WO2011135054A2

WO2011135054A2 - An i-beam

Info

Publication number: WO2011135054A2
Application number: PCT/EP2011/056793
Authority: WO
Inventors: Barry Peter Newell
Original assignee: Barry Peter Newell
Priority date: 2010-04-28
Filing date: 2011-04-28
Publication date: 2011-11-03
Also published as: IE20110211A1; WO2011135054A3

Abstract

An I-beam (1) is formed from folded metal sheet material and has a pair of spaced-apart flanges (2, 3) interconnected by a web (4) which extends between the flanges (2, 3). Each of the flanges (2, 3) and the web (4) comprise at least two overlapping layers of sheet material. Conveniently the I-beam (1) can be formed by a pair of complementary shaped beam elements of folded metal sheet assembled in interlocking nesting engagement.

Description

"An l-Beam"

Introduction This invention is related to construction elements and in particular to l-Beams. Background to the Invention

Conventionally I-beams are made by some form of hot rolling or forging. Generally speaking, it is not possible to make an I-beam by hot rolling with a weight of less than about 23 kilograms per linear metre. Anything lighter leads to excessive distortion and product rejection. For lighter I-beams, it is possible to forge I-beams having weights greater than about 5 kilograms per linear metre. A problem with forging however is that it is relatively expensive. Further, there are many applications where even lighter I-beams could be useful.

The present invention is directed towards overcoming these problems.

Summary of the Invention

According to the invention there is provided an I-beam formed from folded metal sheet material having a pair of spaced-apart flanges interconnected by an intermediate web, each of said flanges and web comprising at least two overlapping layers of sheet material.

Advantageously, according to the invention, a light-weight I-beam can be cheaply formed from folded metal plate material. It is well known to use folded metal sheet in various shapes for purlins, rails and the like construction elements, however, these generally have a relatively limited load bearing capacity and there are a number of more significant load-bearing applications for which they are not suitable, such as joists and support columns, for example. This is a very simple invention. While on the face of it, the invention might appear to be obvious, heretofore apparently it has not been appreciated that I-beams suitable for heavier loadings can be provided by folding metal sheet. The present invention is clearly advantageous in that the metal sheet can be relatively easily handled and folded to the desired shape to provide relatively lightweight I-beams of the order of 3 kg per linear meter and having a simple and robust I-beam section which looks similar to a conventional I-beam. There are many applications where these "lightweight" I- beams of the invention can be used instead of the heavier conventional hot rolled or forged I-beams which are currently used. In fact, the currently used hot rolled or forged I-beams provide a load bearing capacity well in excess of that which is required in many of such applications. Thus, advantageously, the I-beams of the current invention provide a significant saving in terms of costs of material, manufacture and transport. Also, the "lightweight" I-beams of the invention are easier to handle during the construction process.

Further, the conventional hot rolled or forged I-beams are generally manufactured in very limited sizes which often further require a significant amount of cutting, drilling, etc. to meet the requirements of each individual construction job and leads to significant wastage. Advantageously, the present invention provides the possibility of relatively easily and cheaply custom manufacturing I-beams to a desired size and strength for particular applications. In accordance with the present invention, metal sheet material is easily cut to size and then folded to form an I-beam having the desired size and strength characteristics.

In one embodiment of the invention the I-beam comprises a pair of complementary shaped beam elements of folded metal sheet in interlocking nesting engagement. This advantageously provides a particularly convenient and cheap construction, as two relatively simple shaped beam elements can be easily formed and overlapped in nesting engagement to form the I-beam.

In another embodiment said beam elements are interlocked by means of a wraparound flap at each flange, said flap on a flange edge portion of a first beam element forming a socket for reception of a flange edge portion of a second beam element.

In another embodiment the flap clamps the flange edge portion of the second beam element within the socket. ln another embodiment the beam elements are crimped together.

In a preferred embodiment the beam elements are crimped together by a number of crimp detents interconnecting web panels of the beam elements. Conveniently a row of crimp detents may be provided adjacent each end of the web.

In a further embodiment the beam elements are similar, each beam element comprising a web panel having a first flange panel projecting outwardly to one side of the web panel at one end of the web panel and a second flange panel at the other end of the web panel, said second flange panel having a first portion and a second portion, the first portion projecting outwardly of the web panel on the same side as the first flange panel, said first portion having two overlapping layers, and the second portion projecting outwardly of the web panel at the opposite side to the first portion and terminating in an in-turned flap at a free edge of the second portion which receives the first flange panel of the other complementary beam element.

