AU785225B2 - Structural member - Google Patents

Description

P/00/00 1 1 Regulation 3.2

AUSTRALIA

Patent Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

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*0@O Namne of Applicant: Actual Inventor: Address for service in Australia: John Silady John Silady

WALLINGTON-DUMMER

PO Box 297, Rydalmnere NSW 7 101 (12 Clarke Street, Rydalmere NSW 2116) Structural Member 0* 0 S 000 0 @6 0 @0 @0 Invention Title: *Details of Associated Provisional Application: Australian Provisional Application No. PR0344 filed 25 September 2000 Australian Provisional Application No. PR0343 filed 25 September 2000 Australian Provisional Application No. PR0506 filed 3 October 2000 The following statement is a full description of this invention, including the best method of performing it known to us 2 STRUCTURAL MEMBER The present invention relates to a structural member and, more particularly, such a member made from metallic components such as steel or the like.

BACKGROUND

It is known to make beams and other structural components from steel or like materials. Steel, for example, as a material has certain benefits in terms of inherent strength over, for example, wood.

However, steel and many other metallic materials are more dense than wood with the result that many implementations of structural components from steel in substitution for wood components suffer, for example, from being relatively heavy as 0000 e 15 compared with the wooden counterpart when used for a similar @000 "00• application.

A further problem with steel and other metallic implementations of structural components is that when the structural component is formed from a number of sub-components with a view to keeping the weight of the structure to a minimum, some of the inherent strength benefits of the metallic materials are lost as a result of the joining of the sub-components.

It is an object of the present invention to address or •ameliorate one or more of the abovementioned disadvantages.

0000 0000 BRIEF DESCRIPTION OF THE INVENTION Accordingly, in one broad form of the invention there is provided a multi-part structural member comprised of a base, a top panel and first and second side panels interconnected so as 30 to define a closed hollow section; said top panel including enveloping portions which envelope flange portions extending from said first and second side panels; said base including enveloping portions which envelope flange portions extending 3 from base portions of said first and second side panels; said enveloping portions incorporating relative movement resistance means adapted to minimize relative movement between said flange portions and said enveloping portions at least in the plane of engagement of said flange portions with said enveloping portions.

Preferably said movement resistance means comprises indentations in said enveloping portions which are seated in corresponding deformations in said flange portions.

Preferably said indentations are spaced at predetermined intervals along said enveloping portions.

Preferably said predetermined intervals is in the range 1cm to More preferably said predetermined intervals lies in the 15 range 5cms to l0cms.

*0oo In a particular preferred form said closed hollow section is a rectangular hollow section.

n an alternative particular preferred form said closed •co• So hollow section is a square hollow section.

Preferably said structural member is formed by a roll forming process.

Preferably said movement resistance means includes an overfold of said enveloping portions with said flange portions residing therein.

0005 In yet a further broad form of the invention there is O provided a method of joining portions of a multi-part structural member together, said method comprising the steps of: Forming at least a first flange in a first member; Forming an enveloping portion in a second member 30 adapted for interconnection to said first member; Causing said enveloping portion of said second member to envelope said flange of said first portion; 4 Forming indentations at predetermined intervals in said enveloping portions which extend sufficiently into said enveloping portions to cause corresponding indentations in said flange thereby to resist relative movement of said first member with respect to said second member, at least in the plane of engagement of said flange portions with said enveloping portions.

Preferably said method further includes the step of: Inserting said flange loosely in said enveloping portions; Overfolding said enveloping portions complete with said flanges therein; Forming said indentations at predetermined intervals in the resulting overfolded join region thereby to 06*S 15 cause the formation of corresponding deformations in said flanges.

In yet a further broad form of the invention there is provided an interconnection for a first part with a second part of a multi-part structural member, said interconnection comprising a flange of a first part engaged within an enveloping portion of said second part; said interconnection further including indentations in said enveloping portions which extend into corresponding indentations in said flanges.

In yet a further broad form of the invention there is provided a method of formation of the above interconnection "°."wherein said indentations and said corresponding deformations are formed at the same time.

Accordingly, in one broad form of the invention there is provided a multi-part structural member comprised of a base, a 30 top panel and first and second side panels interconnected so as to define a closed hollow section; said top panel including enveloping portions which envelope flange portions extending from said first and second side panels; said base including enveloping portions which envelope flange portions extending from base portions of said first and second side panels; said enveloping portions incorporating relative movement resistance means adapted to minimize relative movement between said flange portions and said enveloping portions at least in the plane of engagement of said flange portions with said enveloping portions.

Preferably said movement resistance means comprises indentations in said enveloping portions which are seated in corresponding deformations in said flange portions.

Preferably said indentations are spaced at predetermined intervals along said enveloping portions.

Preferably said predetermined intervals is in the range 1cm to l0cms.

o0o0 15 More preferably said predetermined intervals lies in the 0*e* range 5cms to l0cms.

In a particular preferred form said closed hollow section is a rectangular hollow section.

000@ 2 In an alternative particular preferred form said closed 20 hollow section is a square hollow section.

Preferably said structural member is formed by a roll forming process.

Preferably said movement resistance means includes an overfold of said enveloping portions with said flange portions 0000 residing therein.

In yet a further broad form of the invention there is provided a method of joining portions of a multi-part structural member together, said method comprising the steps of: Forming at least a first flange in a first member; 30 Forming an enveloping portion in a second member adapted for interconnection to said first member; Causing said enveloping portion of said second member to envelope said flange of said first portion; 6 Forming indentations at predetermined intervals in said enveloping portions which extend sufficiently into said enveloping portions to cause corresponding indentations in said flange thereby to resist relative movement of said first member with respect to said second member, at least in the plane of engagement of said flange portions with said enveloping portions.

Preferably said method further includes the step of: Inserting said flange loosely in said enveloping portions; Overfolding said enveloping portions complete with said flanges therein; Forming said indentations at predetermined intervals in the resulting overfolded join region thereby to ooo 15 cause the formation of corresponding deformations in 0. said flanges.

*see 0: In yet a further broad form of the invention there is 00 provided an interconnection for a first part with a second part of a multi-part structural member, said interconnection :0.

20 comprising a flange of a first part engaged within an enveloping portion of said second part; said interconnection further including indentations in said enveloping portions which extend into corresponding indentations in said flanges.

In yet a further broad form of the invention there is provided a method of formation of the interconnection wherein said indentations and said corresponding deformations are formed at the same time.

In yet a further broad form of the invention there is .5 "provided apparatus for roll forming an elongate panel having 30 ribs therein; said apparatus comprising opposed rollers having periodically raised portions thereon and adapted to impress said ridges into said panel as it passes through a rib forming region of said rollers; said apparatus further including slot guide 7 means adapted to slidingly receive edge portions of said panel therein in such manner as to resist extension of said ribs into such edge portions.

Preferably said guide means comprises opposed first slot guide and second slot guide.

Preferably said apparatus further includes ramp means disposed between said first opposed slot guide and said second slot guide; said ramp means including an inclined face which faces said rib forming region of said rolls.

In yet a further broad form of the invention there is provided a method of forming a ribbed panel; said panel having ribs extending laterally; said panel further including first and second opposed edge regions into which said ribs do not extend; said method comprising providing roll forming apparatus for the 15 formation of said ribs in said panel; said method further comprising providing guide means through which said edge portions slidingly move; said guide means resisting extension of said ribs, during formation thereof, into said edge regions.

Accordingly in one broad form of the invention there is

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20 provided a multi-part structural member comprised of a base, a top panel and first and second side panels interconnected so as to define a closed hollow section; said top panel including enveloping portions which envelope flange portions extending from said first and second side panels; said base including 0 25 enveloping portions which envelope flange portions extending from base portions of said first and second side panels; said enveloping portions incorporating relative movement resistance means adapted to minimize relative movement between said flange

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*0 portions and said enveloping portions at least in the plane of 30 engagement of said flange portions with said enveloping portions.

8 Preferably said movement resistance means includes an overfold of said enveloping portions with said flange portions residing therein.

