BR112020003150B1 - METAL BEAMS, METHOD FOR MANUFACTURING A METAL BEAM AND METAL BEAM SYSTEM - Google Patents

Abstract

The present invention relates to a beam as a light metal beam that may include a first elongated channel member and a second elongated channel member coupled to the first elongated channel member by a wire matrix, wherein the ends of the matrix of wire are situated at the ends of the first and second channel members. A wire array spacing may vary along the length of the beam. Two or more beams may have different lengths when the difference in lengths is not a multiple of the spacing.

Description

FIELD OF TECHNIQUE

[001] The present disclosure relates to structural members, and more particularly, to metal beams.

BACKGROUND DESCRIPTION OF RELATED TECHNIQUE

[002] Metal beams and framing members have been used in the areas of commercial construction and residential construction for many years. Metal beams offer several advantages over traditional building materials such as wood. For example, metal beams can be manufactured to strict dimensional tolerances, which increase consistency and accuracy when constructing a structure. Additionally, metal beams provide significantly improved design flexibility due to the variety of sizes and thicknesses available and the variations in metal materials that can be used. Furthermore, metal beams have inherent strength/weight ratios that allow them to span greater distances and better resist and transmit bending forces and moments.

BRIEF SUMMARY

[003] The various embodiments described herein can provide a beam with improved thermal efficiency over more conventional beams. While metals are typically classified as satisfactory thermal conductors, the beams described herein employ various structures and techniques to reduce conductive thermal transfer therethrough. For example, the use of a wire array, welds such as resistance welds, and specific weld locations such as peaks, vertices, or intersections of the wires in the wire array can contribute to the overall energy efficiency of the beam.

[004] It has been found that lightweight metal beams incorporating a wire matrix can be reinforced or, in some cases, their stiffness or stability can be improved, so as to increase the web wrinkling resistances of the beam ends. , manufacturing the beams so that the ends of the wires in the wire array are situated and/or welded to the ends of the channel members of the beams.

[005] It has also been found that the ability to manufacture beams to any specific length offers distinct advantages, such as improving the efficiency of installing beams on a job site. Accordingly, systems and methods have been developed that permit the continuous fabrication of metal beams having various lengths and having wire ends in a wire array situated and/or welded to the ends of the channel members of the beams. Such methods generally include continuously fabricating a wire array and stretching the wire array to varying degrees corresponding to the various lengths of the beams to be manufactured, prior to welding the wire array to the channel members.

[006] A light metal beam can be summarized as comprising: a first elongated channel member, the first elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along the main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the first elongate channel member, a respective second flange extending along the second edge at a non-zero angle to the respective main face of the first elongate channel member, a respective first end along the main length thereof, and a respective second end along the main length thereof, a first end of the first member of elongated channel opposite the second end of the first elongated channel member through the main length of the first elongated channel member; a second elongated channel member, the second elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along a main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the second elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective main face of the second elongate channel member, a first end thereof along the main length thereof, and a respective second end along the main length thereof, the first end of the second elongate channel member opposite the second end of the second elongate channel member therethrough of the main length of the second elongated channel member; a first continuous wire member having a plurality of bends to form alternating vertices along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof, the first end of the first continuous wire member opposite the second end of the first continuous wire member through the length of the first continuous wire member, the vertices of the first continuous wire member alternatively physically attached to the first and second channel members elongated to the along at least one of the first and second elongated channel members, the first end of the first continuous wire member coupled to the first elongated channel member at the first end of the first elongated channel member, and the second end of the first elongated channel member continuous wire coupled to the first and second elongated channel members at the second end of the first or second elongated channel member; and a second continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof , the first end of the second continuous wire member opposite the second end of the second continuous wire member through the length of the second continuous wire member, the vertices of the second continuous wire member alternatively physically attached to the first and second elongated channel members along at least one of the first and second elongate channel members, the first end of the second continuous wire member coupled to the second elongate channel member at the first end of the second elongate channel member, the second end of the second elongate channel member continuous wire coupled to the second end of the first or second elongated channel member, and the first and second elongated channel members held in a parallel spaced relationship by both the first and second wire members, with a longitudinal passage formed therebetween .

[007] The first and second wire members can be physically attached to each other at each point where the first and second wire members intersect. Each of the vertices of the second wire member may be opposed to one of the respective vertices of the first member through the longitudinal passage. The first and second continuous wires may be physically attached to the respective first flange of both the first and second elongated channel members by welds and not come into physical contact with the respective main faces of the first and second channel members. Welds can be resistance welded. The vertices of the first continuous wire member attached to the first elongated channel member may alternate with the vertices of the second continuous wire member attached to the first elongated channel member so that a difference between the greatest distance between adjacent vertices of the first and of the second continuous wires attached to the first elongated channel member and the shortest distance between the adjacent vertices of the first and second continuous wires attached to the first elongated channel member is at least 1% of an average distance between the adjacent vertices of the first and the second continuous wires attached to the first elongated channel member. The first and second continuous wire members may be plastically deformed wire members. The first and second continuous wire members may carry residual stresses.

[008] A light metal beam can be summarized as comprising: a first elongated channel member, the first elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along the main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the first elongate channel member, and a respective second flange extending to the along the second edge at a non-zero angle to the respective main face of the first elongated channel member; a second elongated channel member, the second elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along a main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the second elongated channel member, and a respective second flange extending along the second edge at a non-zero angle to the respective main face of the second elongated channel member; a first continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, the apexes of the first continuous wire member alternatively physically attached to the first and second channel members elongated along at least one of the first and second elongated channel members; and a second continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, the apexes of the second continuous wire member alternatively physically attached to the first and second channel members elongated along by at least one of the first and second elongated channel members, the vertices of the first continuous wire member attached to the first elongated channel member alternating with the vertices of the second continuous wire member attached to the first elongated channel member such that a difference between the greatest distance between the adjacent vertices of the first and second continuous wires attached to the first elongated channel member and the smallest distance between the adjacent vertices of the first and second continuous wires attached to the first elongated channel member is at least 1% of a distance average between adjacent vertices of the first and second continuous wires attached to the first elongated channel member, the first and second elongated channel members held in a spaced parallel relationship by both the first and second wire members, with a longitudinal passage formed between the same.

[009] A difference between the greatest distance between the adjacent vertices of the first and second continuous wires attached to the first elongated channel member and the smallest distance between the adjacent vertices of the first and second continuous wires attached to the first elongated channel member may be at least 2%, 3% or 5% of an average distance between adjacent vertices of the first and second continuous wires attached to the first elongate channel member.

[010] A method for manufacturing a light metal beam can be summarized as comprising: providing a first elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along the main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the first elongated channel member, and a respective second flange extending along the second edge at a non-zero angle to the respective main face of the first elongated channel member; provide a second elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along a main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the second elongated channel member, and a respective second flange extending along the second edge at a non-zero angle to the respective main face of the second elongated channel member; tensioning a wire array including first and second continuous wire members, each of the first and second wire members having a plurality of bends to form alternating vertices along a respective length thereof; and coupling the first and second elongated channel members together with the tensioned wire matrix, the vertices of the first continuous wire member alternatively physically attached to the first and second elongated channel members along at least one of the first and the second elongated channel members, and the apexes of the second continuous wire member alternatively physically attached to the first and second elongated channel members along at least one of the first and second elongated channel members.

[011] The method may further comprise physically attaching the first and second continuous wire members to each other at points of intersection thereof. Physical attachment of the first and second continuous wire members to each other at points of intersection thereof may occur prior to coupling of the first and second channel members elongated by the wire matrix. Tensioning the wire matrix may include tensioning the wire matrix along a longitudinal axis of the wire matrix. Tensioning the wire matrix may include plastically and/or elastically deforming the wire matrix.

[012] A plurality of beams can be summarized as comprising: a first beam having a first length, the first beam including: a first elongated channel member, the first elongated channel member having a respective main face that has a respective first edge along a main length thereof and a respective second edge along the main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the first elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective main face of the first elongated channel member, a respective first end along the main length thereof, and a respective second end along the main length thereof, the first end of the first elongated channel member opposite the second end of the first elongated channel member across the main length of the first elongated channel member; a second elongated channel member, the second elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along a main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the second elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective main face of the second elongate channel member, a first end thereof along the main length thereof, and a respective second end along the main length thereof, the first end of the second elongate channel member opposite the second end of the second elongate channel member therethrough of the main length of the second elongated channel member; a first continuous wire member having a plurality of bends to form alternating vertices along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof, the first end of the first continuous wire member opposite the second end of the first continuous wire member through the length of the first continuous wire member, the vertices of the first continuous wire member alternatively physically attached to the first and second channel members elongated to the along at least one of the first and second elongated channel members, the first end of the first continuous wire member coupled to the first end of the first elongated channel member, and the second end of the first continuous wire member coupled to the second end of the first or second elongated channel member; and a second continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof , the first end of the second continuous wire member opposite the second end of the second continuous wire member through the length of the second continuous wire member, the vertices of the second continuous wire member alternatively physically attached to the first and second channel members elongated along at least one of the first and second elongated channel members, the first end of the second continuous wire member coupled to the first end of the second elongated channel member, the second end of the second continuous wire member coupled to the second end of the first or second elongated channel member, the vertices of the first continuous wire member attached to the first elongated channel member spaced from adjacent vertices of the second continuous wire member attached to the first elongated channel member by a first spacing, and the first and second elongated channel members maintained in a spaced parallel relationship by both the first and second wire members, with a longitudinal passage formed therebetween; and a second light beam having a second length, the second beam including: a third elongated channel member, the third elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along the main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the third elongated channel member, a respective second flange extending extends along the second edge at a non-zero angle to the respective main face of the third elongated channel member, a respective first end along the main length thereof, and a respective second end along the main length thereof, the first end of the third elongated channel member opposite the second end of the third elongated channel member across the main length of the third elongated channel member; a fourth elongated channel member, the fourth elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along a main length thereof, a respective first flange that extends along the first edge at a non-zero angle to the respective main face of the fourth elongated channel member, a respective second flange that extends along the second edge at a non-zero angle to the respective main face of the fourth member of the elongate channel, a first end thereof along the main length thereof, and a respective second end along the main length thereof, the first end of the fourth elongate channel member opposite the second end of the fourth elongate channel member therethrough. main length of the fourth channel member elongated; a third continuous wire member having a plurality of bends to form alternating vertices along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof, the first end of the third continuous wire member opposite the second end of the third continuous wire member through the length of the third continuous wire member, the vertices of the third continuous wire member alternatively physically attached to the third and fourth channel members elongated to the along at least a portion of the third and fourth elongated channel members, the first end of the third continuous wire member coupled to the first end of the third elongated channel member, and the second end of the third continuous wire member coupled to the second end of the third or fourth elongated canal member; and a fourth continuous wire member having a plurality of bends to form alternating apexes along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof , the first end of the fourth continuous wire member opposite the second end of the fourth continuous wire member through the length of the fourth continuous wire member, the apexes of the fourth continuous wire member alternatively physically attached to the third and fourth elongated channel members along at least a portion of the third and fourth elongated channel members, the first end of the fourth continuous wire member coupled to the first end of the fourth elongated channel member, the second end of the fourth continuous wire member coupled to the second end of the third or fourth elongated channel member, the vertices of the third continuous wire member attached to the third elongated channel member spaced from adjacent vertices of the fourth continuous wire member attached to the third elongated channel member by a second spacing, and the third and the fourth elongated channel members held in a spaced parallel relationship by both the third and fourth wire members, with a longitudinal passage formed therebetween; wherein the first length differs from the second length and the first spacing differs from the second spacing.

