fig. 8

the embodiment of a profile element according to Fig. 1 with two panels mounted thereon;

Fig. 9

the embodiment of the profile element according to Fig. 6 with three panels mounted thereon;

Fig. 10

a third embodiment of the profile element of the present invention;

Fig. 11

a fourth embodiment of a profile element of the present invention;

Fig. 12

a fifth embodiment of a profile element of the present invention; and

Fig. 13

the third embodiment of the profile element of the present invention with seven panels.

Figs. 1 to 5 show a first embodiment of a profile element. The profile element comprises a first flange 10, a second flange 11 and a web 12. The web 12 comprises a cut-out 13 (see Figs. 1, 2 and 5) so that a tab portion 14 (see Figs. 2, 4 and 5) extends in a perpendicular direction from the web 12. The tab portion 14 is hinged from the web 12. A hinge axis is defined by line 15 in Figs. 1 and 2. Line 15 is (substantially) parallel to the longitudinal direction of the profile element. Tab portion 14 defines a first fastening surface 16 being (substantially) parallel to first flange 10 (and second flange 11). First fastening surface 16 is located near to flange 10. It is possible (not shown) to provide a further tab portion near to the second flange 11. A second fastening surface 17 is defined by a projection 18 which is located at a distal end 19 of the first flange 10. The (rectangular) projection 18 is (substantially) in parallel with the first flange 10 and connected with the first flange 10 by a connecting portion 20 (being rectangular and perpendicular to the flange 10). Connecting member 20 and projection 18 define a step onto which a panel or the like may be mounted. For example, a panel may be mounted to the first or second fastening surface 16, 17 via screws, bolts or by bonding or the like. A distal end 21 of the second flange 11 comprises a bent portion 22 (being perpendicular to the second flange 11). It is possible (not shown) to replace the bent portion 22 by a structure corresponding to projection 18 and connecting member 20.

Figs. 6 and 7 show a second embodiment of the profile element. The profile element of the second embodiment may be formed as the first embodiment with the following distinctions. The first fastening surface 16 is formed by rolling a portion of the web 12. Thereby, the first fastening surface 16 is defined by a double layer of the material of the profile element forming a projection 23. The projection 23 extends along the whole length of the profile element. The projection 23 is (substantially) perpendicular to the web 12 (and parallel to the first flange 10) and is located near to the first flange 10. It is possible to provide in addition or alternatively a corresponding projection 23 near to the second flange 11. Moreover, it is possible to provide a second fastening surface at the second flange 11.

Fig. 8 shows a cross-section of the first embodiment of the profile element with panels 24, 25. Panel 24 is fastened to the first fastening surface 16 by a fastening means (e.g. screw) 26. Similarly, the panel 25 is fastened to the second fastening surface 17 by a fastening means 26 (e.g. screw). An end 27 of the panel 24 may be fastened to a further profile element (not shown) which has preferably the same shape as the profile element which is shown in Fig. 8. Thereby, the panel 24 can be installed on both sides to a corresponding profile element. Panels 24, 25 may be, for example noggin panels for supporting a heavy interior (e.g. TV or cupboard). In general, panels 24, 25 may define (a part of) a wall partition.

Fig. 9 shows the second embodiment of the profile element together with panels 24, 25 and 36. Panels 24 and 25 are arranged as in Fig. 8. A further panel 36 is fastened by a fastening means 26 (e.g. screw) to the first flange 10 and defines a second layer on top of panels 24, 25. As can be seen in Figs. 8, 9, a thickness 28 of the panels 24, 25, corresponds with a distance 29 between a plane being defined by the fastening surfaces 16, 17 and a plane defined by the first flange 10. The distance 29 may be, for example 12.5 mm.

Fig. 10 shows a cross-section of a third embodiment of a profile element. The third embodiment is formed as the second embodiment with the following distinctions. In addition to projection 23 a projection 30 is provided (by rolling) near to a second flange 11. Projection 30 defines a third fastening surface 31. At the distal end 21 of the second flange 11, there is located a fourth fastening surface 32. The fourth fastening surface 32 is part of a projection 33 similar to the projection 18 at the distal end 19 of the first flange 10.

First, second and third embodiments are formed by an integral body (of one piece). Figs. 11 shows a fourth embodiment of a profile element consisting of two parts (e.g. being formed by rolling). A first part 34 is a (conventional) C-profile element, a second part 35a i is a (hat-shaped) overlay. Second part 35a defines first and second fastening surfaces 16, 17. First part 34 and second part 35a form together a profile element. This means, second part 35a is an overlay which is (in its final state) fastened to the first part 34. The fastening between the first part 34 and second part 35a can be achieved by bonding (e.g. via the use of a self-adhesive tape 42) or other means (welding, etc.). It is possible (as shown in Fig. 12) that two second (hat-shaped) parts 35a, 35b are provided. In such a further embodiment, the profile element consists of three parts (C-profile and two overlays 35a, 35b) which are fastened together.

The overlays 35a and 35b are fastened to flanges 10a, 10b of the first part 35 (conventional C-profile element) in particular via a (self-adhesive) tape. The overlays 35a, 35b of Figs. 11 and 12 have a "hat-shape" meaning that they comprise a central portion 43, two intermediate portions 44a and 44b being adjacent to the central portion 43 and perpendicular thereto, and fastening portions 45a and 45b being adjacent to the intermediate portions 44a and 44b and perpendicular thereto (and parallel to the central portion 35a). The overlay 35a of Fig. 11 defines first and second fastening surfaces 16, 17 and first flange 10. The second flange 11 is defined by flange 11a of the (conventional) C-profile element 34. In the embodiment of Fig. 12, first and second fastening surfaces 16, 17, are (as in Fig. 11) formed by the overlay 35a. The second flange 11 is formed by the second overlay 35b. First and second overlays 35a and 35b are preferably of the same shape.

Profile element 34 and overlay 35a (of Figs. 11 and 12) and/or overlay 35b (of Fig. 12) may be further fixed together via fastening means (e.g. screws) used to fix the plasterboards (compare Fig. 13).

Fig. 13 shows a part of a double layer partition wall. Altogether, there are seven panels 24, 25, 36, 37, 38, 39 and 40. Panels 24, 25, 37 and 38 are installed within a cavity 41 defined by panels 36, 39 and 40.

Alternatively, layers 24, 25, 37 and 38 may be omitted. Thus, a single layer wall can be achieved (where a double layer partition wall is not really necessary). The panels 39 and 40 may be replaced by one single panel. Panel 36 can be replaced by two panels (analogously to panels 39 and 40 being arranged at the second flange 11). Profile element of Fig. 13 can be replaced by any other profile element (e.g. the profile element of Fig. 11 and 12), wherein arrangement and number of panels can be adapted.

10

First flange

10a

First flange

11

Second flange

11a

First flange

12

Web

13

Cut-out

14

Tab

15

Line

16

First fastening surface

17

Second fastening surface

18

Projection

19

Distal end

20

Connection member

21

Distal end

22

Bent portion

23

Projection

24

Panel

25

Panel

26

Fastening means

27

End

28

Thickness

29

Distance

30

Projection

31

Third fastening surface

32

Fourth fastening surface

33

Projection

34

First part

35a

Second part

35b

Second part

36

Panel

37

Panel

38

Panel

39

Panel

40

Panel

41

Cavity

42

Tape

43

Central portion

44a

Intermediate portion

44b

Intermediate portion

45a

Fastening portion

45b

Fastening portion