In yet a further broad form of the invention there is provided a method of joining portions of a multi-part structural member together, said method comprising the steps of: Forming at least a first flange in a first member; Forming an enveloping portion in a second member adapted for interconnection to said first member; Causing said enveloping portion of said second member to envelope said flange of said first portion; Forming indentations at predetermined intervals in said enveloping portions which extend sufficiently into said enveloping portions to cause corresponding 15 indentations in said flange thereby to resist relative oooo movement of said first member with respect to said oooo second member, at least in the plane of engagement of "said flange portions with said enveloping portions.

~Preferably said method further includes the step of: 20 Inserting said flange loosely in said enveloping portions; Overfolding said enveloping portions complete with said flanges therein; oo Forming said indentations at predetermined intervals in the resulting overfolded join region thereby to cause the formation of corresponding deformations in said flanges.

In yet a further broad form of the invention there is

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.provided an interconnection for a first part with a second part 30 of a multi-part structural member, said interconnection comprising a flange of a first part engaged within an enveloping portion of said second part; said interconnection further 23.Au&. 2006 15:31 Wal I ington-Dummer Sydney No.6438 P. -9including indentations in said enveloping portions which extend into corresponding indentations in said flanges.

In yet a further broad form of the invention there is provided a support member comprising an elongate channel having a base and two spaced apart side panels, each side panel extending upwardly from the base and having a laterally extending flange at its upper edge remote from the base, and having a plurality of integrally formed ribs extending from or from adjacent the base, to the flange, the flange extending tangentially to a curved run out portion of the ribs; said support member further including relative movement resistance means formed in said flange.

In yet a further broad form of the invention there is provided a method of fabricating a support member comprising the steps of: Roll forming the parts comprising said member; pressing the first part of a suitable tool up around the side panels; simultaneously pressing a second cooperating part of the tool downwards onto the inner edges of the flanges, the first part of the tool forming inwardly indented ribs in the sides, and the second part of the tool forming downwardly and outwardly indented ribs across the fold of the flanges.

25 In a further broad form of the invention, there is provided a structural rectangular hollow section member comprising a top panel, a bottom panel and opposing side panels; each said panel separately formed by a roll-forming process from flat metal sheet; "said side panels provided with upper and lower flange portions; said flange portions enfolded by respective enveloping portions along opposing edges of said top panel and of said bottom panel;

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and wherein indentations are formed at predetermined intervals along said enveloping portions; said indentations extending sufficiently into said enveloping portions to cause corresponding 35 indentations in said flange portions; said indentations providing 35 indentations in said flange portions; said indentations providing o COMS ID No: SBMI-04547814 Received by IP Australia: Time 15:35 Date 2006-08-23 23:'Aug. 2006 15:31 WallIington-Dummer Sydney No.6438 P. 6 -9A resistance to longitudinal movement between said flange portions and said enveloping portions; said movement including movement induced by torsional loads.

Preferably, said indentations in said enveloping portions are formed concurrently with said corresponding indentations in said flange portions.

Preferably, each of said predetermined intervals is in the range 1cm to l0cms.

Preferably, each of said predetermined intervals lies in the range Scms to l0cms.

Preferably, the structural member is formed by a roll forming process.

In still a further broad form of the invention, there is provided a method of joining portions of a multi-part structural member together, said method comprising the steps of: roll-forming each part of said multi-part structural member from flat metal sheet, forming at least a first flange in a first part; forming an enveloping portion in a second part adapted for interconnection to said first part; causing said enveloping portion of said second part to envelope said flange of said first part; forming indentations at predetermined intervals in said enveloping portion which extend sufficiently into said enveloping portion to cause corresponding indentations in said flange portion thereby to resist relative movement of said first part with respect to said second part, at least in the plane of engagement of said flange portion with said enveloping portion.

Preferably, the method further includes the step of: inserting said flange portion loosely in said enveloping portion; overfolding said enveloping portion complete with said flange portion therein: COMS ID No: SBMI-04547814 Received by IP Australia: Time (I-tm) 15:35 Date 2006-08-23 23:Aug. 2006 15:31 Wallington-Dummer Sydney No.6438 P. 7 98 forming said indentations at predetermined intervals in the resulting overfolded join region thereby to cause the formation of corresponding deformations in said flange portion.

In still a further form of the invention there is provided an interconnection for a first roll-formed part with a second rollformed part of a multi-part structural member, said interconnection comprising a flange of said first part engaged within an enveloping portion of said second part; said interconnection further including indentations in said enveloping portion which extend into corresponding indentations in said flange.

Preferably, said indentations and said corresponding deformations are formed at the same time.

BRIEF DESCRIPTION OF DRAWINGS Embodiments of the present invention will now be described with reference to the accompanying drawings where: First Embodiment Fig. 1 is a perspective view of a structural member in accordance with the prior art; *0@ ooo *o oooo oooo oO* g COMS ID No: SBMI-04547814 Received by IP Australia: Time 15:35 Date 2006-08-23 0 0@*O

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0e0 10 Fig. 2 is a perspective view of a portion of a structural member in accordance with a first preferred embodiment of the present invention; Fig. 3 is a perspective, exploded view of the structural member of Fig. 2; Fig. 4 is a pre-assembled perspective view before final lock seaming and dimple crimp of the structural member of Fig.

2; Fig. 5 is a pre-assembled, part cut away perspective view of the structural member of Fig. 2 before final lock seaming and dimple crimp; Fig. 6 is a front view and detail view of pre-assembled flanges and webs preparatory to production of the member of Fig.

2; 15 Fig. 7 is a perspective, part cut away view of the member of Fig. 6; Fig. 8 is a front view and detail view of the structural member of Fig. 2; Fig. 9 is a cross section detail view of a crimped portion of the structural member of Fig. 2; Fig. 10 is an exploded view of the structural member of Fig. 2.

Second Embodiment 25 Fig. 11.1 is a perspective view of a structural member in accordance with the prior art; Fig. 11.2 is a perspective view of a portion of a structural member in accordance with a first preferred embodiment of the present invention; Fig. 11.3 is a perspective, exploded view of the structural member of Fig. 11.2; 11 Fig. 11.4 is a pre-assembled perspective view before final lock seaming and dimple crimp of the structural member of Fig.

11.2; Fig. 11.5 is a pre-assembled, part cut away perspective view of the structural member of Fig. 11.2 before final lock seaming and dimple crimp; Fig. 11.6 is a front view and detail view of pre-assembled flanges and webs preparatory to production of the member of Fig.

11.2; Fig. 11.7 is a perspective, part cut away view of the member of Fig. 11.6; Fig. 11.8 is a front view and detail view of the structural member of Fig. 11.2; Fig. 11.9 is a cross section detail view of a crimped 15 portion of the structural member of Fig. 11.2; eoe we** Fig. 11.10 is an exploded view of the structural member of oes Fig. 2; oooe• %e:Fig. 11.11A is a side section view of a roll stand suitable gO *too for roll forming at least some parts of the multi-part Oe 20 structural member of Fig. 1 or Fig. 2; Fig. 11.11B is a side section view of a roll stand suitable for final assembly and interconnection of the multi-part components of the multi-part structural member of Fig. 11.1 or 0 •Fig. 11.2; 25 Fig. 11.12 is a perspective view of a slot guide unit for use in roll forming parts of the multi-part structural member of Fig. 11.1 or Fig. 11.2 including the side panels thereof; Fig. 11.13 is an end view of the slot guide unit of Fig.

11.12; S: 30 Fig. 11.14 is a perspective view of the slot guide unit of Fig. 11.12 with roll pair in use; and Fig. 11.15 is a perspective view of the'slot guide unit of Fig. 11.14 with some parts removed for clarity.

12 Third Embodiment Fig. 12.1 is a perspective view of a structural member in accordance with the prior art; Fig. 12.2 is a perspective view of a portion of a structural member in accordance with a first preferred embodiment of the present invention; Fig. 12.3 is a perspective, exploded view of the structural member of Fig. 12.2; Fig. 12.4 is a pre-assembled perspective view before final lock seaming and dimple crimp of the structural member of Fig.

12.2; Fig. 12.5 is a pre-assembled, part cut away perspective view of the structural member of Fig. 12.2 before final lock 15 seaming and dimple crimp; r Fig. 12.6 is a front view and detail view of pre-assembled flanges and webs preparatory to production of the member of Fig.