[013] The first length may differ from the second length by an amount that is not a multiple of the first offset or the second offset. The first length may differ from the second length by 2.54 cm (1 inch). The first length may differ from the second length by at least 1.27 cm (1/2 inch).

BRIEF DESCRIPTION OF THE VARIOUS VIEWS OF THE DRAWINGS

[014] In the drawings, identical reference numbers identify similar elements or actions. The relative sizes and positions of elements in drawings are not necessarily represented to scale. For example, the shapes of various elements and angles are not necessarily represented to scale, and some of these elements may be arbitrarily enlarged and positioned to improve the legibility of drawings. Furthermore, the particular shapes of the elements as drawn are not necessarily intended to convey any information about the actual shape of the particular elements, and may have been selected only to facilitate recognition in the drawings.

[015] Figure 1A is an isometric perspective view of a metal beam, according to at least one illustrated embodiment.

[016] Figure 1B is an enlarged partial view of the isometric perspective view of a metal beam of Figure 1A, according to at least one illustrated embodiment.

[017] Figure 2 is a schematic view of a wire array of the metal beam of Figure 1A, according to at least one illustrated embodiment.

[018] Figure 3 is a cross-sectional view of a portion of the metal beam of Figure 1A taken along line 3-3 in Figure 1A, in accordance with at least one illustrated embodiment.

[019] Figure 4 is an isometric environmental view showing the metal beam of Figure 1A adjacent to a wall, according to at least one illustrated embodiment.

[020] Figure 5A is a schematic view of a wire array of the metal beam of Figure 1A in an unstressed or unstretched configuration, in accordance with at least one illustrated embodiment.

[021] Figure 5B is a schematic view of the matrix of Figure 5A in a tensioned or extended configuration, according to at least one illustrated embodiment.

[022] Figure 5C is a schematic view of the wire matrix as illustrated in Figure 5A superimposed on the wire matrix as illustrated in Figure 5B, according to at least one illustrated embodiment.

[023] Figure 6 is a schematic view of an assembly line for manufacturing a plurality of metal beams of varying sizes, according to at least one illustrated embodiment.

[024] Figure 7 is a top plan view of a reinforcement plate in a folded configuration, according to at least one illustrated embodiment.

[025] Figure 8 is a front elevation view of the reinforcement plate of Figure 7 in the folded configuration.

[026] Figure 9 is a right side elevation view of the reinforcement plate of Figure 7 in the folded configuration.

[027] Figure 10 is an isometric perspective view of the reinforcement plate of Figure 7 in the folded configuration.

[028] Figure 11 is a top plan view of the reinforcement plate of Figure 7 in a flattened configuration, before being folded to form straight portions or flaps.

[029] Figure 12 is a top isometric perspective view of a metal framing member including a metal beam and reinforcement plate physically coupled thereto proximate at least one end thereof, in accordance with at least one illustrated embodiment. .

[030] Figure 13 is a bottom isometric perspective view of the metal framing member of Figure 12.

[031] Figure 14 is an end elevation view of the metal framing member of Figure 12.

[032] Figure 15 is a bottom view of the metal framing member of Figure 12.

[033] Figure 16 is a cross-sectional view of the metal framing member of Figure 12, taken along section line A-A of Figure 15.

[034] Figure 17 is a cross-sectional view of two sheets of material that have been coupled by jamming or cold radially expanding a cushion assembly.

[035] Figure 18 is a cross-sectional view of two sheets of material that were coupled by a rivet.

[036] Figure 19A is a cross-sectional view of two sheets of material that will be compressed or pressure-joined together.

[037] Figure 19B is a cross-sectional view of the two sheets of material of Figure 19A that have been compressed or pressure joined together.

DETAILED DESCRIPTION

[038] In the following description, certain specific details are presented to provide a complete understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that the embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other cases, known structures associated with the technology have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments.

[039] Unless the context requires otherwise, throughout the following specification and claims, the word "comprising" is synonymous with "including" and is inclusive or non-limited (i.e., does not exclude additional elements not recited or method actions).

[040] The reference, throughout this specification, to "an embodiment" or "an embodiment" means that a particular feature, structure or characteristic described together with the embodiment is included in at least one embodiment. Therefore, the appearance of the phrases "in one (1) modality" or “in a modality” in several places in the specification does not necessarily refer to the same modality. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[041] As used in this specification and the attached claims, the singular forms “a”, “an”, “the” and “a” include plural references unless the context clearly indicates otherwise. It should be noted that the term “or” is generally used in its broadest sense, that is, as representing “and/or” except where the context clearly indicates otherwise.

[042] The titles and Summary of Disclosure provided herein are for convenience only and do not limit the scope or meaning of the embodiments.

[043] Figure 1A shows a light metal beam 10 in accordance with an aspect of the present disclosure. The beam 10 includes a first elongated channel member 12 and a second elongated channel member 14 positioned at least approximately parallel and spatially separated from each other. A wire array 16 is coupled and positioned between the first elongated channel member 12 and the second elongated channel member 14 at various portions along the lengths of the members.

[044] As illustrated in Figure 1B, the wire matrix 16 can be comprised of a first angled continuous wire 18 and a second angled continuous wire 20 coupled to each other (Figure 2). The first and second angled continuous wires 18, 20 may each be a continuous piece of metal wire. The first angled continuous wire 18 includes a plurality of bends that form a plurality of first vertices 22 that successively and alternately come into contact with the first elongate channel member 12 and the second elongate channel member 14. Similarly, the second wire angled continuum 20 may include a plurality of folds that form a plurality of second vertices 24 to successively and alternately come into contact with the first elongate channel member 12 and the second elongate channel member 14 (Figure 3). The wire matrix 16 may be formed by overlapping the first angled continuous wire 18 with the second angled continuous wire 20 and securing the wires together, for example, with a series of welds or resistance welds, thereby forming a series of intersection points. 26 positioned between the first and second elongated channel members 12, 14.

[045] The wire matrix 16 may be attached to the first and second elongated channel members 12, 14 at all first and second vertices 22, 24 so that the first vertices 22 alternate with the second vertices 24 along at least at least a portion of a length of the first elongated channel member 12 and along at least a portion of a length of the second elongated channel member 14. Accordingly, a series of longitudinal passages 28 are formed along a central length of the die of wire 16. The longitudinal passages 28 may be quadrilateral, for example, diamond-shaped longitudinal passages. The longitudinal passages 28 may be sized to receive services, e.g., wiring, wire cables, fiber optic cable, production tubes, tubes, and other conduits.

[046] The first and second angled continuous wires 18, 20 may each have any of a variety of cross-sectional profiles. Typically, the first and second angled continuous wires 18, 20 may each have a round cross-sectional profile. This can reduce materials and/or manufacturing costs and can advantageously eliminate sharp edges that might otherwise degrade serviceability (e.g., electrically insulating sheaths). Alternatively, the first and second angled continuous wires 18, 20 may each have cross-sectional profiles of other shapes, e.g., a polygonal (e.g., rectangular, square, hexagonal). When a polygonal cross-sectional profile is employed, it may be advantageous to have rounded edges or corners between at least some of the polygonal segments. Again, this can eliminate sharp edges that might otherwise degrade services (e.g., electrically insulating sheaths). Furthermore, the second angled continuous wire 20 may have a cross-sectional profile different from that of the first angled continuous wire 18.

[047] Figure 2 shows the specific configuration of a wire array 16 of the beam 10 shown in Figure 1A according to one aspect. The wire array 16 includes a first angled continuous wire 18 that overlies a second angled continuous wire 20, which is shown in dashed lines for illustrative purposes. This illustration shows that each of the first and second angled continuous wires 18, 20 extends between the first and second elongated channel members 12, 14 in an overlapping manner such that a length of each of the first and second angled continuous wires 18, 20 extends from one elongated channel member to the other elongated channel member in an alternating manner (Figure 3). Accordingly, the first angled continuous wire 18 includes a plurality of vertices 22a and 22b on each side of the first angled continuous wire 18, and the second angled continuous wire 20 includes a plurality of vertices 24a and 24b on each side of the second angled continuous wire 20 for attachment to the first and second elongated channel members 12, 14.