A number of through-holes may be provided in the I-beam. These through-holes could include bolt holes for attachment of the I-beam to other construction elements and larger holes in the web for accommodating services. Conveniently the holes may be simply punched or otherwise cut in the metal plates before they are folded to form the I-beam. Alternatively, the holes could be cut in the I-beam after its formation.

The I-beam may conveniently be formed from metal coil having a thickness in the range 0.3mm to 3mm. The metal coil may comprise galvanised steel plate material if desired for added protection. In another embodiment the web has at least one through-hole to facilitate through- passage of services.

In another embodiment the web and/or each flange has a number of bolt mounting holes. ln another aspect, the invention provides a method for forming an I-beam including folding metal sheet material to form the I-beam having a pair of spaced-apart flanges interconnected by an intermediate web, overlapping at least two layers of sheet material to form each of said flanges and said web.

In another embodiment, the method includes the steps of forming a desired array of holes in flat metal sheet material and then folding the flat metal sheet material to form the I-beam.

In another embodiment, the method includes forming a complementary pair of shaped beam elements of folded metal sheet, overlapping the pair of shaped beam elements in nesting engagement and interlocking the shaped beam elements in nesting engagement.

In another embodiment, the method includes interlocking the shaped beam elements by wrapping a flap at a flange edge portion of a first beam element about a flange edge portion of a second beam element. In a further embodiment, the method includes crimping the beam elements together.

Brief Description of the Drawings The invention will be more clearly understood by the following description of some embodiments thereof, given by way of example only, with reference in the accompanying drawings, in which:

Fig. 1 is a perspective view of an I-beam according to the invention;

Fig. 2 is an end elevational view of the I-beam;

Fig. 3 is an exploded end elevational view of a complementary pair of beam elements which form the I-beam; Fig. 4 is an end elevational view of another I-beam according to a second embodiment of the invention;

Fig. 5 is an exploded end elevational view of a complementary pair of beam elements which form the I-beam shown in Fig. 4;

Fig. 6 is an end elevational view of another I-beam according to a third embodiment of the invention;

Fig. 7 is a perspective view of an apex bracket for use with I-beams of the invention;

Fig. 8 is a perspective view of an eaves bracket for use with the I-beams of the invention;

Fig. 9 is a perspective view of foot brackets for use with the I-beams of the invention; Fig. 10 is a perspective view of an apex connector for use with the I-beams of the invention;

Fig. 1 1 is a perspective view of an eaves connector for use with I-beams of the invention; and

Fig. 12 is a perspective view of a foot connector for use with I-beams of the invention;

Detailed Description of the Preferred Embodiments

Referring to the drawings, and initially to Figs. 1 to 3 thereof, there is illustrated an I-beam according to the invention indicated generally by the reference numeral 1. The I-beam 1 is formed from folded metal sheet material and has a pair of spaced- apart flanges 2, 3 interconnected by a web 4 which extends between the flanges 2, 3. Each of the flanges 2, 3, and web 4 comprise at least two overlapping layers of sheet material.

In the construction shown in Figs. 1 to 3, the I-beam 1 is formed by a pair of complementary shaped beam elements 6, 7 (Fig. 3) of folded metal sheet assembled in interlocking nesting engagement as shown in Fig. 2.

Referring in particular to Fig. 3 each beam element 6, 7 has a central web panel 8, 9 forming part of the web 4, said central web panels 8, 9 overlapping to form the web 4. A first flange panel 10, 1 1 projects outwardly to one side of the web panel 8, 9 at one end of the web panel 8, 9. A second flange panel 12, 13 is provided at an opposite end of the web panel 8, 9. A first portion 14, 15 of the second flange panel 12, 13 projects outwardly of the web panel 8, 9 on the same side as the first flange panel 10, 1 1 . Said first portion 14, 15 has two overlapping layers formed by folding the metal sheet back on itself to form one half of the flange 2, 3. A second portion 16, 17 of the second flange panel 12, 13 projects outwardly of the web panel 8, 9 at the opposite side to the first portion 14, 15 and terminates in an in- turned flap 18, 19 (Fig. 2) which receives the first flange panel 10, 1 1 of the other complementary beam element 6, 7. Thus, when the two beam elements 6, 7 are nested together the flaps 18, 19 are formed by wrapping an outer free edge 20, 21 of each second flange panel 12, 13 about an outer free edge 22, 23 of the first flange panel 10, 1 1 which it overlaps to interlock said beam elements 6, 7. The flap 18, 19 essentially forms a socket within which the outer free edge 22, 23 of the first flange panel 10, 1 1 of the other beam element 6, 7 is clamped.