12.2; ~Fig. 12.7 is a perspective, part cut away view of the

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20 member of Fig. 12.6; Fig. 12.8 is a front view and detail view of the structural member of Fig. 12.2; to*: Fig. 12.9 is a cross section detail view of a crimped portion of the structural member of Fig. 12.2; Fig. 12.10 is an exploded view of the structural member of Fig. 12.2; Fig. 12.11A is a side section view of a roll stand suitable for roll forming at least some parts of the multi-part structural member of Fig. 12.1 or Fig. 12.2; S: 30 Fig. 12.11B is a side section view of a roll stand suitable for final assembly and interconnection of the multi-part components of the multi-part structural member of Fig. 12.1 or Fig. 12.2; 13 Fig. 12.12 is a perspective view of a slot guide unit for use in roll forming parts of the multi-part structural member of Fig. 12.1 or Fig. 12.2 including the side panels thereof; Fig. 12.13 is an end view of the slot guide unit of Fig.

12.12; Fig. 12.14 is a perspective view of the slot guide unit of Fig. 12.12 with roll pair in use; Fig. 12.15 is a perspective view of the slot guide unit of Fig. 12.14 with some parts removed for clarity; Fig. 12.16 is a perspective view of a structural support member which can be manufactured according to the methods of this invention; Fig. 12.17 is an end elevation of the member in Figure 12.16; 15 Fig. 12.18 is a perspective view of a support member which ~can be manufactured according to embodiments of the invention; sea* #,so Fig. 12.19 is an end elevation of the member of Figure 12.18; Fig. 12.20 is a perspective view of a support member which 20 can be manufactured according to the methods of this invention; Fig. 12.21 is an end elevation of the member in Figure 12.20; Fig. 12.22 is a perspective view of a support member which can be manufactured according to methods of this invention; 0 0 25 Fig. 12.23 is an end elevation of the member in Figure ,e a12.22; Fig. 12.24 is an exploded view of detail 9 of Figure 12.23; Fig. 12.25 is a perspective view of a support member which 3 can be manufactured according to methods of this invention; S, 30 Fig. 12.26 is an end elevation of the member in Figure Sb 12.25; Fig. 12.27 is a perspective view of a support member which can be manufactured according to methods of this invention; 14 Fig. 12.28 is an end elevation of the member in Figure 12.27; Fig. 12.29 is an exploded part view end elevation of a flange and top assembly of a support member which can be manufactured according to methods of this invention, as shown in detail 14 of figures 12.26 and 12.28; Fig. 12.30 is an exploded part view end elevation of a flange and top assembly of a support member which can be manufactured according to methods of this invention; Fig. 12.31 is a perspective view of a decking member of a pallet for connection to a support member which can be manufactured according to methods of this invention; Fig. 12.32 is a perspective view of first variation of a decking member of a pallet for connection to a support member which can be manufactured according to methods of this invention; Fig. 12.33 is a perspective view of a second variation of a •decking member of a pallet for connection to a support member 0000 Swhich can be manufactured according to methods of this @000 20 invention; 0@0000 Fig. 12.34 is a plan view of several arrangements of decking members on support members in the formation of pallets @0 which support members can be manufactured according to methods of the invention; Fig. 12.35 is a partial side elevation of a pallet, parts of which can be manufactured according to methods of this 000000 00 invention; and °•Fig. 12.36 is a partial side elevation of a pallet, at least parts of which can be manufactured according to methods of this invention and shown at right angles to the view in Figure 12.35.

00 00 o 000 00 0 0 15 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS FIRST PREFERRED EMBODIMENT It is known to make beams and other structural components from steel or like materials. Steel, for example, as a material has certain benefits in terms of inherent strength over, for example, wood.

However, steel and many other metallic materials are more dense than wood with the result that many implementations of structural components from steel in substitution for wood components suffer, for example, from being relatively heavy as compared with the wooden counterpart when used for a similar application.

A further problem with steel and other metallic implementations of structural components is that when the structural component is formed from a number of sub-components with a view to keeping the weight of the structure to a minimum, some of the inherent strength benefits of the metallic materials oo. are lost as a result of the joining of the sub-components.

0000 ee00 It is an object of the present invention to address or *000 20 ameliorate one or more of the abovementioned disadvantages.

000000 S0 Embodiments of the present invention will now be described in the context of multi-part structural members manufactured 00 from metallic sub-components, for example steel sub-components.

A multi-part structural member or support member is known, as for example disclosed in International Patent Application PCT/AU89/00428 which matured to Australian Patent 626330. This 000000 patent particularly describes a press forming method of 00 constructing such members.

O A prior art multi-part structural member 1 of this type is illustrated in Fig. 1 and comprises four sub-components which are assembled and secured to each other so as to form a closed hollow section 2, in this instance a square or rectangular .o- hollow section.

16 In this instance the four sub-components comprise a base 3 and a top panel 8 which are secured to each other by way of a left side panel 4A and a right side panel 4B.

The sub-components are secured to each other by the intermediary of integral laterally extending flanges 5 which form part of and extend from the side panels 4 and are secured to the respective base 3 and top panel 8 by an over-folding of portions of the base 3 and top panel 8 about the laterally extending flanges 5 of the side panels 4A, 4B.

In this specification direction references are as defined in the inset of Fig. 1 wherein the side panels 4A, 4B are oriented in a vertical direction whilst the base 3 and top panel 8 are oriented in a horizontal or lateral direction.

Naturally, the relative orientation of the sub-components to each other could be described using other relative reference frames.

It will be observed that the side panels 4A, 4B of the multi-part structural member 1 include integrally formed ribs 6 e, therein to aid in the stiffening of these members specifically 20 and the structural member 1 generally.

A major problem encountered with this prior art arrangement relates to the manner of interconnection of the side panels 4A, 4B to the top panel 8 and base 3.

It has been found that the press formed arrangement illustrated in Fig. 1 allows for sliding of the flanges 5 with respect to the top panel 8 and base 3 whereby, in use, particularly where torsional loads are involved, the structural "member 1 flexes and otherwise exhibits insufficient stiffness.

Embodiments of a structural member according to the present invention will now be described.

In particular, with reference to Figs. 2 through to 10 the structure of a first embodiment of a multi-part structural 5 5 56 6 66 o 17 member 11 according to a first preferred embodiment of the present invention will now be described.

In this embodiment like components are numbered as for the prior art structural member of Fig. 1 except incremented by So, for example, structural member 1 of the prior art becomes structural member 11 of the first embodiment and closed hollow section 2 of the prior art becomes closed hollow section 12 of the first embodiment.

Thus, with reference to Fig. 2, the structure of a multipart structural member 11 according to a first embodiment of the invention comprises a base 13 connected to a top panel 18 by way of left side panel 14A and right side panel 14B thereby to define a closed section 12.

With reference to Fig. 2 relative movement between flanges 5 and corresponding enveloping portions 20 of base 13 and top panel 18 is prevented or substantially lessened by the incorporation of relative movement resistance means which, in this instance, comprise deformations of or indentations 21 in •go• **enveloping portions The indentations 21 are of sufficient depth, as best seen @0S6*O in Fig. 9, that a corresponding deformation 22 is caused to be formed in flanges 15 as and when indentations 21 are formed in such manner that indentations 21 are, in effect, seated within the corresponding deformations 22 thereby to prevent sliding movement of enveloping portions 20 with respect to flanges at least in the plane of engagement 23 of the enveloping ooo S"0 portions 20 against flanges 15 which, in this instance, is a o.o.

horizontal plane as previously defined with reference to the arrangement of Fig. 1.

In this instance the movement resistance means in the form of the indentations 21 are spaced so as to be formed at regular intervals T along the length of the enveloping portions again as illustrated in Fig. 2. In one particular form the M:Aug. 2006 15:32 Wall inslon-Duromer Sydney No.64318 P. 8 18 interval T lies in the range lcm-l0cm and, more preferably, in the range The interval T will be selected with reference to the size of the component parts forming structural member 11 and the material from which the structural member 11 is constructed in order to effectively limit or substantially minimize any relative movement, particularly in the plane of engagement 23 of the enveloping portions 20 and flanges both throughout the entire structure and also over predetermined sub-intervals thereof in response to deflecting forces which might be experienced by the structural member during use and, more particularly any deflecting loads or torsional loads.