[048] Figure 3 shows a portion of a front cross-sectional view of beam 10 taken along lines 3-3 in Figure 1A. The first elongated channel member 12 and the second elongated channel member 14 are shown positioned parallel and spatially separated from each other with the wire matrix 16 coupling the elongated channel members 12, 14 to each other. The first angled continuous wire 18 is formed with a plurality of bends that form a plurality of first vertices 22a, 22b that successively and alternately come into contact with the first elongated channel member 12 and the second elongated channel member 14. Similarly , the second angled continuous wire 20 is formed with a plurality of bends that form a plurality of second vertices 24a, 24b to successively and alternately come into contact with the first elongated channel member 12 and the second elongated channel member 14.

[049] The wire matrix 16 can be formed by superimposing the first angled continuous wire 18 on the second angled continuous wire 20 and attaching the wires to each other, with a series of welds, such as resistance welds, thus forming a series of points of intersection 26 positioned between the first and second elongated channel members 12, 14. The wire matrix 16 may be attached to the first and second elongated channel members 12, 14, such as by welds such as resistance welds, at the first and second vertices 22a, 22b, 24a, 24b such that the first vertices 22a alternate with the second vertices 24a along a length of the first elongated channel member 12, and the first vertices 22b alternate with the second vertices 24b along a length second elongated channel member 14. Accordingly, a series of longitudinal passages 28 are formed along a longitudinal length of the wire matrix 16. The longitudinal passages 28 have a profile that is substantially separate from the first and second elongated channel members 12 , 14. Thereby, the longitudinal passages 28 can act as a sheath to support and receive utility lines or other devices (Figure 4).

[050] When the beam 10 is vertically installed, the first and second angled continuous wires 18, 20 will move at oblique angles with respect to the ground and a gravitational vector (i.e., the direction of the force of gravity), i.e., no will be neither horizontal nor vertical. In this way, the portions of the first and second angled continuous wires 18, 20 that form each of the longitudinal passages 28 are curved or inclined with respect to the ground. Utilities installed in or passing through a longitudinal passage 28 will tend, under the force of gravity, to settle at a lower point or valley in the longitudinal passage 28. This causes the utility to be at least approximately centered on the beam 10, called self-centering in this document. Self-centering advantageously moves the utility away from the portions of the beam to which the board or other materials will be attached. Thus, self-centering helps protect utilities from damage, for example, damage that could otherwise be caused by the use of fasteners (e.g., screws) used to secure the plate or other materials to the beam 10.

[051] The first elongated channel member 12 may have a main face or web 30 and a first flange 32. Similarly, the second elongated channel member 14 may have a main face or web 34 and a first flange 36 (Figure 3). The wire array 16 may be coupled to the flanges 32, 36 periodically along a length of the first and second elongated channel members 12, 14. In some aspects, the first vertices 22a, 24a may be coupled to the first flange 32 of the first elongated channel member 12 and spatially separated from the main face 30 by a distance L. Similarly, the second vertices 22b, 24b may be coupled to the first flange 36 of the second elongated channel member 14 and spatially separated from the main face 34 by a distance L.

[052] The distance L in any aspect of the present disclosure can vary from a very small distance to a relatively large one. In some configurations, the distance L is less than half an inch, or less than a quarter of an inch, although the distance L may vary beyond such distances. The spatial positioning of the vertices of the main faces 30, 34 of the elongated channel members 12, 14 offers an advantage of reducing manufacturing operations and improving the consistency of the beam size and shape, as the elongated channel members can be positioned and fixed to the wire matrix in relation to each other, as opposed to in relation to the shape and size of the wire matrix, which may vary, for example due to manufacturing tolerances, between applications.

[053] In some aspects, vertices 22 and vertices 24 correspond laterally to each other as coupled to respective first and second elongated channel members 12, 14. For example, the first vertices 22a may be opposite each other, e.g. diametrically opposed, across a longitudinal axis 38 of the beam 10 from the second vertices 24b along a length of the first elongated channel members 12, 14. For example, the apex 22a is positioned at a contact portion of the first channel member. elongated channel 12 that corresponds laterally to the position of the apex 24b in the second elongated channel member 14. The same applies to the apex 24a and the apex 22b, as best illustrated in Figure 3. The plurality of the first and second vertices 22, 24 extend along the length of the beam 10 and is successively and alternately coupled to the first and second elongated channel members 12, 14. As illustrated in Figures 2 and 3, the first and second angled continuous wires 18 and 20 may be mirror images of each other. another through a central longitudinal axis 38 that extends along the length of the beam 10 and through the center of the beam 10 in a direction parallel to the lengths of the first and second elongated channel members 12 and 14, so that the wire matrix 16 is symmetric about axis 38. In other embodiments, the wire array 16 is not symmetric about axis 38.

[054] The first angled continuous wire 18 has an apex 22b coupled to the second elongated channel member 14, while the second angled continuous wire 20 has a vertex 24b coupled to the second elongated channel member 14 adjacent to the apex 22b and separate from the apex 22b by a distance or spacing P. The spacing P may be a given distance less than 25.4 cm (ten inches), or less than 20.3 cm (eight inches), although the given distance may vary beyond such distances. The first and second angled continuous wires 18, 20 may be bent at an angle X, as shown near vertex 22a and vertex 24b. The angle X may be between approximately 60 and 120 degrees, or approximately 90 degrees, or between approximately 30 and 60 degrees, or approximately 45 degrees, although the angle The angle beam 10 for specific applications.

[055] Figure 4 shows a beam system 100 that has a pair of light metal beams in accordance with an aspect of the present disclosure. System 100 includes a first beam 10 and a second beam 10' positioned spatially apart and against a wall 48, as with typical structural arrangements. The first beam 10 and the second beam 10' each include a first elongated channel member 12 and a second elongated channel member 14 positioned parallel and spatially separated from each other. The first beam 10 includes a wire array 16 coupled and positioned between the first elongated channel member 12 and the second elongated channel member 14 at various portions along the lengths of the members, as described with reference to Figures 1 to 3. second beam 10' includes a wire array 116 coupled and positioned between the first elongated channel member 12 and the second elongated channel member 14 at various portions along the length of the elongated channel members, as described with reference to Figures 1 a 3.

[056] The wire arrays 16 and 116 of the beams 10 and 10', respectively, define a plurality of longitudinal passages 28 and 128, respectively, along a central length of the wire arrays 16 and 116. The longitudinal passages 28 and 128 may partially or completely structurally support the utility lines, such as an electrical wire 52 and a pipe 50. Additionally, the longitudinal passages 28 and 128 allow the outlet of the utility lines to physically separate the utility lines from each other and away from the sharp edges of the first and second elongated channel members 12, 14 to reduce or prevent damage to the lines and increase safety.

[057] As illustrated in Figures 1A, 3 and 4, beams 10 and 10' and elongated channel members 12 and 14 may have respective first ends, such as along axis 38, and respective second ends, as opposed to first ends along axis 38. The first and second angled continuous wires 18 and 20 have their respective first ends welded to the first ends of the beams 10 and 10' and to the first ends of the elongated channel members 12 and 14, and the respective second ends welded to the second ends of the beams 10 and 10' and to the second ends of the elongated channel members 12 and 14. In some cases, the first and second ends of the first and second angled continuous wires 18 and 20 may coincide with vertices (e.g., vertices 22a and 24b or vertices 22b and 24a) of the first and second angled continuous wires 18 and 20 within the range of 0.254 mm (0.010 inch).

[058] In some methods of manufacturing a metal beam such as beam 10, a wire matrix such as wire matrix 16 may be manufactured as described above, and may then be tensioned or stretched along its length, which may involve elastically, plastically, or a combination of elastically and plastically extending the wire matrix and which may involve temporarily or permanently increasing the length of the wire matrix, as further described below, before being coupled to the first and second channel members elongated, such as channel members 12 and 14. For example, Figure 5A is a schematic view of the wire array 16 in an untensioned or unstretched configuration, illustrating the first angled continuous wire 18 and the second angled continuous wire 20, as well as such as their intersection points 26 and the longitudinal passages 28 that they form. Figure 5B is a schematic view of the wire array 16 in a modified, tensioned or extended configuration, indicated by reference numeral 16a, including the first angled continuous wire 18 in a modified, tensioned or extended configuration, indicated by reference numeral 18a, and the second continuous angled wire 20 in a modified, tensioned or extended configuration, indicated by reference number 20a, as well as their intersection points 26a and the longitudinal passages 28a that they form.

[059] Figure 5C is a schematic view of the unextended wire matrix 16, as illustrated in Figure 5A, superimposed on the extended wire matrix 16a, as illustrated in Figure 5B. As shown in Figures 5A-5C, a drawing operation performed on the wire die 16 can change various dimensions and characteristics of the wire die 16, while leaving other dimensions and characteristics unchanged. As an example, Figures 5A and 5B illustrate that the first angled continuous wire 18 includes a plurality of linear sections that extend between and interconnect its vertices 22a and 22b, and that the second angled continuous wire 20 includes a plurality of linear sections that extend between and interconnect their vertices 24a and 24b. As illustrated in Figures 5A and 5B, each of these linear sections has a length of L1 in the unextended wire die 16, and a length of L1a in the extended wire die 16a. L1 is the same or equal to L1a, reflecting the fact that the stretching operation does not change the lengths of these individual linear sections.