To additionally secure the two beam elements 6, 7 together a line of spaced-apart crimping detents 26 is provided adjacent each end of the I-beam 1 interconnecting the web panels 8, 9. Conveniently, a number of large spaced-apart through holes 30 are provided in the web 4 for through passage of services. Various other through holes 32 may be provided in the web 4 and flanges 2, 3 for reception of mounting bolts for attachment of the I-beam 1 to other construction elements. Advantageously the I-beam 1 according to the invention can be relatively cheaply produced by folding or roll forming steel coil or galvanised coil of thickness up to about 3 mm and typically in the range 1 .5mm - 3mm. Thus, weights in the order of 3 kilograms per linear metre can be achieved for the I-beam 1 .

Referring now to Figs. 4 and 5, there is shown another I-beam according to a second embodiment of the invention indicated generally by the reference numeral 40. The I-beam 40 has a pair of spaced-apart flanges 42, 43 interconnected by a web 44 extending between the flanges 42, 43. In this case the I-beam 40 is formed by a pair of beam elements 46, 47 of complementary but different shape. The first beam element 46 is formed from a metal sheet folded into a H shape. A second beam element 47 is formed from metal sheet folded into a C shape. The second beam element 47 nests within an opening 48 formed by outwardly extending flange arms 49, 50 on the first beam element 46. A web panel 51 on the second beam element 47 overlaps and abuts against an associated web panel 52 on the first beam element 46. Outer free ends of the flange arms 49, 50 on the first beam element 46 are folded over about outer free ends of flange arms 53, 54 of the second beam element 47 forming flaps 55, 56 which clamp against the flange arms 53, 54 of the second beam element 47.

Referring now to Fig. 6 there is shown another I-beam according a third embodiment of the invention indicated generally by the reference numeral 60. In this case the I-beam 60 is formed from a single metal sheet folded into the I-beam shape illustrated having flanges 62, 63 interconnected by a web 64. A flap 65 along one edge of the metal sheet is folded over and clamped against the opposite side edge of the metal sheet to secure the metal sheet in the folded I- beam configuration illustrated. In an alternative arrangement the free edge of the sheet could possibly be spot welded in the folded position. Figs. 7 to 9 show various mounting brackets for use with the I-beams of the invention.

Fig. 7 shows an apex mounting bracket 70 which has a channel shape in an inverted V configuration for forming the apex at a roof of a building. Bolt holes 71 are provided through the bracket 70 at spacings which correspond to the spacings of the bolt holes 32 in the flanges 2, 3 and web 4 of the I-beam 1 . A pair of these apex brackets 70 are inserted into the channels at each side of the web 4 of the I- beam 1 and bolted to the web 4 and flanges 2, 3 in use. This interconnects a pair of I-beams 1 forming rafters.

Similarly, referring to Fig. 8, an eaves bracket 74 of channel section is shown for providing a transition between the sloped I-beams 1 forming rafters for the roof and the vertical I-beams 1 used as upright support columns at the side walls to support the roof. Here again holes 71 are provided through the bracket 74 which match with the array of bolt holes 32 in the flanges 2, 3 and web 4 of the I-beam 1 .

Referring to Fig. 9 there is shown foot brackets 75 which comprise a flat base plate 76 with channel section uprights 77. As with the previous brackets 70, 74 in this case, the uprights 77 nest within the channels at each side of the web 4 of the I-beam 1 and here again bolt holes 71 at spacings which correspond to the spacings of the bolt holes 32 in the I-beam are provided for securing the flanges 2, 3 and web 4 of the I-beam to the foot bracket 75. The base plate 76 can be bolted (see bolt holes 78) or otherwise secured to a foundation or other support.

Figs. 10 to 12 show various connectors for use with the I-beams of the invention. These are an alternative to the mounting brackets described in Figs. 7 to 9. Referring initially to Fig. 10, there is shown an apex connector 80. In this case the apex connector 80 fits outside the I-beam 1 and has a generally inverted V-shape of box section with through-holes 81 which correspond with and align with the array of bolt holes 32 on the flanges 2, 3 of the I-beam 1 . The interior of the apex connector 80 defines sockets 82 for reception of ends of I-beams 1. A stiffener plate 83 may be added to provide additional strength between the two box-section parts of the apex connector 80.

