GB2565410A

GB2565410A - Corrugated sheet and method of manufacturing same

Info

Publication number: GB2565410A
Application number: GB1809455.7A
Authority: GB
Inventors: Leslie Mann Ronald
Original assignee: Gram Engineering Pty Ltd
Current assignee: Gram Engineering Pty Ltd
Priority date: 2017-06-16
Filing date: 2018-06-08
Publication date: 2019-02-13
Anticipated expiration: 2038-06-08
Also published as: AU2018204150A1; NZ743385A; GB2565410B; US20180361452A1; GB201809455D0

Abstract

Method for corrugating sheet comprising providing metal sheet with first major surface and opposite second major surface, deforming sheet to form parallel corrugations 24, wherein in a cross section of the corrugations some portions of the corrugations comprise a shape approximating a smooth curve, the shape comprising first portions 26a/28a interconnected by second portions 26b/28b, where adjacent first portions are oriented at an angle to one another, and the second portions are plastically deformed during forming. The first portions may not undergo plastic deformation during forming. The second portions may be curved and the first portions may be linear. The curve of best fit of the shape of the smooth curve may have a radius at least 5 times greater than the radius of the second portions. The corrugations may be defined by alternating convex 26 and concave 28 portions, the portions approximating a smooth curve comprising the convex and concave portions. The point of inflection 30 between the concave and convex portions may be at a crest or trough of the corrugations. The radii of the curves of best fit of the convex and concave portions my be equal.

Description

"Corrugated sheet and method of manufacturing same"

Cross-reference [OOOi] This application claims priority to Australian Provisional Patent Application Number 2017902313, filed 16 June 2017, the disclosure of which is incorporated herein by reference in its entirety.

Technical Field [0001] The present disclosure relates to a corrugated sheet and a method of manufacturing such a sheet. The sheet has been developed primarily for use as an infill sheet in a fence panel. However, it will be appreciated that the sheet is not limited to this use and may also be used for other applications, such as wall cladding and roofing.

Background [0002] Some fences are constructed from panels comprising spaced upright support posts to which are attached sturdy upper and lower support rails. One or more infill sheet is fixed between the upper and lower support rails to provide privacy and/or to provide a barrier against the passage of people and animals through the fence. In many applications, the fence can be quite prominent and as such there is a continuing demand for fencing which is visually appealing. As such, the infill sheet(s), which comprise a large proportion of the fence panels, should ideally have aesthetic appeal whilst also being sufficiently strong to perform as a barrier and being cost effective to manufacture.

[0003] Some infill sheets that have previously been developed to address the above needs include roll formed corrugated metal sheets. Typically, such sheets include a plurality of parallel, smoothly curved crests and troughs extending between the side edges of the sheet and defining stiffening ribs and channels extending longitudinally between opposite ends of the sheet, the crests and troughs having a substantially sinusoidal wave form. Another example is the infill sheet disclosed in the present applicant’s earlier Australian Patent No. 2009200462, the entire disclosure of which is incorporated herein by way of reference, which has a point of inflection between adjoining smoothly curved portions at the peak of each crest and the base of each trough to provide a distinctive and visually striking “breaking wave” profile to the sheet.

[0004] The present applicant has identified a problem with infill sheets that are roll formed with smoothly curving portions. This problem relates to the roll formed curves flattening out due to the inherent elasticity of the metal.

[0005] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.

[0006] Throughout this specification: • the words "comprise" and “include”, and variations such as "comprises", "comprising", “includes” and “including”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps; • the terms “sheet of metal” and “metal sheet” will be understood to mean a sheet substantially of metal, but which may also comprise other materials, such as paint and/or galvanic coatings; and • the term “base metal thickness” will be understood to mean the thickness of the metal excluding any coatings, such as galvanic or paint coatings.