This arrangement is particularly suited, although by no means limited, to the production of the component parts of the multi-part structural member 11 by a roll forming process.

The roll forming process can be utilized firstly to produce the component parts and then, as. part of an assembly process as perhaps best seen in Figs. 6, 7 and 8 the components parts are loosely assembled as illustrated in Fig. 6 with flanges residing loosely, slidingly within enveloping portions The loosely assembled arrangement of Fig. 6 can then be passed through a roll forming process wherein the enveloping portions are clamped tightly against flanges 15 and, at the same time, t'he indentations 21 are formed in enveloping portions resulting in the formation of corresponding deformations 22 in flanges 15 in the manner previously described.

It is to be understood that, in this embodiment, the indentations 21 in enveloping portions 20 are made in all enveloping portions 20 shown in Fig. 2 onwards. It follows, therefore, that there are indentations 21 in the enveloping portions 20 which envelope flanges 15 forming part of and extending from base 13. Such indentations and their COMS ID No: SBMI-04547814 Received by IP Australia: Time 15:35 Date 2006-08-23 19 corresponding deformations 22 in the flanges 15 of base 13 are illustrated in phantom in Fig. 2.

In the particular implementation of relative movement resistance means illustrated in the progression from Figs. 6 through to Fig. 9 it will be observed that, in addition to the indentations 21 and corresponding deformations 22 it will be observed that an overfold 25 of enveloping portions 20 with the flanges 15 residing therein is formed prior to the step of applying the indentations 21 thereby forming a particularly secure interaction between the flanges 15 and enveloping portions SECOND PREFERRED EMBODIMENT It is known to make beams and other structural components from steel or like materials. Steel, for example, as a material has certain benefits in terms of inherent strength over, for example, wood.

However, steel and many other metallic materials are more dense than wood with the result that many implementations of @0 0 00 20 structural components from steel in substitution for wood 0 components suffer, for example, from being relatively heavy as compared with the wooden counterpart when used for a similar application.

0 0 0 A further problem with steel and other metallic implementations of structural components is that when the structural component is formed from a number of sub-components oo o with a view to keeping the weight of the structure to a minimum, 0oo.

some of the inherent strength benefits of the metallic materials *0:0are lost as a result of the joining of the sub-components.

30 It is an object of the present invention to address or ameliorate one or more of the abovementioned disadvantages.

0 o 0 00 0 @0 20 Embodiments of the present invention will now be described in the context of multi-part structural members manufactured from metallic sub-components, for example steel sub-components.

A multi-part structural member or support member is known, as for example disclosed in International Patent Application PCT/AU89/00428 which matured to Australian Patent 626330. This patent particularly describes a press forming method of constructing such members.

A prior art multi-part structural member Al of this type is illustrated in Fig. 11.1 and comprises four sub-components which are assembled and secured to each other so as to form a closed hollow section A2, in this instance a square or rectangular hollow section.

In this instance the four sub-components comprise a base A3 and a top panel A8 which are secured to each other by way of a left side panel A4A and a right side panel A4B.

The sub-components are secured to each other by the intermediary of integral laterally extending flanges A5 which form part of and extend from the side panels A4 and are secured 20 to the respective base A3 and top panel A8 by an over-folding of o oo portions of the base A3 and top panel A8 about the laterally .extending flanges A5 of the side panels A4A, A4B.

In this specification direction references are as defined in the inset of Fig. 11.1 wherein the side panels A4A, A4B are oriented in a vertical direction whilst the base A3 and top panel A8 are oriented in a horizontal or lateral direction.

ooo o Naturally, the relative orientation of the sub-components to each other could be described using other relative reference frames.

It will be observed that the side panels A4A, A4B of the multi-part structural member Al include integrally formed ribs A6 therein to aid in the stiffening of these members o o specifically and the structural member Al generally.

21 A major problem encountered with this prior art arrangement relates to the manner of interconnection of the side panels A4A, A4B to the top panel A8 and base A3.

It has been found that the press formed arrangement illustrated in Fig. 11.1 allows for sliding of the flanges with respect to the top panel A8 and base A3 whereby, in use, particularly where torsional loads are involved, the structural member Al flexes and otherwise exhibits insufficient stiffness.

Embodiments of a structural member according to the present invention will now be described.

In particular, with reference to Figs. 11.2 through to 11.10 the structure of a first embodiment of a multi-part structural member All according to a first preferred embodiment of the present invention will now be described.

In this embodiment like components are numbered as for the prior art structural member of Fig. 11.1 except incremented by So, for example, structural member Al of the prior art becomes structural member All of the first embodiment and closed •c hollow section A2 of the prior art becomes closed hollow section 000o 20 A12 of the first embodiment.

Thus, with reference to Fig. 11.2, the structure of a multi-part structural member All according to a first embodiment of the invention comprises a base A13 connected to a top panel o5o A18 by way of left side panel A14A and right side panel A14B thereby to define a closed section A12.

With reference to Fig. 11.2 relative movement between oo oo flanges A5 and corresponding enveloping portions A20 of base A13 0550 gand top panel A18 is prevented or substantially lessened by the incorporation of relative movement resistance means which, in this instance, comprise deformations of or indentations A21 in enveloping portions *The indentations A21 are of sufficient depth, as best seen in Fig. 11.9, that a corresponding deformation A22 is caused to 0° 23: -Aug. 2006 15:32 WallIington-Dummer Sydney No.5439 P. 9 22 be formed in flanges A1S as and when indentations A21 are formed in such manner that indentations A21 are, in effect, seated within the corresponding deformations A22 thereby to prevent sliding movement of enveloping portions A20 with respect to flanges A15, at least in the plane of engagement A23 of the enveloping portions A20 against flanges A15 which, in this instance, is a horizontal plane as previously defined with reference to the arrangement of Fig. 11.1.

In this instance the movement resistance means in the form of the indentations A21 are spaced so as to be formed at regular intervals T along the length of the enveloping portions again as illustrated in Fig. 11.2. In one particular form the interval T lies in the range 1cm-l0om and, more preferably, in the range The interval T will be selected with reference to the size of the component parts forming structural member All and the material from which the structural member All is constructed in order to effectively limit or substantially minimize any relative movement, particularly in the plane of engagement A23 of the enveloping portions A20 and flanges A15 both throughout the entire structure and also over predetermined sub-intervals thereof in response to deflecting forces which might be experienced by the structural member during use and, more particularly any deflecting loads or torsional loads.

25 This arrangement is particularly suited, although by no means C: limited, to the production of the component parts of the multipart structural member All by a roll forming process. The roll forming process can be utilized firstly to produce the component parts and then, as part of an assembly process as perhaps best seen in Figs. 11.6, 11.7 and 11.8 the components parts are loosely assembled as illustrated in Fig. 11.6 with flanges residing loosely, slidingly within enveloping portions A20. The loosely assembled arrangement of Fig. 11.6 COMSID No: SBMI-04547814 Received by IP Australia: Time 15:35 Date 2006-08-23 23 can then be passed through a roll forming process wherein the enveloping portions A20 are clamped tightly against flanges and, at the same time, the indentations A21 are formed in enveloping portions A20 resulting in the formation of corresponding deformations A22 in flanges A15 in the manner previously described.

It is to be understood that, in this embodiment, the indentations A21 in enveloping portions A20 are made in all enveloping portions A20 shown in Fig. 11.2 onwards. It follows, therefore, that there are indentations A21 in the enveloping portions A20 which envelope flanges A1S forming part of and extending from base A13. Such indentations and their corresponding deformations A22 in the flanges A15 of base A13 are illustrated in phantom in Fig. 11.2.

In the particular implementation of relative movement resistance means illustrated in the progression from Figs. 11.6 through to Fig. 11.9' it will be observed that, in addition to r. the indentations A21 and corresponding deformations A22 it will ~be observed that an overfold A25 of enveloping portions A20 with U0e 20 the flanges A15 residing therein is formed prior to the step of applying the indentations A21 thereby forming a particularly secure interaction between the flanges A15 and enveloping portions DETAILED DESCRIPTION OF PREFERRED METHOD OF PRODUCTION The arrangement of a multi-part structural member disclosed r 6 with respect to both the prior art and previous embodiments of the present invention earlier described can be manufactured from stamped components. In an alternative form according to the present embodiment the component parts of the multi-part structural member can be manufactured via a roll-forming process.

