Joint structure and method of forming at least a part of a joint structure

Abstract

Described is a joint structure comprising: a first and a second structural member, each structural member comprising a hollow cross-section defining at least a first wall, and an inner surface and an outer surface of the respective structural member; at least a first fixing plate extending along at least a part of a respective end portion of each of the first and second structural members, and adjacent the respective outer surfaces thereof; a plurality of threaded bolts extending through a corresponding one of a plurality of apertures in the first fixing plate and a corresponding one of a plurality of apertures in the respective first wall of each of the first and second structural members, each one of the plurality of bolts thread-wise engaging a corresponding one of a plurality of threaded nuts secured to the respective inner surface of the respective structural member at a location corresponding to the respective aperture in the respective first wall, such that the first fixing plate holds the first and second structural members in a pre-determined position relative to each other and transfers forces and moments between the first and second structural members. Also described is a method of forming a joint structure.

1 . A joint structure comprising:
 a first and a second structural member, each structural member comprising a hollow cross-section defining at least a first wall, and an inner surface and an outer surface of the respective structural member;   at least a first fixing plate extending along at least a part of a respective end portion of each of the first and second structural members, and adjacent the respective outer surfaces thereof;   a plurality of threaded bolts, each of the plurality of bolts extending through a corresponding one of a plurality of apertures in the first fixing plate and a corresponding one of a plurality of apertures in the respective first wall of each of the first and second structural members, each one of the plurality of bolts thread-wise engaging a corresponding one of a plurality of threaded nuts secured to the respective inner surface of the respective structural member at a location corresponding to the respective aperture in the respective first wall,   such that the first fixing plate holds the first and second structural members in a pre-determined position relative to each other and transfers forces and moments between the first and second structural members.   
     
     
         2 . The joint structure according to  claim 1 , wherein each of the first and second structural members comprises cold-formed first and second profiles, the respective first and second profiles nested into each other to define the respective hollow cross-section. 
     
     
         3 . The joint structure according to  claim 2  wherein each of the first and second profiles comprises a C-shaped cross-section. 
     
     
         4 . The joint structure according to  claim 2 , wherein each of the first profiles is secured to the respective second profile along at least a part of a length thereof by at least one of the processes of welding, metal inert gas (MIG) welding, metal active gas (MAG) welding, stick welding, submerged arc (SAW) welding, tungsten inert gas (TIG) welding, laser welding, brazing, soldering, and/or using an adhesive. 
     
     
         5 . The joint structure according to  claim 1 , wherein the plurality of threaded nuts is secured to the respective inner surface of the respective first and second structural member by at least one of the processes of welding, metal inert gas (MIG) welding, metal active gas (MAG) welding, stick welding, tungsten inert gas (TIG) welding, friction welding, laser welding, brazing, soldering, diffusion bonding, and/or using an adhesive. 
     
     
         6 . The joint structure according to  claim 1 , wherein each of the first and second structural members comprises a second wall, and wherein a second fixing plate is attached to the first and second structural members by a plurality of threaded bolts extending through a corresponding one of a plurality of apertures in the second fixing plate and a corresponding one of a plurality of apertures in the respective second wall of each of the first and second structural members, each one of the plurality of bolts thread-wise engaging a corresponding one of a plurality of threaded nuts secured to the respective inner surface of the respective structural member at a location corresponding to the respective aperture in the respective second wall. 
     
     
         7 . The joint structure according to  claim 6  wherein the first and second fixing plates extend in parallel at opposing sides of each of the first and second structural members, such that the first and second fixing plates hold the first and second structural members between them. 
     
     
         8 . The joint structure according to a  claim 1 , wherein the hollow cross-sections of each of the first and second structural members have a first height parallel to a main load-bearing direction of the first and second structural members, and wherein the first fixing plate, and any second fixing plate, is attached to each of the first and second structural members across substantially the whole of the first height thereof. 
     
     
         9 . The joint structure according to  claim 1 ,
 wherein the plurality of bolts comprises an identical or at least similar number of bolts assigned to each of the first and second structural members, arranged in a bolt pattern suitable for transferring bending moments, torsional moments, sheer forces, and normal forces between the first and second structural member.   
     
     
         10 . The joint structure according to  claim 1 , wherein each of the first and second structural members comprises an end plate welded or otherwise connected to an end section of the respective structural member at a portion thereof where a joint with the respective other of the first and second structural members is formed. 
     