Summary [0007] Disclosed herein is a sheet of metal, the sheet comprising: a first major surface and a second major surface opposite the first major surface; and a plurality of parallel corrugations having a length extending in a first direction along the sheet, a width extending in a second direction across the sheet, and a depth extending in a third direction through the sheet, the corrugations being formed by deformation of the sheet, wherein, in a cross section through the sheet transverse to the length of the corrugations, at least some portions of the corrugations comprise a shape approximating a smooth curve, and wherein the shape approximating a smooth curve comprises a plurality of first portions, wherein adjacent said first portions are oriented at an angle to one another and interconnected by second portions, the metal in the second portions being plastically deformed during forming of the corrugations.

[0008] Also disclosed herein is a method of corrugating a sheet of metal, the method comprising: providing a non-corrugated sheet of metal having a first major surface and a second major surface opposite the first major surface; deforming the sheet to form in the sheet a plurality of parallel corrugations having a length extending in a first direction along the sheet, a width extending in a second direction across the sheet, and a depth extending in a third direction through the sheet, wherein, in a cross section through the sheet transverse to the length of the corrugations, at least some portions of the corrugations comprise a shape approximating a smooth curve, and wherein the shape approximating a smooth curve comprises a plurality of first portions, wherein adjacent said first portions are oriented at an angle to one another and interconnected by second portions, the metal in the second portions being plastically deformed during forming of the corrugations.

[0009] Paragraphs [0010] to [0015] below disclose features that may be included in a sheet as defined in paragraph [0007] above and/or in a method as defined in paragraph [0008] above.

[0010] The metal in the first portions may not undergo plastic deformation during forming of the corrugations. The second portions may be curved and have a radius sufficiently small to cause plastic deformation of the metal when the sheet is deformed to that radius. The corrugations may be formed by roll forming the sheet. The first portions may be substantially linear.

[0011] The first and second major surfaces may be rectangular and bounded by: a first end and a second end opposite the first end; and a first side edge and a second side edge opposite the first side edge.

[0012] Prior to being deformed, the sheet may have a thickness of between 0.2mm and 0.6mm or between around 0.25mm and around 0.5mm. The second portions may have a radius of between 1mm and 10mm or between 2mm and 6mm or of about 3mm.

[0013] A curve of best fit of the shape approximating a smooth curve may have a radius of at least 5 times greater than the radius of the second portions or of at least 10 times greater than the radius of the second portions.

[0014] The peak of each crest and/or the base of each trough of the corrugations may be curved. A curve of best fit of the shape approximating a smooth curve may have a radius of at least 5 times greater than a radius of the curved peaks and/or trough bases or of at least 10 times greater than a radius of the curved peaks and/or trough bases or of at least 20 times greater than a radius of the curved peaks and/or trough bases.

[0015] A curve of best fit of the shape approximating a smooth curve may have a radius: of greater than 10mm; or of between 10mm and 200mm; or of between 10mm and 150mm; or of between 10mm and 100mm; or of between 10mm and 70mm; or of between 10mm and 60mm; or of between 10mm and 50mm; or of between 20mm and 200mm; or of between 20mm and 150mm; or of between 20mm and 100mm; or of between 20mm and 70mm; or of between 20mm and 60mm; or of between 20mm and 50mm; or of about 40mm.

[0016] The first portions may have a length: of less than 0.2 times the radius of the associated said shape approximating a smooth curve; or of between 0.05 and 0.15 times the radius of the associated said shape approximating a smooth curve; or of around 0.1 times the radius of the associated said shape approximating a smooth curve.

[0017] The corrugations may be defined by alternating substantially convex and substantially concave portions (in other words, portions of “reverse curvature”), and the at least some portions of the corrugations comprising a shape approximating a smooth curve may comprise the substantially convex and substantially concave portions. In some embodiments, a point of inflection between adjoining said substantially convex and substantially concave portions may be at a crest (and/or a trough) of the corrugations, for example to provide the corrugations with a “breaking wave” shape. In some embodiments, one point of inflection between adjoining said substantially convex and substantially concave portions may be at a crest of the corrugations and another may be at a location between crests and troughs of the corrugations in the third (i.e., depth) direction. In other embodiments, points of inflection between adjoining said substantially convex and substantially concave portions may be substantially midway between crests and troughs of the corrugations in the third (i.e., depth) direction, for example to provide the corrugations with a substantially sinusoidal shape. The radii of the curves of best fit of the substantially convex and substantially concave portions may be substantially equal.

