Patent Application
20200087913
The present disclosure relates, in general to a construction element, and more specifically to a corrugated construction element for drywall and ceiling construction/gypsum ceiling.
Drywall and gypsum ceilings generally make use of cold rolled metal sections that are made of plain metal sheet or knurled metal sheet (having dimples on it). These metal sections are formed by bending sheet material into desired shapes and typically comprise of an elongate base and a pair of side legs that extend on either side of the base in a perpendicular fashion. These metal sections are used as both vertical studs and horizontal channels or track. These channels and studs may be assembled into a frame and also secured to a corresponding floor, ceiling and the like. The frame may be covered with construction boards on one or both sides to form the wall or a ceiling. The plain or knurled metal sheet may be coated with a protective layer to reduce corrosion and other undesirable effects.
There are several advantages to using knurled metal sheets, compared to plain metal sheets. In order to increase the screw retention, a section may be formed from a metal sheet which is fully knurled or partially knurled. If the metal sheet is partially knurled, the positioning of the knurling can be selected so that the finished section contains knurling at the point where screws will be fixed.
In order to make sections with thin metal and therefore keep weight low, it is desirable to use thin metal. The thickness of sheet metal used to form drywall and gypsum ceiling sections is typically 0.4 mm to 1 mm, although other thicknesses may also be used. However, thin metal can result in metal sections with waviness in their shape. The waviness is overcome by providing certain reinforcing features/forms along the length of the section.
Knurled sheets are created by feeding the metal sheets between two mating rollers to create a dimpled surface. This process stretches the material in both directions (along the length and along the width). This causes cracks in any protective coating on the metal sheet and this can lead to corrosion over a period of time.
While the sections made from plain metal sheet suffer from quality issues such as waviness, twists, bending, less screw retention and stiffness, the knurled sections are prone to cracks and break due to the knurling process itself and have less perceived strength as compared to other sections and also suffer from quality issues due to excessive stretching of the metal. Therefore sections which overcome these disadvantages are required.
Metal profiles having longitudinal beads are known. The longitudinal beads are introduced on the base and/or the side legs connected to the base to reduce carrier-to-noise transmission (as shown in EP1124023) or for improving screw retention (as shown in PCT application 2010/008296). In U.S. publication number 2009/0038255 and 2009/0126315 beads extend in the longitudinal direction of the C-shaped profile and form support surfaces for planking.
These longitudinal beads discussed in the prior art references are provided locally on the base or side legs to improve the quality of the profiles like straightness, twist etc. However these locally provided beads do not increase the moment of inertia that contributes to the strength and stability of the profiles.
Thus it may be desirable to develop a construction element that overcomes the above mentioned quality issues and provides a crack/break resistant profile with improved screw retention, strength and one that withstands quality issues such as waviness, twisting and bending.
The present disclosure relates to a corrugated construction element provided with an array of angular corrugations extending across its surface in a non-parallel direction to the principal axis L of the corrugated construction element. The array of angular corrugations reduces deflection of the corrugated construction element under load conditions and improves screw retention and twist resistance.
In one aspect of the present disclosure, a corrugated construction element for drywall and gypsum ceiling is disclosed. The corrugated construction element has a base profile connected to at least one leg profile and comprises an array of angular corrugations that extend across its surface in a non-parallel direction to the principal axis L of the corrugated construction element. The array of angular corrugations covers a surface area of at least 25% and less than or equal to 100% of the total surface area of the corrugated construction element.
In another aspect of the present disclosure, an apparatus for forming a sheet material into a profile having an array of angular corrugations extending across at least 25% of the surface of the profile is disclosed. The array of angular corrugations is comprised of at least a first set of angular corrugations and a second set of angular corrugations. The apparatus comprises a first roller having a first corrugation region for forming one part of a first set of angular corrugations (D1) and a second corrugation region for forming one part of a second set of angular corrugations (D2). The apparatus further comprises a second roller having a third corrugation region for forming the other part of the first set of angular corrugations (D1) and a fourth corrugation region for forming the other part of the second set of angular corrugations (D2). The angle between the first set of angular corrugations D1 and second set of angular corrugations D2 ranges between 30-150 degrees.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
Embodiments are illustrated by way of example and are not limited to those shown in the accompanying figures.
Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts. Embodiments disclosed herein are related to a corrugated construction element.
The first set of angular corrugation D1 and second set of angular corrugations D2 run angularly (at an angle Y from the principal axis of the corrugated profile L) from the edges of the corrugated profile 770 towards its center. Each angular corrugation from the first set of angular corrugations D1 meets with a corresponding angular corrugation from the second set of angular corrugations D2 to form an angle X between them. The angle X is measured in the plane of the corrugated profile 770. In one embodiment of the disclosure, the angle X between the first set of angular corrugations D1 and the second set of angular corrugations D2 ranges from 30° to 150°.
In one specific embodiment of the disclosure, the angle X between the first set of angular corrugations D1 and the second set of angular corrugations D2 is 90°. In one other embodiment, the angle X between the first set of angular corrugations D1 and the second set of angular corrugations D2 is 45°. The angle X between the first set of angular corrugations D1 and the second set of angular corrugations D2 may be varied between 30° and 150° depending on the desired strength and stiffness required for the wall or ceiling construction.
In one embodiment of the present disclosure, the first set of angular corrugations D1 and second set of angular corrugations D2 cover a surface area greater than 25% and less than or equal to 100% of the total surface area of the corrugated profile 770. In one other embodiment, the first set of angular corrugations D1 and second set of angular corrugations D2 cover a surface area greater than 50% and less than or equal to 75% of the total surface area of the corrugated profile 770.
The base profile 101 and the first leg profile 102a comprise an array of angular corrugations 110. The array of angular corrugations 110 comprises V-shaped grooves 120. The array of angular corrugations 110 extends across the surface of the corrugated construction element 100 in a non-parallel direction to the principal axis L of the corrugated construction element 100. In one embodiment of the disclosure, the array of angular corrugations 110 covers a surface area greater than 25% and less than or equal to 100% of the total surface area of the corrugated construction element 100. In one other embodiment of the disclosure, the array of angular corrugations 110 covers a surface area greater than 50% and less than or equal to 75% of the total surface area of the corrugated wall construction element 100. In yet another embodiment of the present disclosure, the array of angular corrugations 110 is continuous throughout the surface area of the corrugated construction element 100.
The array of angular corrugations 110 is V-shaped with the bottom of the V-shaped being pointed as shown in
In the embodiment shown in
The array of angular corrugations 110 extending on the first leg profile 102a has an angle Y from the principle axis L of the corrugated construction element 100. In one embodiment of the disclosure, the angle Y between the principle axis L of the corrugated construction element 100 and the angular corrugations 110 on the first leg profile 102a ranges from 15° to 75°. In one specific embodiment, the angle Y between the principle axis L of the corrugated construction element 100 and the angular corrugations 110 on the first leg profile 102a is 45°. This exemplary corrugated construction element 100 shown in
In one embodiment of the present disclosure, the angle X lies in the base profile 101 and the angle Y lies in the first leg profile 102a. In such a case the base profile 101 is provided with a first set of angular corrugations D1 and a second set of angular corrugations D2, while the first leg profile 102a is provided with only the second set of angular corrugations D2 (as shown in
Angles X and Y may be adjusted in order to obtain desired stiffness and strength. Although the present disclosure in specific embodiments teaches one or more examples of angles X and Y, alternations to angles X and Y within the claimed ranges should be understood to be encompassed within the scope of the present disclosure.