[060] As another example, also as illustrated in Figures 5A-5C, the first and second angled continuous wires 18 and 20 may be bent at an angle X in the unextended configuration, while the first and second angled continuous wires 18a and 20a can be flexed at an angle Xa in the extended configuration, where the angle Xa is greater than the angle As another example, also as illustrated in Figures 5A-5C, adjacent vertices of the first and second angled continuous wires 18 and 20, e.g., adjacent vertices 22a and 24a, or adjacent vertices 22b and 24b, are separated from each other by a distance or pitch P in the unextended configuration, while the adjacent vertices of the first and second angled continuous wires 18a and 20a are separated from each other by a distance or pitch Pa in the extended configuration, wherein the pitch P is less than the pitch Pa due to a difference in distance Pd.

[061] As another example, also as illustrated in Figures 5A-5C, the wire array 16 has a total length L2 in the unextended configuration, while the wire array 16a has a total length L2a in the extended configuration, when the length L2 is less than the length L2a by a difference in length L2d. As another example, as illustrated in Figures 5A-5C, the wire array 16 has a total width W in the unextended configuration, while the wire array 16a has a total width Wa in the extended configuration, when the width W is greater than the width Wa by a difference in width Wd (note that half the difference in width Wd is illustrated in Figure 5C).

[062] These characteristics and dimensions are geometrically interrelated. For example, as the wire die 16 is longitudinally stretched, the pitch P and the total length L2 increase linearly (i.e., a ratio of Pd to L2d remains constant throughout a stretching operation) according to the degree of stretch. Furthermore, as the wire matrix 16 is longitudinally extended, and therefore as the spacing P and length L2 increase, the angle X increases and the width W decreases in accordance with the degree of stretching and the geometric relationships of the several components. Therefore, the longitudinal stretching of the wire matrix 16 increases the distance L (see Figure 3) by a certain spacing between the first and second elongated channel members 12 and 14. As noted above, the length L1 remains constant or unchanged when throughout a stretching operation as the wire matrix 16 is stretched.

[063] Figure 6 is a schematic view of an assembly line 200 for manufacturing a plurality of metal beams of varying lengths or an individual beam having any specified width and any specified length, including any standard or non-standard width and length. . For example, assembly line 200 can be used to manufacture a plurality of metal beams with respective lengths that differ from each other by increments that are less than a wire die offset from the beams, such as by 10.16 cm (4 inches). 4 inches) or less, 7.62 cm (3 inches) or less, 5.08 cm (2 inches) or less, 2.54 cm (1 inch) or less, 1.27 cm (1/2 inch) or less, 1/4 inch (0.63 cm) or less, 1/8 inch (0.31 cm) or less, 1/16 inch (0.15 cm) or less, or by any desired increment.

[064] As illustrated in Figure 6, the assembly line 200 may include one or more, for example, one or two, zigzag yarn benders or formers 202. The zigzag yarn benders 202 may use the standard and shelf linear wire as input and output of two zigzag wires 204, from which a plurality of angled continuous wires, such as the first and second angled continuous wires 18 and 20, may eventually be separated and formed. In this way, the zigzag threads 204 can have structures corresponding to the structures of the first and second angled continuous threads 18 and 20, as described above, but in a continuous form.

[065] The assembly line 200 may also include a first welding system 206, which may include a plurality of spring-loaded pins 234 driven by a moving conveyor belt 236, and a rotary resistance welding system 238. The first system Welding wire 206 may accept the zigzag wires 204 as input and synchronize the movement of the two zigzag wires 204 by engaging the pins 234 with vertices of the zigzag wires 204 and pulling the zigzag wires 204 so that the vertices of the zigzag wires 204 are spaced apart from each other by a nominal pitch (e.g., as further discussed below). The first welding system 206 may also weld (e.g., resistance welding) the two zigzag wires 204 to each other at their points of intersection, such as using the rotary resistance welding system 238, thereby forming an array of zigzag yarn 208. The zigzag yarns 204 and the continuous yarn array 208 are illustrated in Figure 6 as being oriented vertically and within the page for illustrative purposes, although in practice, the zigzag yarns 204 and the continuous yarn array continuous wire 208 are oriented horizontally and into the page.

[066] The continuous wire matrix 208 may be a continuous wire matrix from which a plurality of individual wire matrices such as the wire matrix 16 may be eventually separated and formed. In this way, the continuous wire matrix 208 can have a structure corresponding to the structure of the wire matrix 16, but in a continuous form. For example, the continuous wire array 208 may have a nominal or unextended pitch corresponding to the pitch P illustrated in Figure 5A, and a nominal or unextended width corresponding to the width W illustrated in Figure 5A. It has been found that the use of a continuous wire die 208 that has a consistent nominal pitch of about 6 inches to fabricate metal beams with a variety of specified overall lengths and widths, and the use of a continuous wire die 208 that has a nominal width that varies based on the specified overall widths of the metal beams that will be manufactured, are advantageous.

[067] The assembly line 200 may also include an expansion mandrel spacing mechanism, which may be called a first upstream conveyor belt 210. The first upstream conveyor belt 210 may include a plurality of extension pins radial 212, a first encoder 214, and a plurality of expansion mandrel segments 218 that can rotate radially inward and outward along the pins 212 between an internal position designated by reference numeral 218a and in which the expansion mandrel segments expansion 218 have a length of 15.24 cm (6 inches) and an external position, designated by reference number 218b and in which the expanding mandrel segments 218 have a length of 16.19 cm (6 3/8 inches). . The radial positions of the expansion mandrel segments 218 can be adjusted along the pins 212 to change the lengths of the expansion mandrel segments 218 between respective pins 212 such that the lengths of the expansion mandrel segments 218 correspond to the clearance nominal of the continuous wire die 208, and so that the continuous wire die 208 can be positioned against the expansion mandrel segments 218 as the continuous wire die passes over the first upstream conveyor belt 210.

[068] As the continuous wire matrix 208 passes over the first conveyor belt 210, the pins 212 may engage with the continuous wire matrix 208, such as by extension through the longitudinal passages extending through the continuous wire matrix 208 and thereby engaging with the welded intersections of the continuous wire array 208 or with the apexes of the zigzag wires 204, to measure the rate at which the continuous wire array 208 exits the first conveyor belt 210 and prevent the array from of continuous yarn 208 leaves the first conveyor belt 210 more quickly than desired. In some cases, this may include applying a force to the continuous wire array 208, e.g., to the welded intersections of the continuous wire array 208 or to the vertices of the zigzag wires 204, in a direction opposite to the direction in which the array continuous wire array 208 travels through the first conveyor belt 210 and through the assembly line 200. In other implementations, the first conveyor belt 210 may engage with the continuous wire array 208 by other techniques, such as those described below for the second conveyor belt 226.

[069] The zigzag wire benders 202, the first welding system 206, and the first conveyor belt 210 can be arranged in a first processing line 240 that can be at an intermediate elevated level on a factory floor. Continuous elongated channel members 216 may be formed by a sheet metal cylinder former located below the raised intermediate level on the factory floor and may be introduced and measured in assembly line 200 along a second processing line 242 located below the elevated intermediate level on the factory floor, which runs parallel to and below the first processing line 240. In alternative implementations, the second processing line 242 may operate above or at the same elevation and to the side of the first processing line 240, rather than below the first processing line 240. A plurality of individual elongated channel members such as the first and second elongated channel members 12 and 14 may be optionally separated and formed from the continuous elongated channel members 216. In this way, the continuous elongated channel members 216 can have a structure corresponding to the matrix structure of the first and second elongated channel members 12 and 14, but in a continuous form.

[070] The assembly line 200 may also include a plurality of cylinders 220 arranged to extend from the last cylinder 220 closer to a second welding system 222, which may be a resistance welding system, and which is described additionally below, and in the second processing line 242, away from the second welding system 222 and towards the first processing line 240, i.e., to extend upstream in relation to the assembly line 200 and upward away from the assembly members. continuous elongated channel 216. Together, the first conveyor belt 210 and the plurality of cylinders 220 form an S-shaped conveyor belt that precisely guides the continuous wire array 208 along a path of constant length and with minimal friction to reduce changes in the degree to which the continuous wire matrix 208 is tensioned or stretched, from the first processing line 240 to the second processing line 242.

[071] The continuous wire array 208 moves over the first conveyor belt 210 and under the plurality of cylinders 220 from the first conveyor belt 210 to the second welding system 222, from the first processing line 240 to the second processing line 242, and in proximity or physical engagement with the continuous elongated channel members 216. The assembly line 200 then drives the continuous wire array 208 and the continuous elongated channel members 216 into the second welding system 222, which may include a spring-loaded, power-wheeled, dual-station rotary welding system to create a welding pressure to weld (e.g., resistance welding) apexes of the continuous wire array 208 to flanges of the continuous elongated channel members 216 The second welding system 222 may weld (e.g., resistance welding) the continuous wire matrix 208 to the continuous elongated channel members 216 to form a continuous elongated metal beam 228.

[072] Thereby, the wheels of the second welding system 222 can engage with the continuous elongated channel members 216 to weld the continuous wire matrix 208 thereto, without bringing the continuous elongated channel members 216 into contact at locations where that the continuous wire array 208 will not be welded. In this way, contact between the wheels of the second welding system 222 and the continuous elongated channel members 216 and the continuous wire array 208 is intermittent. A plurality of elongated metal beams, such as metal beam 10, may be eventually separated and formed from the continuous elongated metal beam 228. In this way, the continuous elongated metal beam 228 may have a structure corresponding to the structure of the beam of metal 10, as described above, but in a continuous form.