[0018] The sheet may have a protective coating. For example, the sheet may be galvanised, such as with an alloy of zinc and aluminium, and/or may include one or more layers of paint. The protective coating may be applied prior to the sheet being deformed.

Brief Description of Drawings [0019] Embodiments of the principles disclosed herein will now be described, by way of example only, with reference to the accompanying drawings, in which: FIG. 1 is an isometric view of a corrugated sheet embodying principles disclosed herein; FIG. 2 shows a cross section through the sheet of FIG. 1, the cross section being taken transverse to the length of the corrugations; FIG. 3 is an enlarged view of part A of FIG. 2, showing one of the corrugations of the sheet; and FIGS. 4 and 5 show transverse cross sections through alternative embodiments of corrugated sheets embodying the presently disclosed principles.

Description of Embodiments [0020] FIGS. 1-3 show a metal sheet 10 embodying the presently disclosed principles. The sheet 10 is substantially rectangular, having a first major surface 12, a second major surface 14 opposite the first major surface, a first end 16 and an opposite second end 18, and a first side edge 20 and an opposite second side edge 22. The sheet 10 has a plurality of parallel corrugations 24 having a length defining a first axis L extending along the sheet, a width defining a second axis W extending across the sheet, and a depth defining a third axis D extending through the sheet. The corrugations 24 are formed by deforming of the metal sheet, such as by roll forming.

[0021] A cross section through the sheet 10 transverse to the length of the corrugations 24 is shown in FIG. 2. The transverse cross section of sheet 10 is constant along axis L. As shown in FIGS. 2 and 3, each of the corrugations 24, in transverse cross section, comprises a substantially convex portion 26 and a substantially concave portion 28. The substantially convex and concave portions 26, 28 each comprise a plurality of substantially linear portions 26a, 28a with curved transition portions 26b, 28b therebetween. The curved transition portions 26b, 28b have a radius sufficiently small to cause plastic deformation of the metal of the sheet during roll forming of the corrugations 24. Despite being formed from a plurality of linear interconnected by curved transition portions, the substantially convex and concave portions 26, 28 each approximate a smooth curve.

[0022] The metal sheet 10 is roll formed from flat sheet steel having a base metal thickness of between 0.2mm and 0.6mm or between around 0.25mm and around 0.5mm, and the curved transition portions 26b, 28b may have a radius of between 1mm and 10mm or between 2mm and 6mm. Based on the yield strength and base metal thickness of the steel being roll formed, the radius of the curved transition portions 26b, 28b required to cause plastic deformation during roll forming of the curved transition portions can be determined. In the illustrated embodiment, the steel sheet 10 is roll formed from coil steel having a minimum yield strength of 550MPa and a base metal thickness of approximately 0.35mm, and the curved transition portions 26, 28 have a radius of approximately 2.8mm.

[0023] In sheet 10, a curve of best fit for the substantially convex and concave portions 26, 28 has a radius of approximately 40mm. As such, the radii of the curves of best fit for the convex and concave portions is more than 10 times greater than the radius of the curved transition portions. In other embodiments, the substantially convex portion 26 and substantially concave portion are differently configured such that the substantially convex portion 26 has a curve of best fit with a different diameter to that of the substantially concave portion 28.

[0024] In sheet 10, the linear portions 26a, 28a have a length of approximately 4.7mm, which is around 0.1 times the radius of the curve of best fit for the substantially convex and concave portions 26, 28. In other embodiments, the ratio of the length of the linear portions 26, 28 to the radius of the curve of best fit for the associated substantially convex or concave portion 26, 28 may be greater than or less 0.1 and may, for example, be another value between around 0.05 and around 0.2 such that the substantially convex and concave portions 26, 28 may more closely or less closely approximate a smooth curve.