Referring to
In the corrugation construction element 100 depicted in this figure, the angle X lies in the base profile 101 and angle Y lies in the first leg profile 102a and second leg profile 102b. The base profile 101 comprises both the first set of angular corrugations D1 and second set of angular corrugations D2. The first leg profile 102a is provided with only the first set of angular corrugations D1 and the second leg profile 102b is provided with only the second set of angular corrugations D2. In one other alternative embodiment, sets of angular corrugations may meet along the base profile 101 and also along the leg profiles 102a, 102b. In such an embodiment, the corrugated construction element 100 comprises three pairs of sets of angular corrugations (D1 and D2; D1′ and D2′; D1″, and D2″). In such an embodiment, D1 and D2 meet at angle X, D1′ and D2′ meet at angle X′ and D1″ and D2″ meet at angle X″.
Illustrated in
The array of angular corrugations 110 provided on the corrugated construction element 100 has a pitch P—this is the distance between two consecutive peaks 140 or troughs 150 of the V-shaped grooves 120. In multiple embodiments of the present disclosure, the pitch P ranges between 2 mm and 6 mm. The array of angular corrugations 110 provided on the corrugated construction element 100 has a height H. In multiple embodiments of the present disclosure, the height ‘H’ ranges between 0.1 mm and 1 mm.
In various embodiments of the present disclosure, the array of angular corrugations 110 may be provided only on the base profile 101 or only on the first leg profile 102a or only on the second leg profile 102b or combinations thereof. The exemplary corrugated construction element 100 depicted in
The exemplary corrugated construction element 100 depicted in
Illustrated in
Illustrated in
In one embodiment, as depicted in
The disclosure also relates to a wall construction comprising a frame assembly configured from a plurality of corrugated construction elements 100. The wall may be a drywall. Illustrated in
The floor channel 520 and ceiling channel 530 are spaced apart from each other. A plurality of corrugated construction elements 100 are configured to be disposed in each of the floor channel 520 and ceiling channel 530. One end of each of the corrugated construction element 100 is disposed in the floor channel 520 and a second end opposite to the first end of each of the corrugated construction element 100 is disposed in the ceiling channel 530. The corrugated construction elements 100 are spaced apart from each other in the frame 510. In one embodiment of the present disclosure, the corrugated construction elements 100 are equidistantly spaced from each other.
Various parameters related to the corrugated construction elements 100, such as, the number of the corrugated construction element 100 in the frame 510, the width of the corrugated construction element 100, height ‘G’ of the first and second leg profiles 102a, 102b of the corrugated construction element 100, vertical length of the corrugated construction element 100, cross-section of the corrugated construction element 100, spacing of the corrugated construction element 100 may suitably vary based on the type of application. For example, the parameters related to the corrugated construction elements 100 may depend on the size of the wall 500 required for the application, strength of the wall 500 etc.
The wall 500 may include construction boards 550 coupled to the frame 510. In one example, the construction board 550 may be a gypsum board. In an embodiment, the construction board 550 may be attached to the frame 510 on one or more sides thereof. In a preferred embodiment, the construction board 500 may be attached to the corrugated construction elements 100 of the frame 510. Any suitable fastening mechanisms, for example, screws, adhesives etc. may be used to accomplish the coupling between the frame 510 and the construction boards 550, as applicable. Further, a suitable jointing method may be used to attach the construction boards 550 to each other.
In an example, the construction board 550 may be reinforced and may include a polymeric binder and a plurality of fibres. The plurality of fibres may include glass fibres, synthetic polymer fibres or natural fibres, either separately or in combination. Further, the polymeric binder may include any of starch, synthetic material etc. In various other embodiments, the construction board 550 may include any other material such as, but not limited to, MDF, plywood, glass, metal sheet, cement, fiber cement, plastic sheet or a combination thereof.
The construction wall 500 may also include one or more insulation elements (not shown). In one embodiment, the insulation element is disposed between the frame 510 and the construction board 550. In other embodiments, the insulation element is disposed at other locations in the wall 500 based on the specific type of application. In various examples, the insulation element may include a foam material or other materials to provide any of acoustic properties, strength or other properties to the wall 500. Alternatively, the wall 500 may be configured without an insulation element.