0 S we 0S 24 The roll-forming process can be utilized to form predetermined lengths of the component parts including base A3, A13, side panels A4, Al4 and top panel A8, A18.

A roll-forming process can also be used to assemble and interconnect the component parts so as to form the finished structural member Al, All.

The component parts of the multi-part structural member Al, All can be roll formed in accordance with the general methods illustrated in Figs. 11.11A and 11.lIB.

Fig. 11.11A illustrates a roll forming stand A30 comprised of five consecutive roll pairs A31, A32, A33, A34, A35 through which an initially flat sheet A36 of steel or like material is passed through the roll pairs A31, A35 with each stand progressively turning upwardly edge portions thereof so as to achieve the profiles A31A, A32A, A33A, A34A, A35A ultimately to achieve a profile suited for use, for example, as base A3, A13 with enveloping portions A20 along opposed edges thereof.

With reference to Fig. 11.lIB the same roll forming arrangement can be utilized to produce some forms of side panels e g. 000 20 A4, A14 and the flanges A5, A15 extending therefrom.

ee.. With reference to Fig. 11.lIB, in order to produce a completed multi-part structural member Al, All roll stand comprising roll pairs A41, A42, A43, A44, A45 can be utilized to compress enveloping portions A20 onto flanges A5, A15 once the components making up the structural member Al, All have been loosely assembled as illustrated in Fig. 11.lIB and prior to roeeo$ entry into the roll stand of1 As the loosely assembled multi-part structural member Al, SAll passes through the roll pairs A41-A45 the enveloping portions A20 and the flanges A5, A15 therein are compressed and folded as illustrated at the various stages of A41A, A42A, A43A, A44A, A45A resulting in the interconnected structure comprising ee C CQ S e 25 the finished multi-part structural member Al, All as perhaps best seen in Fig. 11.8.

With reference to Figs. 11.12, 11.13, 11.14, 11.15, where the multi-part structural member Al, All includes ribs A16 therein in the side panels A4, A14 particular care needs to be taken in the formation of the side panels A4, A14 when produced by a roll forming process.

Fig. 11.12 illustrates a strip guide unit A50 for use in conjunction with a roll pair A51 as, perhaps best illustrated in Fig. 11.14. The strip guide unit A50 comprises first slot guide A52 mounted in opposed relationship to second slot guide A53.

As perhaps best seen in the end view of Fig. 11.13 the slot guides A52, A53 include respective guide slots A54, A55 adapted to slidably retain therein edge portions A56 of strip of steel sheet A57 as it is formed, in this case, into a side panel A4, A14 as it passes through roll pair A51.

First slot guide A52 and second slot guide A53 are maintained in space relationship by cross members A58, A59.

•In addition a ramp A60 extends between first slot guide A52 20 and second slot guide A53 immediately prior to rib forming region A61 or roll pair A51.

OS@S

The height H of slots A54, A55 are sized so that, in use, the natural inclination of the edge portions A56 to deform in conformity with ribs A16 as they are formed by roll pair A51 is resisted to a controlled extent while still allowing the formed steel sheet A57 to progress through the slot guide unit A50 so eeas to be formed, in this instance, into side panels A4, A14 of the type usable with the multi-part structural member Al, All.

*OS@

The side panels A4, A14 thus formed can then have their edge portions A56 progressively bent to reach a right angle orientation so as to form flanges A5, A15 utilising roll forming 0• o* apparatus similar to that described with reference to Fig.

S.11.11A.

26 Then, as previously described, the side panels A4, A14 may then be loosely assembled so that flanges A5, A15 reside within enveloping portions A20 of base A3, A13 and top panels A8, A18 for subsequent passing through the roll forming apparatus of Fig. 11.11B.

Finally, in accordance with the second embodiment described with reference to Fig. 11.2 a relative movement resistance means in the form of indentations A21 together with corresponding defamations A22 can be roll formed periodically into the enveloping portions A20 and respective flanges A15 in the manner previously described with reference to Fig. 11.2 thereby, by roll forming means, to form a structure particularly resistant to movement, in use, of the flanges A15 within enveloping portions THIRD PREFERRED EMBODIMENT It is known to make beams and other structural components from steel or like materials. Steel, for example, as a material has certain benefits in terms of inherent strength over, for 20 example, wood.

However, steel and many other metallic materials are more dense than wood with the result that many implementations of structural components from steel in substitution for wood components suffer, for example, from being relatively heavy as compared with the wooden counterpart when used for a similar application.

*SSS

ooo A further problem with steel and other metallic implementations of structural components is that when the o. structural component is formed from a number of sub-components with a view to keeping the weight of the structure to a minimum, some of the inherent strength benefits of the metallic materials are lost as a result of the joining of the sub-components.

SS

0 27 It is an object of the present invention to address or ameliorate one or more of the abovementioned disadvantages.

Embodiments of the present invention will now be described in the context of multi-part structural members manufactured from metallic sub-components, for example steel sub-components.

A multi-part structural member or support member is known, as for example disclosed in International Patent Application PCT/AU89/00428 which matured to Australian Patent 626330. This patent particularly describes a press forming method of constructing such members.

A prior art multi-part structural member B1 of this type is illustrated in Fig. 12.1 and comprises four sub-components which are assembled and secured to each other so as to form a closed hollow section B2, in this instance a square or rectangular hollow section.

In this instance the four sub-components comprise a base B3 and a top panel B8 which are secured to each other by way of a 0@OS Os. *left side panel B4A and a right side panel B4B.

•The sub-components are secured to each other by the 20 intermediary of integral laterally extending flanges B5 which 0 000 form part of and extend from the side panels B4 and are secured :0 to the respective base B3 and top panel B8 by an over-folding of portions of the base B3 and top panel B8 about the laterally extending flanges B5 of the side panels B4A, B4B.

In this specification direction references are as defined 00: in the inset of Fig. 12.1 wherein the side panels B4A, B4B are oriented in a vertical direction whilst the base B3 and top 000 panel B8 are oriented in a horizontal or lateral direction.

000:0 0 Naturally, the relative orientation of the sub-components to each other could be described using other relative reference frames.

It will be observed that the side panels B4A, B4B of the multi-part structural member B1 include integrally formed ribs 28 B6 therein to aid in the stiffening of these members specifically and the structural member B1 generally.

A major problem encountered with this prior art arrangement relates to the manner of interconnection of the side panels B4A, B4B to the top panel B8 and base B3.

It has been found that the press formed arrangement illustrated in Fig. 12.1 allows for sliding of the flanges with respect to the top panel B8 and base B3 whereby, in use, particularly where torsional loads are involved, the structural member B1 flexes and otherwise exhibits insufficient stiffness.

Embodiments of a structural member according to the present invention will now be described.

In particular, with reference to Figs. 12.2 through to the structure of a first embodiment of a multi-part structural member B11 according to a first preferred embodiment of the present invention will now be described.

In this embodiment like components are numbered as for the 0O@O prior art structural member of Fig. 12.1 except incremented by 0*ee 0. So, for example, structural member B1 of the prior art 20 becomes structural member B11 of the first embodiment and closed hollow section B2 of the prior art becomes closed hollow section *5eS B12 of the first embodiment.

Thus, with reference to Fig. 12.2, the structure of a multi-part structural member B11 according to a first embodiment of the invention comprises a base B13 connected to a top panel B18 by way of left side panel B14A and right side panel B14B [[thereby to define a closed section B12.

With reference to Fig. 12.2 relative movement between be..

flanges B5 and corresponding enveloping portions B20 of base B13 and top panel B18 is prevented or substantially lessened by the incorporation of relative movement resistance means which, in this instance, comprise deformations of or indentations B21 in enveloping portions enveloping portions 820.

