BOX BEAM AND METHOD OF MANUFACTURING

Abstract

A box beam is provided. In embodiments, the box beam includes a first side portion; a second side portion opposite the first side portion; a top portion; a bottom portion opposite the top portion; and at least one stiffener positioned along a length of the box beam.

Description

BACKGROUND

Aspects of the present invention relate generally to a box beam and, more particularly, to a box beam and method of manufacturing within the American Society for Testing and Materials (ASTM®©) standards or better.

SUMMARY

In a first embodiment, a box beam includes a first side portion; a second side portion opposite the first side portion; a top portion; a bottom portion opposite the top portion; and at least one stiffener positioned along a length of the box beam.

In a second embodiment, a box beam includes a first side portion; a second side portion opposite the first side portion; a top portion; a bottom portion opposite the top portion; at least one stiffener positioned along a length of the box beam; and at least one end cap stiffener.

In a third embodiment, a method of fabricating a box beam includes cutting sheet metal to a predetermined size for a box beam; forming a ridge along a midway portion of a length of the sheet metal; turning up opposite ends of the sheet metal at right angles along the length of the sheet metal; turning up first and second top portions adjacent to the opposite ends, respectively, at about right angles; turning up first and second side portions adjacent to the first and second top potions, respectively, at about right angles; and forming at least one stiffener within the box beam.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present invention are described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention.

FIG. 1 depicts a cross section of a box beam according to a first embodiment of the invention.

FIG. 2 depicts a cross section of a box beam according to a second embodiment of the invention.

FIG. 3 is an end view of a piece of sheet metal cut to width prior to fabrication into a box beam according to embodiments of the invention.

FIG. 4 is an end view of the piece of sheet metal of FIG. 3 with a ridge formed along the length of the sheet metal according to embodiments of the invention.

FIG. 5 is an end view of the piece of sheet metal of FIG. 4 showing the ends turned up at about right angles to the sheet metal according to embodiments of the invention.

FIG. 6 is an end view of the piece of sheet metal of FIG. 5 showing the first and second loop portions turned up at about right angles to the sheet metal according to embodiments of the invention.

FIG. 7 is an end view of the sheet metal of FIG. 6 showing the first and second side portions turned up at about right angles to the sheet metal and spaced apart abut the bottom portion of the box beam according to embodiments of the invention.

FIG. 8 illustrates an embodiment of the box beam of the present invention according to embodiments of the invention.

DETAILED DESCRIPTION

Aspects of the present invention relate generally to a box beam and, more particularly, to a box beam and method of manufacturing. Embodiments of the invention relate to the box beam comprising a universal light steel beam for structures having points of contact, positioning, and load bearing conditions. The added stiffener in the box beam increases structural stability along the side portions of the box beam. In further embodiments, deformation on the side portions in the box beam is reduced in all bearing and or concentrated load paths with aside portion stiffener or stiffeners attached.

In further aspects of the present invention, the added stiffener of the box beam is made of various forms, shapes, and thickness. In embodiments, the added stiffener is attached within or on outer side portions in a strategic arrangement for improved strength in or on the box beam side portion. Accordingly, the box beam stiffener limits deformation and meets structural engineering requirements. In further embodiments, the box beam include portions which are attached by a variety of methods including screws, welds, press, rivets, welding, fastening, etc.

In embodiments of the present invention, the attached stiffener to the box beam is applied in various builds where a concentrated load takes place to prevent buckling and deformation in side portions of the box beam. Accordingly, the box beam of the present invention protects connecting areas from unwanted movement, preventing fasteners being loosened in vertical gravity, typical and or load transfer connection portions in a horizontal box beam, a vertical post, a post column, and/or diagonal vector connections

In aspects of the present invention, the box beam with stiffeners improves shearing, seismic, vector and lateral forces, etc., and maximizes connections in advance framing techniques in a structural design. In embodiments, the box beam includes the structural design in one of a perpendicular, longitudinal, single and horizontal arrangements to provide an advanced load path and limit critical local buckling stress. In aspects of the present invention, the box beam may limit and control axis and/or unwanted movement to connected areas.

In embodiments, the box beam of the present invention can accommodate insulation to lower energy requirements for heating and cooling. Accordingly, the box beam of the present invention improves a carbon footprint in comparison to conventional beams. Further, the box beam of the present invention also includes less material than conventional built up beams. In further aspects of the present invention, the box beam may be comprised of a one piece of galvanized cold rolled steel to form a box like structure with ribs and bends to enhance strength.