[073] The assembly line 200 also includes a second encoder 224 and a second downstream conveyor belt 226, which may include a plurality of drive rollers that engage the continuous elongated metal beam 228, e.g., engage flanges of the assembly members. continuous elongated channel 216 of the continuous elongated metal beam 228 by friction or otherwise mechanically, or by other techniques, such as those described above for the first conveyor belt 210, and measuring the rate at which the continuous elongated metal beam 228 exits the second conveyor belt 226, and to prevent the continuous elongated metal beam 228 from exiting the second conveyor belt 226 more slowly than desired. In some cases, this may include applying a force to the continuous elongated metal beam 228 in a direction aligned with the direction in which the continuous elongated metal beam 228 travels across the second conveyor belt 226 and through the assembly line 200.

[074] In this way, the first conveyor belt 210 can act to retain the continuous wire matrix 208 as it moves through the assembly line 200 (for example, it can apply a force to the continuous wire matrix 208 which acts in a direction opposite to this direction of travel, i.e., in an upstream direction), while the second conveyor belt 226 may act to pull the continuous elongated metal beam 228 and thereby the wire matrix 208, forward as they move through the assembly line 200 (e.g., it may apply a force to the continuous elongated metal beam 228 that acts in a direction aligned with its direction of travel, i.e., in a downstream direction ). In this way, together, the first conveyor belt 210 and the second conveyor belt 226 can apply tension to the continuous yarn matrix 208 so that the continuous yarn matrix 208 is stretched, both elastically and plastically, between the first conveyor belt 210 and the second conveyor belt 226, and held in a tensioned or extended configuration as it is welded (e.g., resistance welded) to the continuous elongated channel members 216. This may be called “pre-tensioning” the continuous wire array 208.

[075] As a result of stretching, the continuous yarn matrix 208 may travel through the first processing line 240 at a first speed, which may be constant along the first processing line 240, and through the second processing line 242 at a second speed, which may be constant along the second processing line 242. In some cases, such as when the continuous wire array 208 is extended, the second speed is greater than the first speed. In other cases, such as when the continuous wire array 208 is not extended, the second speed is equal to the first speed. The first and second speeds can be between 200 and 300 feet per minute.

[076] Furthermore, by controlling a rate at which the first conveyor belt 210 measures the continuous wire matrix 208 and controlling a rate at which the second conveyor belt 226 measures the continuous elongated metal beam 228, the tension developed in the continuous wire matrix 208, and a degree to which the continuous wire array 208 is extended, can be precisely controlled. For example, after being extended, the continuous wire array 208 may have an extended pitch corresponding to the pitch Pa illustrated in Figure 5B, which is typically greater than the nominal pitch of about 6 inches (15.24 cm) by the pitch difference. Pd illustrated in Figure 5C, and an extended width corresponding to the width Wa illustrated in Figure 5B, which is typically greater than the nominal width by the width difference Wd illustrated in Figure 5C. In some implementations, the Pd offset difference can be from 0 inches to at least 0.95 cm (3/8 inch).

[077] During operation of the assembly line 200, the first encoder 214 may measure a length of the continuous wire array 208 measured outside the first conveyor belt 210, such as by counting the number of welded intersections of the wires of the wire array 208 passing through on the first conveyor belt 210. During operation of the assembly line 200, the first encoder 224 may measure a length of the continuous wire array 208 measured within the second conveyor belt 226, such as measuring a length of the continuous elongated metal beam 228 that enters the second conveyor belt 226. In some cases, encoders 214 and 224 may be reset whenever a material length corresponding to an individual metal beam is measured by encoder 214 or 224, respectively, to reduce or eliminate the accumulation of measurement errors. measurement on a large number of beams.

[078] An output from the first encoder 214 may be compared with an output from the second encoder 224 to verify that the continuous wire array 208 is being extended to a specified degree. If comparison of these outputs reveals that the continuous wire array 208 is being extended to the specified degree, then no corrective action can be taken. If comparison of these outputs reveals that the continuous wire array 208 is being extended beyond the specified degree, then corrective action may be taken to speed up the first processing line 240 or slow down the second processing line 242. If comparison of these outputs outputs reveal that the continuous wire array 208 is being extended to less than the specified degree, then corrective action can be taken to slow down the first processing line 240 or speed up the second processing line 242.

[079] The assembly line 200 may also include a laser scanning system 230, which may analyze the continuous elongated metal beam 228 as it exits the second conveyor belt 226. For example, the laser scanner 230 may analyze the continuous elongated metal beam 228 and measuring the distance between adjacent welded intersections of the wire array wires 208. Such distances can be calculated by taking a length of the continuous elongated metal beam 228 that corresponds to a length of an individual beam that will be separated from the continuous elongated metal beam 228, such an average can then be compared with a desired average clearance for the individual beam.

[080] If this comparison reveals that the continuous wire array 208 is being extended to the specified degree, then no corrective action can be taken. If this comparison reveals that the continuous wire array 208 is being extended beyond the specified degree, then corrective action may be taken to speed up the first processing line 240 or slow down the second processing line 242. If this comparison reveals that the continuous wire matrix 208 is being extended to less than the specified degree, then corrective action can be taken to slow down the first processing line 240 or speed up the second processing line 242.

[081] The assembly line 200 may also include a continuous shear cutting system 232, which can shear or cut the continuous elongated metal beam 228 to separate and form a plurality of individual metal beams, such as metal beam 10, from the continuous elongated metal beam 228. Actuation of the continuous shear cutting system 232 to cut the continuous elongated metal beam 228 may be activated by a signal provided by the laser scanner 230 that signifies that a desired or specified number of Welded intersections of the wires from the wire array 208 passed through the laser scanner 230.

[082] Upon receipt of such a signal from the laser scanner 230, the continuous shear cutting system 232 can accelerate a cutting unit thereof from an initial position in the direction of travel of the continuous elongated metal beam 228 to the speed of the cutting unit corresponds to the speed of the continuous elongated metal beam 228, at such point, the cutting unit can be actuated to cut the continuous elongated metal beam 228. The cutting unit can then be decelerated to a stop and then returned to your Home page. A position of the laser scanner 230 may be experimentally adjusted and calibrated during operation of the assembly line 200 until the cutting unit cuts the continuous elongated metal beam 228 at the apexes of the wire die 208 to within an accuracy of 0.025 cm (0.010 inch). By using the features described in this document, errors that affect this accuracy are not cumulative and therefore accuracy can remain constant throughout production. In some cases, this adjustment and calibration may be accomplished with a continuous elongated metal beam 228 having a wire array 208 spaced 6 inches apart, and the laser scanner 230 may be mounted on a servo-driven positioner so that the laser scanner 230 can be moved and adjusted as necessary during operation of the assembly line 200 to ensure that the cutting unit cuts individual metal beams with wire arrays of different spacings at the apexes of the wire arrays.

[083] A method of using assembly line 200 to manufacture a metal beam, such as metal beam 10, to have a specified overall width Ws, for example, in a direction from the first main face 30 to the second main face 34, and a specified total length Ls, for example, in a direction along axis 38 in Figure 3, may include first selecting a specified total width Ws for the metal beam 10 and a specified total length Ls for the beam of metal 10. For example, the specified overall width Ws may be about 20.32 cm (8 inches), about 15.24 cm (6 inches), or about 9.20 cm (3 5/8 inches), and the specified total length Ls may be about 2.43 m (8 feet), about 3 m (10 feet), or about 3.65 m (12 feet). The method may also include selecting a nominal pitch for the continuous wire array 208, which may be about 15.24 cm (6 inches) and distance L, as shown in Figure 3.

[084] Once these dimensions have been selected or otherwise identified, a degree of stretch of the continuous wire matrix 208 can be determined. For example, it has been found to be advantageous to manufacture the metal beam 10 so that when the metal beam 10 is fabricated and separated, as by the continuous shear cutting system 232, the vertices (e.g., vertices 22a, 22b, 24a and/or 24b) of the first and second angled continuous wires 18 and 22 are situated at both ends of the metal beam 10 along its length and welded to the respective ends of the first and second elongated channel members 12 and 14 along its length. along its length, as illustrated in Figures 1A, 3 and 4.

[085] In this way, the degree of stretching can be determined such that, after the continuous wire array 208 is stretched, a first pair of vertices of the zigzag wires 204 (e.g., when the first pair of vertices is diametrically opposed by a width of the zigzag wires 204) is separated from a second pair of vertices of the zigzag wires 204 (e.g., when the second pair of vertices is diametrically opposite by a width of the zigzag wires -zag 204) by the selected specified total length Ls of the metal beam 10. Thus, when the continuous elongated metal beam 228 is separated by the continuous shear cutting system 232, the first pair of vertices are situated at a first end of the selected metal beam 10, the second pair of vertices is situated at a second end of the selected metal beam 10 opposite its first end, the first pair of vertices is welded to the respective first ends of the selected channel members 12 and 14, and the second pair of vertices are welded to respective second ends of the selected channel members 12 and 14 opposite the first ends.

[086] The method may then include determining a nominal width for the continuous wire array 208, which may be configured to facilitate assembly of the metal beam 10 to have the selected specified total width Ws. For example, the nominal width may be equal to the specified total width Ws, minus the combined thicknesses of the first and second main faces 30 and 34, minus twice the selected distance L, plus an expected width difference corresponding to the width difference Wd, resulting from stretching the continuous wire matrix 208 by the determined degree of stretching.

[087] The zigzag wire benders 202 can then form the zigzag wires 204 so that once they are welded together by the first welding system 206 to form the continuous wire array 208, and before the continuous wire array 208 is extended, the continuous wire array 208 has the nominal pitch selected and the nominal width determined. The first welding system 206 can then weld the zigzag wires 204 together to form the continuous wire array 208. The first and second conveyor belts 210, 226 can then pull the continuous wire array 208 in opposite directions to stretch the continuous yarn matrix 208 by the determined stretch degree, both elastically and plastically, and to pull the continuous yarn matrix 208 through the assembly line 200. The first conveyor belt 210 and the plurality of cylinders 220 may then drive the extended continuous wire array 208 from the first processing line 240 to the second processing line 242, and into proximity and/or physical engagement with the continuous elongated channel members 216.