[0025] The corrugations 24 of sheet 10 are defined by an alternating (“reverse curvature”) pattern of substantially convex and concave portions 26, 28 across the sheet. The point of inflection between each adjoining substantially convex and substantially concave portion 26, 28 is at either a crest or a trough of the corrugations 24 to provide the corrugations with a “breaking wave” shape as best illustrated in FIG. 2 and 3. A curved transition portion 30 is provided between each adjoining substantially convex and concave portion 26, 28 and defines the peak of each crest and the base of each trough of the corrugations 24. The curved transition portions 30 have a radius of approximately 1.4mm.

[0026] The corrugations can repeat at a pitch in the range of about 50mm to about 300mm in a direction across the sheet 10 (i.e., parallel to axis W). In sheet 10, the corrugations repeat at a pitch of about 80mm, with each of the concave and convex portions 26, 28 extending approximately 40mm in a direction parallel to axis W. Thus, the base of each trough is substantially mid-way between two adjacent crest peaks. In other embodiments, each of the convex portions 26 may extend a greater distance in a direction across the sheet 10 than the concave portions 28, or vice versa, such that the base of each trough is offset from the mid-point between adjacent crest peaks.

[0027] The distance between the crest peaks and trough bases measured in a direction through the sheet 10 (i.e., parallel to axis D) can be from about 20mm to about 200mm, or more usually from about 20mm to about 75mm. In the illustrated embodiment, the distance between the crest peaks and the trough bases measured in a direction through the sheet 10 is approximately 26mm.

[0028] Sheet 10 has a width of approximately 810mm. Sheet 10 can be made in various lengths, such as lengths of approximately 1490mm or 1790mm. However, in other embodiments, sheet 10 can be wider or narrower and/or longer or shorter to suit a particular application.

[0029] Sheet 10 is formed from G550 coil steel complying with Australian Standard 1397 2011. The coil steel for sheet 10 has a galvanic coating overlaid by one or more paint layers.

[0030] To form sheet 10, the coil steel is cut to size and roll formed using a roll forming apparatus. Roll forming apparatus are well known in the art and generally have a plurality of pairs of forming rolls. The profile of sheet 10, including corrugations 26, 28, is formed as the coil steel passes through a nip of the respective pairs of rolls.

[0031] It will be appreciated that sheet 10 is ideally suited for use as an infill between rails and posts of a steel fence panel. However, it may also be used in other applications where a barrier is required and may, for example, be used as cladding for a wall or roof or as a shade element in an awning.

[0032] FIGS. 4 and 5 show transverse cross sections through alternative embodiments of sheets 10’ embodying the presently disclosed principles. Sheets 10’ have many features in common with sheet 10, with corresponding reference numerals indicating corresponding features with corresponding functionality. As with sheet 10, sheets 10’ also have corrugations 24 formed from substantially convex and concave portions 26, 28 made up of a plurality of substantially linear portions with curved transition portions therebetween. The points of inflection of the substantially convex and concave portions 26, 28 of sheets 10’ are, however, positioned differently to those of sheet 10 in order to create differently shaped corrugations 24; specifically, alternative “breaking wave” shaped corrugations and substantially sinusoidal corrugations. Persons of skill in the art will, however, understand that these are merely some examples of alternative corrugation shapes and that the presently disclosed principles can be applied to any of a myriad of other corrugation shapes having a portion that approximates a smooth curve.

[0033] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Examples of possible variations and/or modifications include, but are not limited to: • the shape and/or size of the corrugations 24 may be varied from those disclosed above and in the accompanying figures, for example by having a greater or lesser height and/or a greater or lesser pitch, such as may be provided by modifying the substantially convex and concave portions 26, 28 to have a curve of best fit with a larger or smaller radius, and/or by increasing or reducing the radius of the curved transition portions 30; • to more closely approximate a smooth curve, the ratio of the length of the linear portions 26a, 28a to the radius of the curve of best fit of the substantially convex and concave portions 26, 28 may be reduced; and/or • the sheet 10, 10’ may be formed of a metal other than steel or from a metal alloy.