FIGS. 1 and 2 depict an exemplary box beam 10 having a continuous outer surface 5 defined by first and second side portions 16, 24, a bottom portion 18, and first and second top portions 14, 26 that are substantially coplanar and spaced apart by a seam 38 (see FIGS. 7 and 8). In embodiments, a ridge 20 is provided along a length 22 of the box beam 10 in the bottom portion 18 generally midway between the side portions 16, 24. First and second seam allowance ends 12, 28 (see FIG. 6) are provided depending from the top portions 14, 26, respectively. In further aspects of the present invention, the box beam 10 is fabricated of sheet metal 34. In other embodiments, the box beam 10 is fabricated of cold rolled sheet steel. In further aspects of the present invention, the sheet metal 34 is galvanized.

In FIGS. 1 and 2, the box beam 10 includes at least one stiffener 13 in various arrangements. As shown in FIG. 1, the at least one stiffener 13 may comprise two stiffeners which are arranged in a side by side configuration in a front portion 15 of the length 22 of the box beam 10. In further embodiments, the front portion 15 of FIG. 1 may also include an end cap stiffener (not shown). The at least one stiffener 13 comprising two stiffeners in the front portion 15 create a heavier load condition on a load path. In addition, the at least one stiffener 13 may comprise two stiffeners which are arranged in a back to back configuration in a middle portion 17 of the length 22 of the box beam 10. The at least one stiffener 13 comprising two stiffeners in the middle portion 17 may be subject to a span table and calculation on an overall length of the box beam 10. The at least one stiffener 13 comprising two stiffeners in the middle portion 17 may create a heavier loading on the load path. The at least one stiffener 13 may also comprise a single stiffener in an end portion 19 which is typically aligned within the length 22 of the box beam 10. In further aspects of the present invention, the single stiffener faces an end of the box beam 10. Accordingly, in FIG. 1, the configuration of the box beam 10 provides a bearing and concentrated load path, gravity load path, and load transfer path which improves deformation on the side portions 16, 24 of the box beam 10.

In further embodiments, the box beam 10 in FIG. 2 includes the at least one stiffener 13 may comprise a first single stiffener in a front portion 21 of the length 22 of the box beam 10. In further aspects of the present invention, the box beam in FIG. 2 also include an end cap stiffener 11 (e.g., extra layer 11) which is attached to a back portion of the first single stiffener in the front portion 21 of the length 22 of the box beam 10. However, embodiments are not limited and the end cap stiffener 11 (e.g., extra layer 11) may not be needed in the present invention. In embodiments, an L-shaped bracket can also be attached to the end cap stiffener 11. In further aspects of the present invention, the first single stiffener in the front portion 21 faces an end of the box beam 10. In embodiments, the at least one stiffener 13 may comprise two stiffeners which are arranged in a side by side configuration in a first middle portion 23 of the length 22 of the box beam 10. In embodiments, the at least one stiffener 13 comprising two stiffeners in the first middle portion 23 may create a wider widening deformation control within vertical load paths to a side portion of the beam 10. In further embodiments, the at least one stiffener 13 may comprise a second single stiffener in a second middle portion 25 of the length 22 of the box beam 10. The second single stiffener in the second middle portion 25 faces a first second side portion 16 of the box beam 10. In aspects of the present invention, the at least one stiffener 13 may comprise a third single stiffener in an end portion 27 of the length 22 of the box beam 10. The third single stiffener in the end potion 27 faces a second side portion 24 of the box beam 10. Accordingly, in FIG. 2, the configuration of the box beam 10 provides a bearing and concentrated load path, gravity load path, and load transfer path which improves deformation on the side portions 16, 24 of the box beam 10.

In further aspects of the present invention, the box beam 10 can be arranged as a horizontal box beam connected to a side beam. In embodiments, the horizontal box beam is connected to the side beam using an L-shaped bracket which connects the horizontal box beam to the cap 11 of the side beam. In this configuration, the box beam 10 has continuous load paths with other framing members combined which provides a rigid connection for seismic, lateral, and/or other forces. In further embodiments, the box beam 10 can be arranged as a diagonal box beam connected to the side beam to provide the rigid connection. In this embodiment, the diagonal box beam is connected to the side beam using the L-shaped bracket which connects the diagonal box beam to the cap 11 of the side beam.

In aspects of the present invention, in FIGS. 1, 2, and 6, the allowance ends 12, 28 and the side portions 16, 24 each depend from opposite edges 7, 9 of the top portions 14, 26, respectively, in substantially a common direction and at about right angles to the top portions 14, 26. The side portions 16, 24 extend between the top portions 14, 26, respectively, and the bottom portion 18. The side portions 16, 24 are connected to the bottom portion 18 at about right angles thereon, and respectively, at opposite ends 6, 8 thereof. The bottom portion 18 is generally parallel with the top portions 14, 26. The ridge 20 provided in the bottom portion 18 and is raised generally toward the top portions 14, 26. Further, in embodiments, the bottom portion 18 is sized to accept a side portion stiffener inside the box beam 10.