[088] The second welding system 222 can then weld the continuous wire matrix 208 to the continuous elongated channel members 216, and the continuous shear cutting system 232 can cut the continuous elongated metal beam 228, such as cutting the continuous elongated metal beam 228 at locations where the vertices (e.g., the first and second pairs of vertices) of the continuous wire array 208 are welded to the flanges of the continuous elongated channel members 216, in individual or separate metal beams such as metal beam 10. Such separate metal beams may have wire arrays that remain in tension after singulation and even after installation at a job site. Therefore, the methods described herein can result in metal beams that have wire arrays that carry residual stresses after fabrication.

[089] By manufacturing the continuous wire matrix 208 to have a nominal pitch of about 15.24 cm (6 inches), and stretching the continuous wire matrix 208 to have an extended pitch that is greater than the nominal pitch by a difference of spacing between 0 inch and at least 0.95 cm (3/8 inch), the assembly line 200 and the features described herein can be used to manufacture the metal beam 10 to have apexes of its first and second strands angled continuous members 18 and 20 welded to both ends of the first and second elongated channel members 12 and 14 while having any specified total length Ls above 2.43 m (8 feet).

[090] It has been found that the characteristics described herein can be used to manufacture a metal beam having a variation in the spacing of its wire matrix along its length within the range of ±0.062 inch, or in some cases within of the range ±0.25 mm (±0.010 inch), and having ends of the first and second angled continuous wires 18 and 20 that coincide with the vertices (e.g., vertices 22a and 24b or vertices 22b and 24a) of the first and of the second angled continuous wires 18 and 20 within the range of 0.25 mm (0.010 inch). Thus, the characteristics described in this document can be used to manufacture a metal beam with an accuracy of its length within the range of ±1.01 mm (±0.040 inch), within the range of ±0.76 mm (± 0.030 inch) or within the range of ±0.50 mm (±0.020 inch). It has also been found that the features described herein can be used to fabricate a metal beam with a variation in the spacing of its wire array along its length (e.g., a difference between the largest individual spacing and the smallest individual spacing). individual along its beam length) that is relatively large, such as at least 1%, at least 2%, at least 3%, at least 4%, or at least 5% of the mean (e.g., median) offset from the wire array along the length of the beam.

[091] A method of continuously manufacturing a plurality of metal beams using assembly line 200 may include receiving an order for a plurality of metal beams with a variety of specific lengths and a variety of specific widths, as may be requested by a customer and select the specified total width Ws and the specified total length Ls for each of the plurality of metal beams to match the dimensions requested by the customer. The method may also include continuously manufacturing the two zigzag wires 204, continuously welding the zigzag wires 204 to each other to continuously form the continuous wire array 208, continuously drawing the continuous wire array 208, forming and introducing continuously the continuous elongated channel members 216, and continuously weld the continuous wire matrix 208 to the continuous elongated channel members 216, to continuously form the continuous elongated metal beam 228, in accordance with the characteristics described above to form a metal beam individual.

[092] As the continuous elongated metal beam 228 travels through the continuous shear cutting system 232, the cutting system 232 can cut or separate the continuous elongated metal beam 228 into a series of individual metal beams, as a series of metal beams each having the specified total length Ls and the specified total width Ws for that respective metal beam. In some cases, the requested beam that has the lowest specified degree of stretch may be the first beam that will be formed and separated with beams of the same specified degree of stretch formed and separated immediately thereafter. Once the beams of the specified lowest degree of stretch have been formed, the assembly line 200 can be adjusted to manufacture the requested beam having the second lowest specified degree of stretch. Such adjustment can be accomplished by increasing the forces that the first and second conveyors 210 and 226 exert on the continuous yarn die 208 or by increasing the difference in the speeds at which the first and second processing lines 240 and 242 move the yarn die. continuous wire 208 through assembly line 200. Such an adjustment may result in the fabrication of a transition beam that has a wire array with two different pitches, or with a variable pitch, which in some cases can be discarded, while in other cases , may be usable as one of the requested beams, depending on the circumstances.

[093] Once the assembly line 200 has been adjusted, all requested beams having the second lowest degree of stretching can be manufactured, and the process can be repeated for all requested beams. In other cases, the requested beam that has the greatest specified degree of stretch may be the first beam that will be formed and separated, with beams of decreasing specified degrees of stretch formed and separated until all requested beams are manufactured. Adjustments of the assembly line 200 can be made in such cases by decreasing the forces that the first and second conveyor belts 210 and 226 exert on the continuous wire matrix 208 or by decreasing the difference in the speeds at which the first and second conveyor lines processing 240 and 242 move the continuous wire matrix 208 through the assembly line 200.

[094] In some cases, the requested beam that has the smallest specified total length Ls and/or the smallest specified total width Ws may be the first beam that will be formed and selected, with beams of the same specified total length Ls and/or the same specified total width Ws formed and selected immediately thereafter. The assembly line 200 may then be adjusted to manufacture the requested beam having the second smallest specified total length Ls and/or the second smallest specified total width Ws, such as by adjusting the operation of the first and second conveyors 210, 226 for adjusting the assembly line 200 to manufacture a beam having a specified total length Ls, adjusting the operation of the continuous shear cutting system 232 to cut beams having a greater specified total length Ls, and/or adjusting the benders of zigzag wire 202 to adjust the assembly line 200 so as to manufacture a beam with a greater specified overall width Ws. The process can be repeated for all requested beams. In other cases, the requested beam that has the largest specified total length Ls, and/or the largest specified total width Ws may be the first beam that will be formed and separated, with beams of decreasing dimension grades formed and separated until all beams are formed and separated. requested to be manufactured.

[095] As described above, the features described herein can be used to manufacture the metal beam 10 to have apexes of its first and second angled continuous wires 18 and 20 welded to both ends of the first and second channel members elongated 12 and 14 while having any specified total length Ls above 2.43 m (8 ft). Such results provide important advantages. For example, by manufacturing metal beams to specific lengths in a factory environment, the need to cut or trim beams to length during installation can be reduced or eliminated, improving installation efficiency.

[096] Furthermore, manufacturing metal beams such as metal beam 10 to have apexes of its first and second angled continuous wires 18 and 20 welded to both ends of the first and second elongated channel members 12 and 14 makes the beam metal wire 10 symmetrical, so that installers can install beam 10 without regard to which end of the beam is the top or bottom end of beam 10, eliminates the sharp ends of wires 18 and 20 that would otherwise pose hazards during installation and increases the disabling resistances of beam 10 at their respective ends. Furthermore, manufacturing metal beams such as metal beam 10 to have apexes of its first and second angled continuous wires 18 and 20 welded to both ends of the first and second elongated channel members 12 and 14 facilitates the installation of a series of metal beams so that the passages 28 are aligned, or at least more closely aligned, through the series of metal beams.

[097] Figures 7 to 11 show a reinforcement plate 600 for use with the metal beam to manufacture a metal framing member 1100 (Figures 12 to 16), in accordance with at least one illustrated embodiment. In particular, Figure 11 shows the reinforcement plate 600 in a flattened or unbent configuration, while Figures 7 to 10 show the reinforcement plate 600 in a folded configuration.

[098] The reinforcement plate 600 may have a rectangular profile, which has a length Lp and a width Wp, and a gauge or material thickness G that is generally perpendicular to the profile, and then the length Lp and the width Wp. The reinforcement plate 600 has a first pair of opposing edges 602a, 602b, a second edge 602b of the first pair opposite a first edge 602a of the first pair through the length Lp of the reinforcement plate 600. The reinforcement plate 600 has a second pair of opposing edges 604a, 604b, a second edge 604b of the second pair opposite a first edge 604a of the second pair across the width Wp of the reinforcement plate 600.

[099] Between the first and second pair of opposing edges 602a, 602b, 604a, 604b is a center or plate portion 606 of the reinforcement plate 600. The center or plate portion 606 of the reinforcement plate 600 is preferably , corrugated, with a plurality of ridges 608a and valleys 608b (only one of each named for clarity of illustration), the ridges 608a and valleys 608b extending between the first and second edges 602a, 602b of the first pair of edges opposite sides, which is across the other side of the length Lp of the reinforcement plate 600. The ridges 608a and valleys 608b repeat, preferably in a direction along which the first and second edges 602a, 602b extend, which repeat along the width Wp of the gusset plate 600. The corrugations provide structural rigidity to the gusset plate 600. The pattern may be continuous, or as illustrated may be discontinuous, for example, omitting the ridges 608a and valleys 608b in sections between the pairs of opposing flaps (e.g., pair of opposing flaps 610a, 612a, and pair of opposing flaps 610b, 612b).

[0100] Although the first and second edges 602a, 602b are illustrated as straight edges that extend in a straight line between opposing edges 604a, 604b, the first and second edges 602a, 602b may advantageously be notched or sawn to minimize contact between the first and second edges 602a, 602b and the elongated channel members 12, 14, with contact limited to only a few portions that are attached or attached directly to the channel members 12, 14, thereby reducing heat transfer.

[0101] The reinforcement plate 600 has at least one vertical portion 610a-610b along the first edge 602a and at least one vertical portion 612a-612b along the second edge 602b. The pendant portions 610a, 610b may take the form of a respective pair of tabs extending perpendicularly from the plate portion 606 along the first edge 602a and a respective pair of tabs extending perpendicularly from the plate portion 606 along the second edge 602b.