23M*ug. 2006 15:32 WallIinglon-Dummer Sydney No.643B P. 29 The indentations B21 are of sufficient depth, as best seen in Fig. 12. 9, that a corresponding deformation 822 is caused to be formed in flanges 815 as and when indentations 821 are formed in such manner that indentations 821 are, in effect, seated within the corresponding detonmations 522 thereby to prevent sliding movement of enveloping portions B320 with respect to flanges at least in the plane of engagement B23 of the enveloping portions against flanges B15 which, in this instance, is a horizontal plane as previously 'defined with reference to the arrangement of Fig. 12.1.

In this instance the movement resistance means in the form of the indentations B21 are spaced so as to be formed at regular intervals T along the length of the enveloping portions B20, again as illustrated in Fig. 12.2. In one particular form the interval 1S T lies in the range lcm-i0cm and, more preferably, in the range 5cm-l1om.

The interval T will be selected with reference to the size of the component parts forming structural member all and the material from which the structural member B11 is constructed in order to effectively limit or substantially minimize any relative movement, particularly in the plane of engagement 523 of the enveloping portions B20 and flanges B15 both throughout the entire structure and also over predetermined sub-intervals thereof in response to deflecting forces which might be experienced by the structural 25 member during use and, more particularly any deflecting loads or torsional loads.

This arrangement is particularly suited, although by no means limited, to the production of the component parts of the multipart structural member 511 by a roll forming process. The roll forming process can be utilized firstly to produce the component parts and then, as part of an assembly process as perhaps best seen in Figs. 12.6, 12.7 and 12.8 the components parts are loosely assembled as illustrated in Fig. 12.6 with COMS ID No: SBMI-04547814 Received by IP Australia: Time 15:35 Date 2006-08-23 30 flanges B15 residing loosely, slidingly within enveloping portions B20. The loosely assembled arrangement of Fig. 12.6 can then be passed through a roll forming process wherein the enveloping portions 20 are clamped tightly against flanges and, at the same time, the indentations B21 are formed in enveloping portions B20 resulting in the formation of corresponding deformations B22 in flanges B15 in the manner previously described.

It is to be understood that, in this embodiment, the indentations B21 in enveloping portions B20 are made in all enveloping portions B20 shown in Fig. 12.2 onwards. It follows, therefore, that there are indentations B21 in the enveloping portions B20 which envelope flanges B15 forming part of and extending from base B13. Such indentations and their corresponding deformations B22 in the flanges B15 of base B13 are illustrated in phantom in Fig. 12.2.

In the particular implementation of relative movement ooo resistance means illustrated in the progression from Figs. 12.6 oo through to Fig. 12.9 it will be observed that, in addition to 20 the indentations B21 and corresponding deformations B22 it will o be observed that an overfold B25 of enveloping portions B20 with *see r the flanges B15 residing therein is formed prior to the step of applying the indentations B21 thereby forming a particularly secure interaction between the flanges B15 and enveloping portions oo oo DETAILED DESCRIPTION OF PREFERRED METHOD OF PRODUCTION 6 0 °ooo The arrangement of a multi-part structural member disclosed with respect to both the prior art and previous embodiments of the present invention earlier described can be manufactured from stamped components. In an alternative form according to the present embodiment the component parts of the multi-part oo o 31 structural member can be manufactured via a roll-forming process.

The roll-forming process can be utilized to form predetermined lengths of the component parts including base B3, B13, side panels B4, B14 and top panel B8, B18.

A roll-forming process can also be used to assemble and interconnect the component parts so as to form the finished structural member B1, B11.

The component parts of the multi-part structural member B1, B11 can be roll formed in accordance with the general methods illustrated in Figs. 12.11A and 12.11B.

Fig. 12.11A illustrates a roll forming stand B30 comprised of five consecutive roll pairs B31, B32, B33, B34, B35 through which an initially flat sheet B36 of steel or like material is passed through the roll pairs B31, B35 with each stand progressively turning upwardly edge portions thereof so as to achieve the profiles B31A, B32A, B33A, B34A, B35A ultimately to se* ,achieve a profile suited for use, for example, as base B3, B13 0.00 with enveloping portions B20 along opposed edges thereof.

20 With reference to Fig. 12.11B the same roll forming arrangement can be utilized to produce some forms of side panels B4, B14 and the flanges B5, B15 extending therefrom.

With reference to Fig. 12.11B, in order to produce a completed multi-part structural member B1, B11 roll stand comprising roll pairs B41, B42, B43, B44, B45 can be utilized to compress enveloping portions B20 onto flanges B5, B15 once the components making up the structural member B1, B11 have been loosely assembled as illustrated in Fig. 12.11B and prior to entry into the roll stand As the loosely assembled multi-part structural member B1, B11 passes through the roll pairs B41-B45 the enveloping S portions B20 and the flanges B5, B15 therein are compressed and r folded as illustrated at the various stages of B41A, B42A, B43A, 32 B44A, B45A resulting in the interconnected structure comprising the finished multi-part structural member B1, B11 as perhaps best seen in Fig. 12.8.

With reference to Figs. 12.12, 12.13, 12.14, 12.15, where the multi-part structural member BI, B11 includes ribs B16 therein in the side panels B4, B14 particular care needs to be taken in the formation of the side panels B4, B14 when produced by a roll forming process.

Fig. 12.12 illustrates a slot guide unit B50 for use in conjunction with a roll pair B51 as, perhaps best illustrated in Fig. 12.14. The slot guide unit B50 comprises first slot guide B52 mounted in opposed relationship to second slot guide B53.

As perhaps best seen in the end view of Fig. 12.13 the slot guides B52, B53 include respective guide slots B54, B55 adapted to slidably retain therein edge portions B56 of steel sheet B57 as it is formed, in this case, into a side panel B4, B14 as it passes through roll pair B51.

First slot guide B52 and second slot guide B53 are .maintained in space relationship by cross members B58, B59.

20 In addition a ramp B60 extends between first slot guide B52 and second slot guide B53 immediately prior to nip region B61 or roll pair B51.

The height H of slots B54, B55 are sized so that, in use, the natural inclination of the edge portions B56 to deform in conformity with ribs B16 as they are formed by roll pair B51 is resisted to a controlled extent while still allowing the formed 0000 0000 steel sheet B57 to progress through the slot guide unit B50 so •0o• as to be formed, in this instance, into side panels B4, B14 of 0000 0 the type usable with the multi-part structural member B1, B11.

The side panels B4, B14 thus formed can then have their edge portions B56 progressively bent to reach a right angle orientation so as to form flanges B5, B15 utilising roll forming 0 0 0 0 33 apparatus similar to that described with reference to Fig.

12.11A.

Then, as previously described, the side panels B4, B14 may then be loosely assembled so that flanges B5, B15 reside within enveloping portions B20 of base B3, B13 and top panels B8, B18 for subsequent passing through the roll forming apparatus of Fig. 12.11B.

Finally, in accordance with the second embodiment described with reference to Fig. 12.2 a relative movement resistance means in the form of indentations B21 together with corresponding defamations B22 can be roll formed periodically into the enveloping portions B20 and respective flanges B15 in the manner previously described with reference to Fig. 12.2 thereby, by roll forming means, to form a structure particularly resistant to movement, in use, of the flanges B15 within enveloping portions 0000 •FURTHER EMBODIMENTS •o "Further and alternative preferred embodiments to the 20 structure of Fig. 12.2 will now be described, each of which can S0include relative movement resistance means of one form or another in the interconnection between various parts of the multi-part structural members to be described. Most commonly the relative movement resistance means is included in and forms part of the flanges of the side panels and the corresponding enveloping portions of the top and bottom panels (where .0000. provided) thereby to form an interconnection involving the 0000 flanges which includes the relative movement resistance means.

0000 In addition, and separately, each of the embodiments to be described includes side panels which can be roll formed with advantage utilizing the apparatus described with reference to Figs. 12.12 to 12.15.

00 o 34 In addition, and separately, the top and base panels can be manufactured utilizing the roll forming methods described in earlier embodiments and can have formed in them the indentations whereby relative movement resistance means can be provided and formed according to the roll-forming methods earlier described in this specification.