In further embodiments, in FIGS. 1, 2, and 6, the outer surface 5 of the box beam 10 is substantially continuous. The first allowance end 12 abuts the second allowance end 28 to define a seam 38. In embodiments, the first allowance end 12 and the second allowance end 28 are spaced apart at a distance up to ½ inch. The first top portion 14 extends from the first allowance end 12 at about a right angle. The first side portion 16 extends at about a right angle from the first top portion 14 on the edge 7 of the first top portion 14 opposite the edge 9 connected to the first allowance end 12. The bottom portion 18 extends at about a right angle from the first side portion 16 on the edge of the first side portion 16 opposite the first top portion 14. The ridge 20 is formed in the bottom portion 18 along the length 22 of the box beam 10 approximately midway about the width 30 of the box beam 10 at the bottom portion 18. In embodiments, the width 30 represents a desired wall thickness of the frame structure. The second side portion 24 extends at about a right angle from the bottom portion 18 on the end 8 of the bottom portion 18 opposite the first side portion 16. The second top portion 26 extends at about a right angle from the second side portion 24 on the edge of the second side portion 24 opposite the bottom portion 18. The second allowance end 28 extends at about a right angle from the second top portion 26 on the edge 9 of the second top portion 26 opposite the edge 7 connected to the second side portion 24.

In aspects of the present invention, the length 22, the width 30, and the height 32 are dimensions of the box beam 10 and may be cut to size prior to fabrication of the box beam 10. In embodiments, the length 22 may be cut to its final lengths. In further embodiments, the width 30 and the height 32 may have not cuts, but accepted design punch outs, and may have a pre calculated carrying capacity for a desired span. In embodiments, the box beam 10 is fabricated at the site of its intended use once the required dimensions 22, 30, and 32 are determined. In further embodiments, the height 32 and the width 30 of the box beam 10 are set by the position of the bends 48 formed by a break press or roll formed in the sheet metal 34 for fabricating the box beam 10. In embodiments, the height 32 represents a desired span calculation with a desired gauge thickness for a final length to provide improved strength. For example, the heavier the gauge and the taller the side portions, the box beam 10 has an improved pounds per foot and or span of the beam to carry and determined by span table calculations. A break press or roll press may be powered by electrical, hydraulic, or pneumatic means. In yet other embodiments, the box beam 10 is fabricated away from the site of the intended use and is transported to the site as described. In other embodiments, the box beam 10 is fabricated on the site if feasible.

In embodiments, during fabrication of the box beam 10 in FIGS. 5-8, the bends 48 are formed in the sheet metal 34 by turning up one portion of the box beam 10 relative to another until the angle between them is about a right angle (90 degrees). In other embodiments, the internal radius of each bend 48 are formed in about 1.5 times the thickness 36 of the sheet metal 36.

In further embodiments, the sheet metal 34 is of a standard thickness 34 having a selected gauge. In further aspects of the present invention, the gauge thickness of the sheet metal 34 is from about 10-gauge to about 20-gauge. Gauge thickness may be selected according to the structure requirements for the box beam 10 manufactured according to the embodiments of the present invention. In other embodiments, the yield strength of the sheet metal 34 is from about 30-kilo-pound per square inch (e.g., 30 KSI) to about 50 KSI to improve structure requirements for the box beam 10. In FIG. 8, the bottom ridge and the upper return flange will be up to one inch (e.g., 1″) from a top to a bottom for a stiffener to fit within. The box beam 10 can also be manufactured according to certain yield strengths (i.e. working load limits) in kilo-pound per square inch (e.g., ksi). For example, materials of the box beam is typically a big and heavy roll of precise strength in ksi with a galvanized or coated protectant. In further embodiments, the box beam 10 can be manufactured using any method of manufacturing, press break, roll former, beading machine, any method to bend forms, etc.

Conventional box beams are fabricated in widths of between about 2 inches and about 6 inches, according to standard wall thicknesses. Conventional box beams are also fabricated in heights of 6 inches, 8 inches, 10 inches, 12 inches, 14 inches, and 16 inches, according to preference and structural purpose. Conventional box beams are additionally fabricated in lengths from several inches to several feet, according to preference and structural placement of the box beam 10. The embodiments of the box beam 10 of the present invention may conform to conventional determinations of dimensions of width, height, and length. Regardless of dimensions 22, 30, and 32, the steps for fabricating embodiments of the box beam 10 disclosed herein remain generally the same.