[0102] As illustrated in Figures 12 to 16, the reinforcement plate 600 may be physically secured to the metal beam 10 through the at least one vertical portion 610a-610b along the first edge 602a and the at least one vertical portion 612a, 612b along the second edge 602b. For example, the reinforcement plate 600 may be welded to the metal beam 10 through tabs 610a, 610b, 612a, 612b extending perpendicularly from the plate portion 606. For example, a first set of welds may attach physically the respective pair of tabs 610a, 610b extending perpendicularly from the plate portion 606 along the first edge 602a to the first flange 32 of the first elongate channel member 12, and a second set of welds can physically secure the respective pair of flaps 612a, 612b extending perpendicularly from the plate portion 606 along the second edge 602b to the first flange 36 of the second elongated channel member 14.

[0103] The reinforcement plate 600 may be physically secured to the metal beam 10 such that the edges 602a, 602b of the reinforcement plate 600 are within and enclosed by the first and second elongated channels 12 and 14. For example, the first edge 602a may be positioned adjacent to the main face 30 and between flanges 32 and 42, and the second edge 602b may be positioned adjacent to the main face 34 and between flanges 36 and 44. In such an embodiment, the reinforcement plate 600 may be adjacent , bordering and in contact with the wire matrix 16, and may be on or within the metal beam 10.

[0104] In various embodiments, the reinforcement plate 600 may be physically secured, connected, secured, or coupled to the other components of the metal beam 10 using any suitable mechanisms, methods, fasteners, or adhesives. For example, the reinforcement plate 600 may be physically secured to the other components of the metal beam 10 by an interference fit between the first and second elongated channel members 12, 14, such as between their respective main faces 30 and 34. In In such an example, the length Lp of the reinforcement plate 600 may be slightly greater than a distance between the main faces 30 and 34, so that the reinforcement plate 600 is fixed by an interference fit between the main faces 30, 34 when positioned between them.

[0105] As another example, the reinforcement plate 600 may be resistance welded to the other components of the metal beam 10. In such an example, the tabs 610a, 610b, 612a and 612b of the reinforcement plate 600 may be resistance welded to the main faces 30 and 34, or the center or plate portion 606 of the gusset plate 600 may be resistance welded to the flanges 32 and 36 or to the wire matrix 16. As yet another example, the gusset plate 600 may be attached to the other components of the metal beam 10 by crushing or radially cold expanding a pad or assembly of pads through the passage of a conical mandrel, wherein the pad extends through aligned openings or holes formed in the main faces 30 and 34 and in the flanges 610a, 610b, 612a and 612b. For example, Figure 17 illustrates a pad assembly 702 that extends through aligned openings in flap 610a and main face 30, and that has been cold pressed or radially expanded to secure flap 610a to main face 30. As yet another For example, the reinforcement plate 600 may be attached to the other components of the metal beam 10 by extending through aligned openings or holes formed in the main faces 30 and 34 and in the flaps 610a, 610b, 612a and 612b. For example, Figure 18 illustrates a rivet 708 that extends through aligned openings in tab 610a and main face 30, and which was used to secure tab 610a to main face 30.

[0106] As another example, the reinforcement plate 600 may be physically secured to other components of the metal beam 10 by closing or pressurizing the reinforcement plate 600 to the first and second elongated channel members 12 and 14. In such an example , the tabs 610a, 610b, 612a and 612b of the gusset plate 600 may be riveted to the main faces 30 and 34 of the elongated channel members 12 and 14 or the center or plate portion 606 of the gusset plate 600 may be riveted to the flanges. 32 and 36 of the elongated channel members 12 and 14. For example, Figure 19A illustrates the tab 610a that is positioned adjacent the main face 30 in preparation for a riveting operation, and Figure 19B illustrates the tab 610a riveted to the main face 30 after the riveting operation is completed. The riveting operation may use a punch to press and deform the tab 610a and the main face 30 at a location indicated by reference numeral 704 to form a locking structure indicated by reference numeral 706 to lock the tab 610a to the main face 30. Information Additional information on riveting operations can be found in US Patent Nos. 8,650,730, 7,694,399, 7,003,861, 6,785,959, 6,115,898 and 5,984,563, and in US Pub. Nos. 2015/0266080 and 2012/0117773, all attributed to BTM Corporation.

[0107] A first reinforcement plate 600 can be fixed at least close to or at a first end of the metal beam 10, and a second reinforcement plate 600 can be fixed at least close to or at a second end of the same metal beam 10. metal 10. The first and second reinforcing plates 600 may be coupled to the other components of the metal beam 10 by any of the mechanisms, methods, fasteners or adhesives described herein. The first and second reinforcing plates 600 may be coupled to the other components of the metal beam 10 by the same or different mechanisms, methods, fasteners, or adhesives.

[0108] Patent Cooperation Treaty application number PCT/CA2016/050900, published as international publication number WO 2017/015766, and US Provisional Patent Application No. 62/545,366, are incorporated herein by reference in their totality.

[0109] The skilled artisan will recognize that many of the methods presented herein may employ additional actions, may omit some actions, and/or may perform actions in an order other than that specified.

[0110] The various modalities described above can be combined to provide additional modalities. These and other changes may be made to the embodiments in light of the detailed description above. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and claims, but should be construed to include all possible embodiments, along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims (22)