Claims

CLAIMS:

1. A method of corrugating a sheet of metal, the method comprising: providing a non-corrugated sheet of metal having a first major surface and a second major surface opposite the first major surface; deforming the sheet to form in the sheet a plurality of parallel corrugations having a length extending in a first direction along the sheet, a width extending in a second direction across the sheet, and a depth extending in a third direction through the sheet, wherein, in a cross section through the sheet transverse to the length of the corrugations, at least some portions of the corrugations comprise a shape approximating a smooth curve, and wherein the shape approximating a smooth curve comprises a plurality of first portions, wherein adjacent said first portions are oriented at an angle to one another and interconnected by second portions, the metal in the second portions being plastically deformed during forming of the corrugations.

2. A method according to claim 1, wherein the metal in the first portions does not undergo plastic deformation during forming of the corrugations.

3. A method according to claim 1 or claim 2, wherein the second portions are curved and have a radius sufficiently small to cause plastic deformation of the metal when the sheet is deformed to that radius.

4. A method according to any one of the preceding claims, wherein the first portions are substantially linear.

5. A method according to any one of the preceding claims, wherein a curve of best fit of the shape approximating a smooth curve has a radius of at least 5 times greater than the radius of the second portions.

6. A method according to any one of the preceding claims, wherein each of the second portions has a radius of between 1mm and 10mm, and wherein, prior to being deformed, the sheet has a thickness of between 0.2mm and 0.6mm.

7. A method according to claim 6, wherein, prior to being deformed, the thickness of the sheet is between around 0.25mm and around 0.5mm.

8. A method according to claim 6 or claim 7, wherein each of the second portions has a radius of between 2mm and 6mm.

9. A method according to any one of claims 6 to 8, wherein each of the second portions has a radius of about 3mm.

10. A method according to any one of the preceding claims, wherein a curve of best fit of the shape approximating a smooth curve has a radius of greater than 10mm.

11. A method according to claim 10, wherein the radius of the curve of best fit of the shape approximating a smooth curve is: between 10mm and 200mm; or between 10mm and 150mm; or between 10mm and 100mm; or between 10mm and 70mm; or between 10mm and 60mm; or between 10mm and 50mm; or between 20mm and 200mm; or between 20mm and 150mm; or between 20mm and 100mm; or between 20mm and 70mm; or between 20mm and 60mm; or between 20mm and 50mm; or about 40mm.

12. A method according to any one of the preceding claims, wherein each of the first portions has a length of less than 0.2 times the radius of the associated said shape approximating a smooth curve.

13. A method according to claim 12, wherein the length of each of the first portions is between 0.05 and 0.15 times the radius of the associated said shape approximating a smooth curve.

14. A method according to claim 13, wherein the length of each of the first portions is around 0.1 times the radius of the associated said shape approximating a smooth curve.

15. A method according to any one of the preceding claims, wherein the corrugations are defined by alternating said substantially convex and substantially concave portions, and the at least some portions of the corrugations comprising a shape approximating a smooth curve comprise the substantially convex and substantially concave portions.

16. A method according to claim 15, wherein a point of inflection between adjoining said substantially convex and substantially concave portions is at a crest and/or a trough of the corrugations.

17. A method according to claim 15, wherein one point of inflection between adjoining said substantially convex and substantially concave portions is at a crest of the corrugations and another is at a location between crests and troughs of the corrugations in the third direction.

18. A method according to claim 15, wherein points of inflection between adjoining said substantially convex and substantially concave portions are substantially midway between crests and troughs of the corrugations in the third direction.

19. A method according to claim 16 or claim 18, wherein the radii of the curves of best fit of the substantially convex and substantially concave portions are substantially equal.

20. A corrugated sheet of metal produced using a method according to any one of the preceding claims.