Turning now to describe the member as illustrated in Figure 12.16 and Figure 12.17, there is shown a support member indicated generally at B101. The support member B101 comprises an elongate channel B102 having a base B103 and two spaced apart side panels B104, the channel having a generally shaped cross-section. Throughout the specification the terms horizontal and lateral will correspond to the planar direction defined by the base B103 of a and similarly the term vertical will correspond with the direction of the upwardly extending arms of a 'U' Each side panel B104, extends vertically upwards from base •ego B103 terminating in an outwardly directed horizontal flange re B105. Ribs B106 are pressed into the support member at regular 20 intervals along its length in order to increase its stiffness.

Ribs B106 are pressed upwards into base B103, inwards into 0*ee side panels B104, and downwards into the flanges B105 on their inner edge. The ribs B106 are wider at the bottom of the arms of the where they meet the base B103 than they are at the top where the arms meet the flanges B105, and ribs B106 taper uniformly as they rise up side panels B104.

Accordingly the ribs B106 may be conveniently pressed into the support member B101 by a suitable tool having two cooperating parts, the first which is pressed up the side panels B104 of the and into the base B103, and the second of which is pressed down onto the inner edges of the flanges B105. The S parts of the two co-operate with each other in order to press the ribs into the support member and are shaped so as to be 35 easily released after the pressing action has taken place.

In the regions where the flanges B105 meet the top of the side panels B104 of the the profile of the rib B106 changes from being inwardly pressed to being outwardly pressed. It should be appreciated that the support member B101 may include a number of variations, for instance the flanges B105 may extend inwardly rather than outwardly and is also possible that the flanges could both extend in the same direction, with one extending inwardly and the other extending outwardly.

The flanges B105 may be created when the support member B101 is fabricated or they may be formed afterwards by bending the upper ends of the arms of the Alternatively separate flanges may be welded to the upper ends of the arms of the 'U' The method of construction of this embodiment will vary to some extent according to size. Where the support members are for use as bearers in the construction of pallets, the channel, complete with flanges can be produced in one single press e* e operation.

For structural beams of varying length the sheet metal is 0*eS 20 first roll-formed into a section channel and the ribs are 0 00 then pressed into the section twenty ribs at a time as a second stage operation.

Typically the dimensions of the construction beams are as follows: WIDTH HEIGHT 50 X 50 X 100 *Ose X 150 as% 75 X 200 75 X 250 X 300 1' 00 X 400 S. (where WIDTH flange edge to flange edge and typical S *e 36 flange width 14mm).

The ribs have a pitch of 30mm, and taper in width from at the base to 10mm at the top. The metal thickness is between 0.3 and 1.2mm.

In the following descriptions of further embodiments of this invention all common parts are identified by corresponding numerals.

Another form of member to which methods of the invention can be applied is shown in Figure 12.18 and Figure 12.19. In order to increase the height and stiffness of the support member B29, it is possible to connect two of the channels B202 as shown. The connection is made between the bases B203 of each support member B201 to create an shaped cross-section support member shown generally at B207. The connection between the channels B202 can be made by means of welds, rivets, adhesive or any other suitable form of connection. However, in a preferred form the connection is made by means of cylindrical Os..

*extensions from the base of one of the shaped support 6• members which engage in corresponding holes in the base B203 of see.

20 the other shaped support member B201 and are then hammered down to connect the members in the same way as if they were Voconnected by rivets.

Referring now to Figures 12.21 and 12.22 there is shown another embodiment of the invention comprising a fabricated channel B302 to which is fixed a top panel B308.

5o4 The channel comprises two vertical side panels B304, each -°-having a series of inwardly indented ribs B306 and each having two outwardly directed flanges one at the base of the panel and oo one at the top of the panel. The run out 309 of the ribs B306 extends right up to the flange to give maximum strength and rigidity when connected to the base B303, and top B308 respectively. In this embodiment the base B303 and top B308 are 3 connected to the side panels 304 by a single fold of the top 37 panel B308 and base B303 about the flanges B305 of the side panels B304.

In fabricating the support member B301 the side panels B304 are made from flat sheets of metal, preferably steel or aluminium, by roll forming a series of vertical ribs B306 all along the length of each side panel B304 as described with reference to Figs. 12.11-12.15. The ribs B306 extend from near the top to near the bottom of the side panel. Then, the top and bottom part of each side panel are bent around to form horizontally extending flanges B305. It is important that the vertical ribs extend right up to the point at which the flanges are bent and that the flange extends as a continuation of the run out curve B309 of each rib B306 to maximize the strength of the construction. In this and all fabricated embodiments of the channel, the ribs are parallel and about 15mm in width. The top panel B308 and base B303 are also made from flat sheets of metal The two side panels B304 are then placed side by side with the .0o @flanges B305 extending outwardly and the top section and base *000 r B303 are then moved into place such that they extend beyond the *000 20 flanges B305 of the side panels B304. The outer ends B310 of the .0 top panel B308 and base B303 are then bent around the horizontally extending flanges B305 to sandwich them and create oa rigid structure. If desired the folded end of the base B303 and top panel B308 may be crimped or spot welded onto the flanges B305 to ensure a rigid fix.

e: With reference to figures 12.22, 12.23 and 12.24 there is shown a further construction of a member B401. Parts of the •ere figures 12.22, 12.23 and 12.24 corresponding to parts of figures 12.20 and 12.21 are identified by corresponding numerals but in the B400 series. The member B401 differs from the member B301 in two respects, most clearly shown in Figure 12.24. One difference is that the top panel B408 and base B403 (instead of being bent around horizontal flanges B405 to give three thicknesses of 38 metal as in Figure 12.20 and Figure 12.21) are folded together as shown in Figure 12.24 with flange B405 to give a join in which three thicknesses of the top panel B408 or base B403 are joined with two thicknesses of the horizontal flange B405.

If the horizontal extending flange of the member of Figure 12.20 has a width of then the corresponding part of the embodiment of Figure 12.22 has a width of approximately 2W and the top panel B408 and base B403 overhangs horizontal flange B405 to outer end B410 by a further width of almost prior to folding. The join of Figure 12.24 is then formed by roll forming as described with reference to Figs. 12.11-12.15.

A second difference is that the top panel B408 and base B403 are provided with longitudinally extending ribs B411 and B412 along their length. The ribs B411 are of cross-section and indented. The two outer ribs adjacent the side panels B404 are closely adjacent the interior side of the vertical ribs B406 and as such assist in centering the top panel B408 and base B403 g* with respect to the side panels B404 during assembly wedging the side panels B404 with the flanges B405 against the outer ribs *$too 20 B412, as well as stiffening the top and base panels.

0 The longitudinally extending ribs B411 and B412 are formed in the base B403 and top panel B408 prior to assembly with side a ge panels B404.

The structural support members B401 described resist twisting and can withstand higher pressures at thinner metal thicknesses than for example section purlins.

00,* oFor example a support member for use in a pallet may be made using 0.45mm or thinner high tensile galvanized steel (or Szinc alum G 300) for the top panel B408 and base B403 and 0.55mm S.n almG30 thickness or less for the side panels B404.

Referring now to figures 12.25 and 12.26 there is shown a S' member B501. The construction of this member is almost identical go *to that discussed in relation to member B101 referred to in 0.

39 figures 12.16 and 12.17. The major difference in the construction of the channel B502 is that the section is substantially of a shaped construction having a very narrow integral base B503 from which the side panels B504 extended in an upwardly and outwardly direction. In this construction the ribs B506 are of constant width. As in figures 12.20 to 12.24 inclusive the run out B509 of the ribs extends up to the flange.

In this example the top panel 508 has two outer longitudinally extending ribs B512 of a substantially shaped section, the comprising two curved portions corresponding to the curve of the run out B509, located so that on assembly the two ribs are disposed in Supporting engagement with the innermost surfaces of the channel ribs B506. The top panel B508 is connected to the channel B502 by the same method as described in discussion of the member B401 with reference to Figure 12.24, excepting that the corresponding curves of the longitudinally extending ribs of o. the top panel B508 provide a more positive support with the ribs •00• B506 of channel B502 (see Figure 12.29).

A further member B601 as illustrated in figures 12.27 and 20 12.28 is almost identical in the method of construction to *000 member B501 discussed in reference to figures 12.25 and 12.26.