The array of angular corrugations 110 increases the screw retention properties of the corrugated construction elements 100 for screwing the construction boards 550 to the frame 510. In some embodiments the angle Y of the angular corrugations 110 on the first and second leg profiles 102a, 102b of the floor channel 520 and ceiling channel 530 correspond to that on the vertically disposed corrugated construction elements 100 and hence help in interlocking the corrugated construction elements 100 between the floor channel 520 and the ceiling channel 530. This interlocking may help to secure the vertical element within the channel without the need for crimping, screwing or other techniques used to prevent the vertical element from moving within the channel. In the illustrated embodiment of
In one embodiment of the present disclosure, the corrugated construction elements 100 are fastened to the base profile 101 of the floor channel 520. In an example, mechanical fasteners such as, bolts, screws and the like may be used to fasten the corrugated construction elements 100 to the floor channel 520.
The present disclosure also relates to an apparatus for forming a sheet material into a corrugated profile comprising an array of angular corrugations 110. The corrugated construction element 100 of the present disclosure is formed from a flat sheet material 700. The flat sheet material 700 is typically passed through a series of consecutive pair of rollers to form a corrugated profile on the sheet material. In one embodiment of the present disclosure, the array of angular corrugations 110 extends over at least 25% of the surface area of the profile.
Illustrated in
The second roller 620 comprises a third corrugation region 630b and a fourth corrugation region 640b. The third corrugation region 630b forms the other part of the first set of angular corrugations D1 and the fourth corrugation region 640b forms one part of the second set of angular corrugations D2. The first corrugation region 630a and third corrugation region 630b are co-operable and comprise V-shaped grooves 120 that correspond with each other. Similarly, the second corrugation region 640a and fourth corrugation region 640b are co-operable and comprise V-shaped grooves 120 that correspond with each other.
In an alternate embodiment, the first roller 610 and second roller 620 may have multiple sets of first, second, third and fourth corrugation regions (630a, 630b, 640a and 640b). For example a first roller and a second roller comprising three sets of first, second, third and fourth corrugation regions viz., 630a1, 630b1, 640a1 and 640b1; 630a2, 630b2, 640a2 and 640b2; and 630a3, 630b3, 640a3 and 640b3 would produce a corrugated profile 770 with three pairs of sets of angular corrugations (D1 and D2, D1′ and D2′, D1″ and D2″). When bent into shape, such a corrugated profile would have three pairs of sets of angular corrugations such that one pair (D1 and D2) is on the base profile with angle X between them, one pair (D1′ and D2′) is on the first leg profile with angle X′ between them and one pair (D1″ and D2″) is on the second leg profile with angle X″ between them. Angles X, X′ and X″ could be the same or different from each other.
Passage of the flat sheet material 700 through the successive pairs of rollers causes the angular corrugations on the base profile 101, first leg profile 102a, second leg profile 102b and flange profiles 160 (160a, 160b), 170 (170a, 170b). The pair of rollers 610 and 620 stretch the sheet material angularly and effectively increases (doubles) the thickness of the sheet material. The height ‘H’ and pitch P of the array of angular corrugations created on the sheet material depends on the initial thickness of the sheet material.
For example, a flat sheet material 700 having a thickness of 0.5 mm when passed through the mating rollers 610, 620 will form a corrugated profile 770 having a thickness of lmm Such a corrugated profile 770 will have a pitch P of 3.5 mm. Similarly, a flat sheet material 700 having a thickness of 0.9 mm when passed through the mating roller 610, 620 will form a corrugated profile 770 having a thickness of 1.8 mm Such a corrugated profile 770 will have a pitch P of 4.5 mm Examples
To demonstrate reduced deflection of the corrugated construction element 100 of the present disclosure, comparative studies were carried out as described below.
All comparative examples described below present the results of simulations of three different construction elements:
The simulated construction element with linear corrugations comprises corrugations extending over the entire surface of the construction element. The linear corrugations are parallel to the principle axis of the construction element (e.g. parallel to the longest dimension of the construction element) and have a pitch of 3.5 mm and a depth of 0.5 mm.