A method for fabricating the box beam 10 from sheet metal is shown in FIGS. 3-7. Referring first to FIG. 3, a piece of sheet metal 34 is selected having gauge thickness desired and is cut to size according to the dimensions 22, 30, 32 required. In embodiments, cutting the sheet metal 34 is performed using a shear or other conventional cutting tool.

In embodiments of FIG. 4, the ridge 20 is formed along the length 22 of the sheet metal 34 generally midway about the width 30 thereof. The ridge 20 is raised from the sheet metal 34 at a distance from about ¼ inch to about 1 inch. The ridge configuration of the ridge 20 may be determined in accordance with strength requirements for the box beam 10 and tooling and equipment available. In further embodiments, the ridge 20 is formed by clamping the sheet metal 34 between a suitable male die or roll former positioned on one side 33 of the sheet metal 34 and a corresponding female die or roll former positioned on the opposite side 35 of the sheet metal 34. In other embodiments, the ridge 20 has a wide configuration.

In further embodiments of FIG. 5, the first and second allowance ends 12, 28 are formed by turning up the opposite ends 37, 39 of the sheet metal 34 at about right angles thereto along the length 22 thereof. The opposite ends 37, 39 are turned up generally equidistantly. In aspects of the present invention, the allowance ends 12, 28 are formed and turned up not more than about 1 inch. In FIG. 6, first and second top portions 14, 26 measure a distance equal to or less than about ½ the width 30 desired for the box beam 10.

In aspects of the present invention, in FIG. 7, the first and second side portions 16, 24 are formed by turning up portions of the sheet metal 34 adjacent to the formed top portions 14, 26, respectively, at about right angles from the sheet metal 34. In further embodiments, the turned up portions for the side portions 16, 24 are spaced apart along the sheet metal 34 about the width 30 desired for the box beam 10. In embodiments, the sheet metal 34 extending between the side portions 16, 24 comprises the bottom portion 18 of the box beam 10. In yet other embodiments, the ridge 20 is generally centered between the side portions 16, 24 on the bottom portion 18.

In aspects of the present invention, it is within the scope of the disclosure to combine any of these steps or to insulate portions of a step to accommodate available equipment or otherwise incorporate efficiency techniques to the overall fabrication of an embodiment of a box beam 10 according to the present invention, including modifications to these steps to fabricate the alternative embodiments.

The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.

Claims

1. A box beam comprising:

a first side portion;

a second side portion opposite the first side portion;

a top portion;

a bottom portion opposite the top portion; and

at least one stiffener positioned along a length of the box beam.

2. The box beam of claim 1, wherein a material of the box beam comprises sheet metal.

3. The box beam of claim 2, wherein the sheet metal comprises steel.

4. The box beam of claim 3, wherein the steel comprises galvanized steel.

5. The box beam of claim 3, wherein the steel comprises cold rolled steel.

6. The box beam of claim 1, further comprising an end cap stiffener.

7. The box beam of claim 1, wherein the ridge is formed within the bottom portion.

8. The box beam of claim 7, wherein the ridge is raised from the bottom portion and towards the top portion.

9. The box beam of claim 1, wherein the at least one stiffener comprises two stiffeners configured in a side by side configuration.

10. The box beam of claim 1, wherein the at least one stiffener comprises two stiffeners configured in a back to back configuration.

11. The box beam of claim 1, wherein the at least one stiffener comprises a single stiffener in a front portion of the length of the box beam.

12. The box beam of claim 11, wherein the single stiffener faces an end of the box beam.

13. The box beam of claim 1, wherein the at least one stiffener comprises a single stiffener in an end potion of the length of the box beam.

14. The box beam of claim 13, wherein the single stiffener faces an end of the box beam.

15. The box beam of claim 1, wherein the at least one stiffener comprises a single stiffener facing a side portion of the box beam.

16. A box beam comprising:

a first side portion;

a second side portion opposite the first side portion;

a top portion;

a bottom portion opposite the top portion;

at least one stiffener positioned along a length of the box beam; and

at least one end cap stiffener.

17. The box beam of claim 16, wherein the at least one stiffener comprises a single stiffener in a front portion of the length of the box beam and connected to the at least one end cap stiffener.

18. The box beam of claim 16, wherein the at least one stiffener comprises two stiffeners configured in a side by side configuration.

19. The box beam of claim 16, wherein the at least one stiffener comprises a single stiffener facing a side portion of the box beam.

20. A method of fabricating a box beam, comprising:

cutting sheet metal to a predetermined size for a box beam;

forming a ridge along a midway portion of a length of the sheet metal;

turning up opposite ends of the sheet metal at right angles along the length of the sheet metal;

turning up first and second top portions adjacent to the opposite ends, respectively, at about right angles;

turning up first and second side portions adjacent to the first and second top potions, respectively, at about right angles; and

forming at least one stiffener within the box beam.