1. Metal beam (10) CHARACTERIZED by the fact that it comprises: a first elongated channel member (12), the first elongated channel member (12) having a respective main face (30) which has a respective first edge along a main length (Ls) thereof and a respective second edge along the main length (Ls) thereof, a respective first flange (32) extending along the first edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12), a respective second flange extending along the second edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12), a respective first end along the main length (Ls) thereof, and a respective second end along the main length (Ls) thereof, the first end of the first elongate channel member (12) opposite the second end of the first member of elongated channel (12) through the main length (Ls) of the first elongated channel member (12); a second elongated channel member (14), the second elongated channel member (14) having a respective main face (34) having a respective first edge along a main length (Ls) thereof and a respective second edge along the main length (Ls) thereof, a respective first flange (36) extending along the first edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14), a respective second flange extending along the second edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14), a respective first end along the main length (Ls) thereof, and a respective second end along the main length (Ls) thereof, the first end of the second elongated channel member (14) opposite the second end of the second elongated channel member (14) across the main length (Ls) of the second elongated channel member (14); a first continuous wire member (18) having a plurality of bends to form alternating vertices (22) along a respective length (Ls) thereof, a respective first end along a respective length (Ls) thereof, and a respective second end along the respective length (Ls) thereof, the first end of the first continuous wire member (18) opposite the second end of the first continuous wire member (18) across the length of the first continuous wire member ( 18), the vertices (22) of the first continuous wire member (18) alternatively physically attached to the first and second elongated channel members (12, 14) along at least a portion of the first and second elongated channel members (12, 14), the first end of the first continuous wire member (18) coupled to the first elongated channel member (12) at the first end of the first elongated channel member (12), and the second end of the first wire member continuous (18) coupled to the first or second elongated channel member at the second end of the first or second elongated channel member; and a second continuous wire member (20) having a plurality of bends to form alternating vertices (24) along a respective length (Ls) thereof, a respective first end along a respective length (Ls) thereof, and a respective second end along the respective length (Ls) thereof, the first end of the second continuous wire member (20) opposite the second end of the second continuous wire member (20) across the length of the second continuous wire member (20) (20), the vertices (24) of the second continuous wire member (20) alternatively physically attached to the first and second elongated channel members (12, 14) along at least a portion of the first and second channel members (12, 14), the first end of the second continuous wire member (20) coupled to the second elongated channel member (14) continuous (20) coupled to the second end of the first or second elongated channel member, and the first and second elongated channel members (12, 14) held in separate parallel relationship to each other by both the first and second wire members , with a longitudinal passage formed between them. 2. Metal beam (10), according to claim 1, CHARACTERIZED by the fact that the first and second wire members are physically fixed to each other at each point where the first and second wire members intersect . 3. Metal beam (10), according to claim 2, CHARACTERIZED by the fact that each of the vertices (24) of the second wire member is opposite one of the respective vertices (22) of the first wire member through the longitudinal passage. 4. Metal beam (10), according to claim 1, CHARACTERIZED by the fact that the first and second continuous wires (18, 20) are physically fixed to the respective first flange of both the first and second elongated channel members by welds and do not come into physical contact with the respective main faces (30, 34) of the first and second elongated channel members (12, 14). 5. Metal beam (10), according to claim 4, CHARACTERIZED by the fact that the welds are resistance welded. 6. Metal beam (10), according to claim 1, CHARACTERIZED by the fact that the vertices (22) of the first continuous wire member (18) fixed to the first elongated channel member (12) alternate with the vertices (24) of the second continuous wire member (20) attached to the first elongated channel member (12) such that a difference between a greater distance between the adjacent vertices of the first and second continuous wires (18, 20) attached to the first elongated channel member (12) and a shorter distance between adjacent vertices of the first and second continuous wires (18, 20) attached to the first elongated channel member (12) is at least 1% of an average distance between adjacent vertices of the first and second continuous wires (18, 20) attached to the first elongated channel member (12). 7. Metal beam (10), according to claim 1, CHARACTERIZED by the fact that the first and second continuous wire members (18, 20) are plastically deformed wire members. 8. Metal beam (10), according to claim 1, CHARACTERIZED by the fact that the first and second continuous wire members (18, 20) carry residual stresses. 9. Metal beam, CHARACTERIZED by the fact that it comprises: a first elongated channel member (12), the first elongated channel member (12) having a respective main face (30) that has a respective first edge along of a main length (Ls) thereof and a respective second edge along the main length (Ls) thereof, a respective first flange (32) extending along the first edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12) and a respective second flange extending along the second edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12); a second elongated channel member (14), the second elongated channel member (14) having a respective main face (34) having a respective first edge along a main length (Ls) thereof and a respective second edge along the main length (Ls) thereof, a respective first flange (36) extending along the first edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14) and a respective second flange extending along the second edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14); a first continuous wire member (18) having a plurality of bends to form alternating vertices (22) along a respective length (Ls) thereof, the vertices (22) of the first continuous wire member (18) alternatively physically attached to the first and second elongated channel members (12, 14) along at least a portion of the first and second elongated channel members (12, 14); and a second continuous wire member (20) having a plurality of bends to form alternating vertices (24) along a respective length (Ls) thereof, the vertices (24) of the second continuous wire member (20) alternatively physically attached to the first and second elongated channel members (12, 14) along at least a portion of the first and second elongated channel members (12, 14), the vertices (22) of the first continuous wire member ( 18) attached to the first elongated channel member (12) that alternate with the apexes (24) of the second continuous wire member (20) attached to the first elongated channel member (12) so that a difference between a greater distance between the adjacent vertices of the first and second continuous wires attached to the first elongated channel member (12) and a smaller distance between the adjacent vertices of the first and second continuous wires attached to the first elongated channel member (12) is at least 1% of an average distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member (12), the first and second elongated channel members (12, 14) being maintained in separate parallel relationship to each other both by the first and second wire members, with a longitudinal passage formed therebetween. 10. Metal beam according to claim 9, CHARACTERIZED by the fact that a difference between a greater distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member and a smaller distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member is at least 2% of an average distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member. 11. Metal beam according to claim 9, CHARACTERIZED by the fact that a difference between a greater distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member and a smaller distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member is at least 3% of an average distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member. 12. Metal beam according to claim 9, CHARACTERIZED by the fact that a difference between a greater distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member and a smaller distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member is at least 5% of an average distance between adjacent vertices of the first and second continuous wires attached to the first elongated channel member. 13. Method for manufacturing a metal beam, CHARACTERIZED by the fact that the method comprises: providing a first elongated channel member (12) having a respective main face (30) having a respective first edge along a main length (Ls) thereof and a respective second edge along the main length (Ls) thereof, a respective first flange (32) extending along the first edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12) and a respective second flange extending along the second edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12); provide a second elongate channel member (14) having a respective main face (34) that has a respective first edge along a main length (Ls) thereof and a respective second edge along a main length (Ls) thereof , a respective first flange (36) extending along the first edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14) and a respective second flange extending along the second edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14); tensioning a wire array (16) including first and second continuous wire members (18, 20), each of the first and second wire members having a plurality of bends to form alternating vertices (22, 24) along the along a respective length (Ls) thereof; and coupling the first and second elongated channel members (12, 14) together with the tensioned wire matrix (16), the vertices (22) of the first continuous wire member (18) alternatively physically attached to the first and second members elongated channel members (12, 14) along at least a portion of the first and second elongated channel members (12, 14), and the vertices (24) of the second continuous wire member (20) alternatively physically attached to the first and to the second elongated channel members (12, 14) along at least a portion of the first and second elongated channel members (12, 14). 14. Method, according to claim 13, CHARACTERIZED by the fact that it further comprises: physically fixing the first and second continuous wire members (18, 20) to each other at points of intersection thereof. 15. Method, according to claim 14, CHARACTERIZED by the fact that the physical fixation of the first and second continuous wire members (18, 20) to each other at points of intersection thereof occurs before the coupling of the first and the second elongated channel members (12, 14) joined by the wire matrix (16). 16. Method, according to claim 13, CHARACTERIZED by the fact that tensioning the wire matrix (16) includes tensioning the wire matrix (16) along a longitudinal axis of the wire matrix (16). 17. Method, according to claim 13, CHARACTERIZED by the fact that tensioning the wire matrix (16) includes plastically deforming the wire matrix (16). 18. Method, according to claim 13, CHARACTERIZED by the fact that tensioning the wire matrix (16) includes elastically deforming the wire matrix (16). 19. Metal beam system (100) CHARACTERIZED by the fact that it comprises: a first beam (10) having a first length, the first beam (10) including: a first elongated channel member (12), being that the first elongated channel member (12) has a respective main face (30) that has a respective first edge along a main length (Ls) thereof and a respective second edge along a main length (Ls) thereof , a respective first flange (32) extending along the first edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12), a respective second flange extending along the second edge at a non-zero angle to the respective main face (30) of the first elongated channel member (12), a respective first end along the main length (Ls) thereof, and a respective second end along the main length (Ls) thereof, and a respective second end along the main length (Ls) thereof, Ls) thereof, the first end of the first elongated channel member (12) opposite the second end of the first elongated channel member (12) through the main length (Ls) of the first elongated channel member (12); a second elongated channel member (14), the second elongated channel member (14) having a respective main face (34) having a respective first edge along a main length (Ls) thereof and a respective second edge along the main length (Ls) thereof, a respective first flange (36) extending along the first edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14), a respective second flange extending along the second edge at a non-zero angle to the respective main face (34) of the second elongated channel member (14), a respective first end along the main length (Ls) thereof, and a respective second end along the main length (Ls) thereof, the first end of the second elongated channel member (14) opposite the second end of the second elongated channel member (14) across the main length (Ls) of the second elongated channel member (14); a first continuous wire member (18) having a plurality of bends to form alternating vertices (22) along a respective length (Ls) thereof, a respective first end along a respective length (Ls) thereof, and a respective second end along the respective length (Ls) thereof, the first end of the first continuous wire member (18) opposite the second end of the first continuous wire member (18) through the length (Ls) of the first continuous wire member (18) continuous wire (18), the vertices (22) of the first continuous wire member (18) alternatively physically attached to the first and second elongated channel members (12, 14) along at least a portion of the first and second members of elongated channel members (12, 14), the first end of the first continuous wire member (18) coupled to the first end of the first elongated channel member (12), and the second end of the first continuous wire member (18) coupled to the second end of the first or second elongated channel member; and a second continuous wire member (20) having a plurality of bends to form alternating vertices (24) along a respective length (Ls) thereof, a respective first end along a respective length (Ls) thereof, and a respective second end along the respective length (Ls) thereof, the first end of the second continuous wire member (20) opposite the second end of the second continuous wire member (20) through the length (Ls) of the second member of continuous wire (20), the vertices (24) of the second continuous wire member (20) alternatively physically attached to the first and second elongated channel members (12, 14) along at least a portion of the first and second elongated channel members (12, 14), the first end of the second continuous wire member (20) coupled to the first end of the second elongated channel member (14), the second end of the second continuous wire member (20) coupled to the second end of the first or second elongated channel member, the vertices (22) of the first continuous wire member (18) attached to the first elongated channel member (12) separated from the adjacent vertices of the second continuous wire member (20) attached to the first elongated channel member (12) by a first spacing (Pa) and the first and second elongated channel members (12, 14) held in separate parallel relationship to each other by both the first and second wire members, with a longitudinal passage formed between them; and a second beam (10') having a second length, the second beam (10') including: a third elongated channel member, the third elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along the main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the third elongated channel member , a respective second flange extending along the second edge at a non-zero angle to the respective main face of the third elongate channel member, a respective first end along the main length thereof, and a respective second end along the main length thereof, the first end of the third elongated channel member opposite the second end of the third elongated channel member through the main length of the third elongated channel member; a fourth elongated channel member, the fourth elongated channel member having a respective main face having a respective first edge along a main length thereof and a respective second edge along a main length thereof, a respective first flange extending along the first edge at a non-zero angle to the respective main face of the fourth elongated channel member, a respective second flange extending along the second edge at a non-zero angle to the respective main face of the fourth elongate channel member, a first end thereof along the main length thereof, and a respective second end along the main length thereof, the first end of the fourth elongate channel member opposite the second end of the fourth elongate channel member therethrough of the main length of the fourth elongated channel member; a third continuous wire member having a plurality of bends to form alternating vertices along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof, the first end of the third continuous wire member opposite the second end of the third continuous wire member through the length of the third continuous wire member, the vertices of the third continuous wire member alternatively physically attached to the third and fourth channel members elongated to the along at least a portion of the third and fourth elongated channel members, the first end of the third continuous wire member coupled to the first end of the third elongated channel member, and the second end of the third continuous wire member coupled to the second end of the third or fourth elongated canal member; and a fourth continuous wire member having a plurality of bends to form alternating vertices along a respective length thereof, a respective first end along a respective length thereof, and a respective second end along a respective length thereof , the first end of the fourth continuous wire member opposite the second end of the fourth continuous wire member through the length of the fourth continuous wire member, the apexes of the fourth continuous wire member alternatively physically attached to the third and fourth elongated channel members along at least a portion of the third and fourth elongated channel members, the first end of the fourth continuous wire member coupled to the first end of the fourth elongated channel member, the second end of the fourth continuous wire member coupled to the second end of the third or fourth elongated channel member, the vertices of the third continuous wire member attached to the third elongated channel member separated from the adjacent vertices of the fourth continuous wire member attached to the third elongated channel member by a second spacing and the third and the fourth elongated channel members held in separate parallel relationship to each other by both the third and fourth wire members, with a longitudinal passage formed therebetween; where the first length differs from the second length and the first spacing (Pa) differs from the second spacing. 20. Metal beam system (100), according to claim 19, CHARACTERIZED by the fact that the first length differs from the second length by an amount that is not a multiple of the first spacing or the second spacing. 21. Metal beam system (100), according to claim 19, CHARACTERIZED by the fact that the first length differs from the second length by 2.54 cm (1 inch). 22. Metal beam system (100), according to claim 19, CHARACTERIZED by the fact that the first length differs from the second length by less than 1.27 cm (1/2 inch).