Similarly, referring to Fig. 1 1 , a box-section eaves connector 84 is shown having sockets 85 for reception of I-beams 1 and bolt holes 81 at the corresponding spacings to the bolt holes 32 in the flanges 2, 3 of the I-beam 1 . The eaves connector 84 forms a connection between an I-beam 1 forming an upright support column and another I-beam 1 forming a rafter. Fig. 12 shows a foot connector 87 for supporting an I-beam 1 in an upright orientation to form a support column. The foot connector 87 has a box section upright 88 defining a socket 89 for reception of the I-beam 1 . Holes 81 in the upright 88 correspond to the bolt holes 32 in the flanges 2, 3 of the I-beam 1 . A base flange 90 at a bottom of the upright 88 can be secured to a foundation or similar support, by bolts which engage bolt holes 91 , for example.

The invention is not limited to the embodiments hereinbefore and described which may be varied in both construction and detail within the scope of the appended claims.

Claims

An I-beam (1 ) formed from folded metal sheet material having a pair of spaced-apart flanges (2,3) interconnected by an intermediate web (4), each of said flanges (2,3) and web (4) comprising at least two overlapping layers of sheet material.

The I-beam (1 ) as claimed in claim 1 wherein the I-beam (1 ) comprises a pair of complementary shaped beam elements (6,7) of folded metal sheet in interlocking nesting engagement.

The I-beam (1 ) as claimed in claim 2 wherein said beam elements (6,7) are interlocked by means of a wrap-around flap (18,19) at each flange (2,3), said flap (18,19) on a flange edge portion of a first beam element (6,7) forming a socket for reception of a flange edge portion (22,23) of a second beam element (6, 7).

The I-beam (1 ) as claimed in claim 3 wherein the flap (18,19) clamps the flange edge portion (22,23) of the second beam element (6,7) within the socket.

The I-beam (1 ) as claimed in any preceding claim wherein the beam elements (6,7) are crimped (26) together.

The I-beam (1 ) as claimed in claim 5 wherein the beam elements (6,7) are crimped together by a number of crimp detents (26) interconnecting web panels (8,9) of the beam elements (6,7).

The I-beam (1 ) as claimed in any of claims 2 to 6 wherein the beam elements (6,7) are similar, each beam element (6,7) comprising a web panel (8,9) having a first flange panel (10,1 1 ) projecting outwardly to one side of the web panel (8,9) at one end of the web panel (8,9) and a second flange panel (12,13) at the other end of the web panel (8,9), said second flange panel (12,13) having a first portion (14,15) and a second portion (16,17), the first portion (14,15) projecting outwardly of the web panel (8,9) on the same side as the first flange panel (10,1 1 ), said first portion (14,15) having two overlapping layers, and the second portion (16,17) projecting outwardly of the web panel (8,9) at the opposite side to the first portion (14,15) and terminating in an in-turned flap (18,19) at a free edge of the second portion (16,17) which receives the first flange panel (10,1 1 ) of the other complementary beam element (6,7).

The I-beam (1 ) as claimed in any preceding claim wherein said I-beam (1 ) formed from metal coil having a thickness in the range 0.3mm to 3mm.

9. The I-beam (1 ) as claimed in any preceding claim wherein the web (4) has at least one through-hole (30) to facilitate through-passage of services.

10. The I-beam (1 ) as claimed in any preceding claim wherein the web (4) and/or each flange (2,3) has a number of bolt mounting holes (32).

1 1 . A method for forming an I-beam (1 ), as claimed in any preceding claim, including folding metal sheet material to form the I-beam (1 ) having a pair of spaced-apart flanges (2, 3) interconnected by an intermediate web (4), overlapping at least two layers of sheet material to form each of said flanges (2, 3) and said web (4).

The method for manufacturing an I-beam (1 ) as claimed in claim 1 1 including the steps of forming a desired array of holes (30,32) in flat metal sheet material and then folding the flat metal sheet material to form the I-beam (1 ).

The method as claimed in claim 1 1 or claim 12, wherein the method includes forming a complementary pair of shaped beam elements of folded metal sheet, overlapping the pair of shaped beam elements in nesting engagement and interlocking the shaped beam elements in nesting engagement.

14. The method as claimed in claim 13, wherein the method includes interlocking the shaped beam elements by wrapping a flap at a flange edge portion of a first beam element about a flange edge portion of a second beam element.

The method as claimed in claim 13 or claim 14 wherein the method includes crimping the beam elements together.