     
         11 . The joint structure of  claim 10  wherein each end plate has a shape substantially identical to the respective hollow cross-section at the end section, and is continuously welded to the corresponding one of the first and second structural members along a periphery of its cross-section. 
     
     
         12 . The joint structure according to  claim 1 , wherein the hollow cross-section of each structural member comprises a maximum clearance dimension h max  and wherein the plurality of bolts is distributed along a major axis of each of the first and second structural members along a distance d parallel to a main bearing direction of each of the first and second structural members, a relationship between the maximum clearance dimension h max  and the distance d being defined by h max ≤d≤10·h max , and preferably by 2·h max ≤d≤5·h max . 
     
     
         13 . The joint structure according to  claim 1 , wherein the first and second structural components are arranged in one of an apex joint or frame corner configuration, wherein respective major axes of the first and second structural members are arranged in a common plane and at an angle to each other. 
     
     
         14 . A method of forming at least a part of a joint structure, comprising:
 S1. Providing at least a first and a second sheet blank to create flat projections of corresponding first and second profiles;   S2. In a pre-determined pattern, forming a plurality of apertures at end portions of the respective first and second sheet blanks;   S3. Cold-forming the first and second sheet blanks to create the first and second profiles, each of the first and second profiles having an open cross-section;   S4. Securing a plurality of threaded nuts to a first surface of each of the first and second profiles, such that each one of the plurality of nuts protrudes from the first surface at a location of a corresponding one of the plurality of apertures, and is configured to receive a corresponding threaded bolt inserted through the respective one of the plurality of apertures;   S5. Nesting the first and second profiles into each other to create a first structural member comprising a hollow cross-section defining at least a first wall, an inner surface, and an outer surface of the first structural member, wherein the nesting is performed such that the plurality of threaded nuts is located at the inner surface and within the hollow cross-section of the first structural member.   
     
     
         15 . The method of  claim 14 , wherein securing the plurality of threaded nuts to the first surface of each of the first and second profiles comprises applying at least one of the processes of welding, metal inert gas (MIG) welding, metal active gas (MAG) welding, stick welding, tungsten inert gas (TIG) welding, friction welding, laser welding, brazing, soldering, diffusion bonding, and/or using an adhesive. 
     
     
         16 . The method of  claim 14 , further comprising:
 S6. Securing the first and second profiles to each other at adjacent surfaces and along a length-wise direction thereof.   
     
     
         17 . The method of  claim 16 , wherein securing the first and second profiles to each other comprises applying at least one of the processes of welding, metal inert gas (MIG) welding, metal active gas (MAG) welding, stick welding, tungsten inert gas (TIG) welding, laser welding, friction welding, brazing, soldering, diffusion bonding, and/or using an adhesive. 
     
     
         18 . The method of  claim 14 , further comprising:
 S7. Securing, preferably by welding, a corresponding end plate to at least one end of the hollow cross-section of the first structural member, to form a closed end of the first structural member.   
     
     
         19 . The method of  claim 14 , further comprising: comprising the
 S8. Performing at least steps S1 to S5 and, preferably, steps S6 to S7, to thereby form a second structural member;   S9. Positioning the first and second structural members in a desired position relative to each other;   S10. Providing at least a first fixing plate extending along at least a part of a respective end portion of each of the first and second structural members, and adjacent their respective outer surfaces, the at least first fixing plate comprising a plurality of apertures corresponding to the plurality of apertures in the first and second structural members;   S11. Inserting a plurality of bolts through the plurality of apertures in the at least one fixing plate and the corresponding apertures in the at least first wall of each of the first and second structural members, such that each one of the plurality of bolts engages with and is thread-wise secured to a respective one of the plurality of threaded nuts.   
     
     
         20 . The method of  claim 19 , wherein:
 step S10 comprises providing a second fixing plate parallel to the first fixing plate such that the first and second structural members are held between the first and second fixing plates, the second fixing plate comprising a plurality of apertures corresponding to a plurality of apertures in the first and second structural members; and wherein   step 11 comprises inserting a plurality of bolts through the plurality of apertures in the second fixing plate and the corresponding apertures in the at least first wall of the first and second structural members, such that each one of the plurality of bolts engages with and is thread-wise secured to a respective one of the plurality of threaded nuts.   
     
     
         21 . The method of  claim 19 , wherein step S9 of positioning the first and second structural members in a desired position relative to each other comprises positioning the first and second structural members in one of an apex joint or frame corner configuration, wherein respective major axes of the first and second structural members are arranged in a common plane and at an angle to each other. 
     
     
         22 . (canceled) 
     
     
         23 . (canceled)