The simulated construction element with square indentations comprises small square indentations covering the entire surface of the construction element. The small square indentations were created having a pitch of 3.3 mm, a diameter of 1.5 mm and a depth of 0.5 mm. An illustration of a portion of the surface of such a construction element with square indentations is shown in
The simulated corrugated construction element 100 in accordance with the present disclosure comprises angular corrugations over the entire surface of the construction element. The angle between the corrugations and the principle axis of the construction element was 45°. The corrugations have a pitch of 3.5 mm and a depth of 0.5 mm.
Each simulated construction element is 300 mm long. Unless specified, all other parameters (e.g. dimensions and geometry) were the same for each simulated construction element.
Simulations of deflection under lateral load condition were compared for the three construction elements described above. In the simulation, a load of 0.5 kg was applied on both the leg profiles (as shown in
Simulations of deflection under longitudinal load condition (as shown in
The results are shown in Table 2. The results showed that the corrugated construction element 100 of the present disclosure was stronger than the sections having square indentations but not as strong as construction elements having linear corrugations for ceiling constructions.
Deflection of the 1200 mm corrugated construction element 100 of the present disclosure due to self-weight, as shown in
The above results show that though construction elements with linear corrugations are stronger to longitudinal deflection and deflection due to self-weight, the corrugated construction element 100 of the present disclosure is strongest when subjected to lateral deflection that may cause the leg profiles 102a, 102b to collapse while the construction board is being screwed to the frame and may lead to instability of the construction.
A construction element comprising square indentations and a corrugated construction element 100 of the present disclosure were placed vertically on an UTM machine and were applied with different loads. The maximum load at which the construction elements axially buckled was recorded. The results are shown in Table 4. The corrugated construction element 100 of the present disclosure axially buckled at a load of 9.20 kN which was much higher compared to the construction element with square Indentations.
Three-point bending test was performed for the construction element comprising square indentations and a corrugated construction element 100 of the present disclosure by screwing together the base profiles of a pair of each of the construction elements using metal screws. A load of 1 kN was applied on the construction element comprising square indentations and a deflection of 16 mm was observed. Then the corrugated construction element 100 of the present disclosure was applied with load until a 16 mm deflection was detected. It was found that a 16 mm deflection appeared on the corrugated construction element 100 at a load of 1.2 kN. This showed the corrugated construction element 100 of the present disclosure to have 20% increased load bearing capacity.
The shear strength of the corrugated construction element 100 of the present disclosure was measured and compared with the shear strength of the construction element comprising square indentations. The corrugated construction element 100 was found to withstand a load of 2.11 kN while the construction element comprising square indentations was found to take up a load of only 2.05 kN. Hence the improved shear strength of the corrugated construction element 100 of the present disclosure was illustrated.
With the implementation of the corrugated construction elements 100 of the present disclosure, quality issues associated with construction elements such as flange deflection, deflection due to self-weight, twisting and bending may be avoided. Further, using of these corrugated construction elements also increase the screw retention property and load bearing capacity of the construction elements. The array of the angular corrugations 110 provide for interlocking of vertically disposed corrugated construction elements 100 between the floor channel 520 and ceiling channel 530.
The invention also relates to a method of forming a corrugated profile 770 comprising an array of angular corrugations 110 extending across at least 25% of the surface of the sheet material 700. The method involves passing the flat sheet material 700 between the first roller 610 and second roller 620. The sheet material 700 is pressed against the V-grooves 120 present on the corrugation regions (630a, 630b, 640a, 640b) of the first roller 610 and second roller 620.
Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.
Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Certain features, that are for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in a sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.
The description in combination with the figures is provided to assist in understanding the teachings disclosed herein, is provided to assist in describing the teachings, and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, the use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.
While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
Title: A Corrugated Construction Element
| Number | Date | Country | Kind |
|---|---|---|---|
| 201741018271 | May 2017 | IN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IN2018/050205 | 4/10/2018 | WO | 00 |