The major difference is that the shape of the channel B602 includes a base portion B603 of width greater than discussed in respect to member B501 but narrower than the width of top panel 25 B508. This example of the invention has an additional longitudinally extending rib B611 midway along its width. The goes method of attachment of the channel to the top panel B608 is as described in the description of member B501 and shown in more detail in Figure 12.29.

Figure 12.30 shows an alternate method of attachment and S"folding of the top panel B708 with the channel B702. As shown the member B701 includes a top panel B708 incorporating longitudinally extending ribs B712 of the same section as 40 described for members B501 and B601.

It is highly desirable that the ribs extend fully to the flanges. As illustrated in particular in Figure 12.21, and again in more detail in figures 12.24, 12.29 and 12.30, the indented ribs B706 terminate at each end in a curved run out portion B709. The outer surface of this portion extends tangentially as a continuation of the curve to form the flange B705. All subsequent folds of the flange with a top panel B708 or bottom panel B703 are precisely nested in a spiral formation against the corner of panel B704. This provides a strong fold that will resist buckling.

In member B701 the top panel B708 and flanges B705 are extended by an additional width which is folded against the side panels B704 thereby increasing the rigidity at the join.

Referring finally to figures 12.31 to 12.36 there is shown an example of use where the support members B801 are used as 0e@@ bearers for a pallet. The support members used as bearers are of the type described in the first embodiment and referred to in figures 12.16 and 12.17.

Referring now to Figure 12.31 decking member B814 has a generally shaped cross-section comprising vertical outer a 000 legs B815 joined at their tops to inwardly extending horizontal webs B816 which are joined at their inner ends to the tops of inclined webs B817 which define a central portion of the o: 25 The lower ends of each of outer legs B815 are bent or formed inwards to form horizontal flanges B818, the lower surfaces of flanges B818 being co-planar with the lower surface 555* of the extremity, or in this case approximately B819, of the 'V' portion B820.

Referring now to Figure 12.32 the same reference numerals will be used where appropriate to refer to the corresponding 0 elements of Figure 12.31. The cross-section of decking member B814' is identical to decking member B814 except that the 41 central portion B820 has a flattened extremity with a horizontal portion B821 joining the lower ends of inclined portions B817. The lower surface of the flattened extremity of the portion, that is the underside of portion B821, being co-planar with the lower surfaces of flanges B818.

Figure 12.32 shows a further embodiment in which flanges B818 are turned outwards rather than inwards to form a decking member B814 which has outwardly extending flanges B818 the lower surfaces of which are co-planar with the lower surface of the apex B819 of the central portion B820. It should of course be appreciated that the decking member may be embodied in other forms as well, for instance the Figure 12.32 example could be formed with the flanges extending outwardly rather than inwardly. It is also possible that the flanges could both extend in the same direction, with one extending inwardly and the other extending outwardly.

oThe flanges B818 may be created when the decking member is fabricated, or they may be formed afterwards by bending the ooo lower ends of the legs of the M. Alternatively separate flanges 20 may be welded to the lower ends of the legs of the M. It is not important which fabrication technique is adopted, the essential part of this aspect of the invention being the shape of the one section which results.

It should also be appreciated that although this aspect of 25 the invention has been described with reference to particular eexamples where the legs of the have been vertical and the

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flanges and webs horizontal this need not be the case and the .legs may be offset from the vertical and the flanges and web offset from the horizontal. Nevertheless it is preferred that the webs B816 have co-planar upper surfaces since this is o essentially the surface upon which, in a pallet, the load rests.

:It is helpful if the lowermost points of the lower surfaces of the flanges B818 are co-planar, but it is not necessary that 42 the lower surfaces of the flanges B818 are flat, and they could for instance be rippled or corrugated.

Turning now to Figure 12.35, various decking members B814 and B814' are shown attached to a support member B101. The support member B101 defines a flat horizontal support surface B822. The decking members B814 and B814' lie against, and generally transverse support member B101 such that the lower surfaces of flanges B818 and the extremity of the portion B819 lie against support surface B822. The decking members B814 and B814' being attached to support member B101 by means of welds B823 at the contacting portions.

A pallet having at least some components manufactured according to the method of Figs. 12.11-12.15 may be constructed from two or more spaced apart support members B101 interconnected by two or more decking members B814 as indicated.

In an assembled pallet the upper surfaces of flanges B105 are attached to the lower surfaces of flanges B818 and apex B820 or flattened extremity 821 of the decking members. This is illustrated in figures 12.35 and 12.36.

Five complete pallets B824 are shown in Figure 12.34. It 0 a' *0S@ can be seen that six welds B825 interconnect each decking member B814 with each support member B101 thus giving a very strong and rigid connection between them. The connection between the support members and the decking members may be a weld as 25 indicated, although it would be appreciated that the connection 0.•9 may be equally well achieved by means of rivetting, screwing or *555 similar mechanical processes.

When made from hi-ten galvanized steel or stainless steel a 5 pallet of adequate strength may be fabricated from material having a thickness between 0.55 to 1.00mm. When made from S. aluminium a thickness of 1 to 2mm is preferred. Alternatively S. plastics material can be used to fabricate the decking and support members. The height of the return of the deck may vary00 support members. The height of the return of the deck may vary 43 between 20mm to 10mm depending on the application.

Also while the section is shown centrally located along the decking members it can be offset to one side or the other if desired. The section of the decking member need not be constant along its entire length but may of course vary along that length provided the required shaped section is available at the points of contact with the support members.

Additional stiffness can be obtained by the connection of additional decking members to the support member; these additional decking members may be connected to the top of the support members or to the bottom such that the lower surfaces of the flanges B818 and extremity of the portion B820 are connected to the underside of base B103. Figures 12.35 and 12.36 show one such additional decking member B824. This sandwiching of the support members by decking members increases the rigidity of the resulting pallet.

A pallet having additional height can be obtained by substituting for the single shaped support member shown in Figure 12.16 the double shaped support member shown in 20 figures 12.18 and 12.19.

The above describes only some embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope and spirit of the present invention.

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Claims (6)

1. 2. The structural member of Claim 1 wherein said indentations in said enveloping portions are formed concurrently with said *~.corresponding indentations in said flange portions-
2. 3. The structural member of Claim 1 or 2 wherein each of said *0S0*predetermined intervals is in the range 1cm to l0oms. The structural member of Claim 1 or 2 wherein each of said predetermined intervals lies in the range 5cms to l0ans. The structural member of any previous claim formed by a roll forming process.
3. 6. A method of joining portions of a multi-part structural member together, said method comprising the steps of: roll-forming each part of said multi-part structural member from flat metal sheet, COMS ID No: SBMI-04694764 Received by IP Australia: Time 17:42 Date 2006-09-07 7iSep. 2006 17:41 Wallington-Dummer Sydney No.6596 P. 4 forming at least a first flange in a first part; forming an enveloping portion in a second part adapted for interconnection to said first part; causing said enveloping portion of said second part to envelope said flange of said first part; forming indentations at predetermined intervals in said enveloping portion which extend sufficiently into said enveloping portion to cause corresponding indentations in said flange thereby to resist relative movement of said first part with respect to said second part, at least in the plane of engagement of said flange portion with said 00-00 enveloping portion. 0* 07. The method of Claim 6 further including the step of: inserting said flange portion loosely in said enveloping portion; overfolding said enveloping portion complete with said flange portion therein; forming said indentations at predetermined intervals in 20 the resulting overfolded join region thereby to cause the formation of corresponding deformations in said flange S* portion. o o .ooo
4. 8. An interconnection for a first roll-formed part with a second roll-formed part of a multi-part structural member, said interconnection comprising a flange of said first part engaged within an enveloping portion of said second part; said interconnection further including indentations in said enveloping portion which extend into corresponding indentations in said flange. COMS ID No: SBMI-04694764 Received by IP Australia: Time 17:42 Date 2006-09-07 7.Sep.. 2006 17:41 Wallin gt n-Dummer Sydney No.6595 P.
5. 9. A method of formation of the interconnection of Claim 8, wherein said indentations and said corresponding deformations are formed at the same time.
6. 10. A structural member as particularly claimed in claim 1 and as herein described with respect to what is shown in the accompanying drawings. 9.o .9. *9 o COMS ID No: SBMI-04694764 Received by IP Australia: Time 17:42 Date 2006-09-07