Patent Application
20240384532
The present disclosure relates to a lightweight construction element, in particular, to a lightweight construction element having a plurality of a web members spaced at a predetermined distance from each other. More specifically, the present disclosure relates to a lightweight construction element having two flange members spaced apart and coupled together with the plurality of web members.
Conventional construction element and framing members have been widely used as a part of a drywall system wherein the partition boards are connected to the conventional construction element. A plurality of the conventional construction element are placed at a predetermined spacing such that the partition boards can be installed and affixed to the conventional construction element from one or both sides. Typically, a conventional construction element is comprised of a central region which is the web with a minimum of two flanges rising from either side of the web. Typically, the conventional construction elements are formed from one piece of metal and weigh about 1.4 kg to 1.6 kg per meter for a height of around 3.2 meter to 3.6 meter. It is significant to note that the manufacture of every single conventional construction element involves a huge quantity of metal consumption.
Over the years, there have been various developments in the configuration and structure of the conventional construction element leading to its design improvements. These design improvements include various attempts at structural modifications of the conventional construction element structure, targeted towards varied functionalities including but not limited to sound insulation and thermal insulation, among others. There have also been attempts at design improvements for reduction of metal consumption in the past. However, past changes in design and technology in this space have not resulted in substantially less metal usage over that of a conventional construction element.
For example, in the prior art KR20130036982A, there is a structural modification made to the web of the stud such that the web is bent in a W-shaped format which thereby delays the noise and vibration transmission path. Further, some of the embodiments of this prior art, disclose a plurality of slots in the web for blocking a sound and vibration transmission path. However, the structural modification doesn't result in a substantial reduction in metal consumption or metal usage.
In yet another prior art WO2020125916A1, there has been a structural modification done in the web of the conventional construction element, which is a stud, aiming at the thermal decoupling of two limbs (or flanges). The webs in the prior art are in the form of plates which are fastened to a portion of the limbs. The structural modification so formed also results in reduced sound propagation. Still, there is no substantial reduction in metal usage of the stud and also the mode of connection of the web with the limbs could potentially result in disconnection of the joint during twisting and bending and thus resulting in the failure of the stud. In addition, it would be complex to manufacture and assemble the construction elements described in WO2020125916A1.
In the recent times, design improvements have also been targeted towards reduction in the weight of the stud, whereby skilled artisans explore means to reduce raw material consumption as a means of reducing the carbon footprint. It is well known that, for construction and framing elements, each step of the manufacturing process (metal casting, metal forming, metal machining, metal joining, finishing and the related) involves a huge amount of CO2 emission.
Hence, there have been attempts in the prior art to reduce the weight of the conventional construction element. However, the prior art design modifications have certain drawbacks which include complexity in manufacturing and handling, additional manufacturing operation requirement, weakening of the construction element such that it is incapable of resisting forces such as bending moments or even punching of metal parts which thereafter leads to metal wastage.
For example, as in the prior art WO2017015766A1, a conventional web in a stud is replaced by a wire matrix which in turn also provides passages for utility lines. Though the prior art results in reduction of the overall weight of the construction element, the arrangement of the web adds complexity and demands a technical expertise for installation, thus increasing the cost.
Further, the prior art KR101637145B1 describes a structural modification of the construction element, which is a stud, resulting in a lightweight stud. However, the complex arrangement makes the whole stud cumbersome to manufacture.
Thus, the known prior art references may result in reduction of metal usage and weight reduction of the construction element, but the solutions add complexity and difficulties to the manufacture of the products leading to increased manufacture and sale cost. Further, increased manufacturing complexity is likely to involve increased CO2 emission, which will offset any CO2 savings due to reduction in overall metal amount. Furthermore, there is no evidence in the prior art that the proposed lightweight construction elements do indeed result in decrement of CO2 emission.
Thus, there is still need in the art to develop a construction element addressing the shortcomings of the prior art mentioned above. In particular, there is a need in the art to develop a lightweight construction element that results in reduced CO2 emission in the process of its manufacture and is simple and economical to manufacture.
Thus the present disclosure provides a lightweight construction element which eliminates the requirement of any additional manufacturing complexity, reduces the metal consumption and metal wastage and thereby results in a significant reduction in CO2 emission. Most importantly, the present disclosure results in a lightweight construction element which has 30-40% lower weight as compared to any conventional construction element.
In one aspect of the present disclosure, a lightweight construction element is disclosed comprising a first and a second flange member and a plurality of web members. Each flange members have a front surface facing each other and a back surface non-facing each other. The first flange member and the second flange member are aligned alongside each other such that they are spaced at a distance X measured between the closest points on each flange member. Each of the plurality of web members has a plate portion with a length, width, a first edge region, a second edge region, a third edge region and a fourth edge region. The arrangement is such that the first edge region and the second edge region lies across the width of the plate portion, the third edge region and the fourth edge region lies across the length of the plate portion and the width of the plate portion defines the spacing between the first flange member and the second flange member. Further, the web members are physically coupled to the first and second flange members by attaching to either the front surface or the back surface of each flange member and the web members are bent such that plate portion lies at an angle ranging between 90 to 110 degrees with the first flange member and the second flange member.
In yet another aspect of the present disclosure, a method of making a lightweight construction element is disclosed. The method involves the steps of placing the first and second flange members alongside each other spaced at a distance X measured between the closest points on each flange member; placing a plurality of web members spaced at a predetermined distance either on the front surface or the back surface of the flange members with their first and second edge regions on the first and second flange members; and coupling the plurality of web members to the flange members along a predetermined attachment line.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
The present disclosure can be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. Embodiments are illustrated by way of example and are not limited in the accompanying figures.
The use of the same reference symbols in different drawings indicates similar or identical items.
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 disclosure.
Features and advantages of the present disclosure will become more apparent in light of the following detailed description of embodiment, as illustrated in the accompanying figures. As will be realized, the disclosure is capable of modifications in various respects, all without departing from the present disclosure. Accordingly, the drawings and the description are to be regarded as illustrative in nature, and not restrictive.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts. Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.
As used throughout, a “U-shaped” construction element is defined as a construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by a web.
As used throughout, a “C-shaped” construction element is defined as a construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly at their base by a web, with the pair of flanges having return edges pointing inwards substantially parallel to the web.
As used throughout, an “I-shaped” construction element is defined as a construction element comprising a pair of flanges substantially parallel to each other and connected substantially perpendicularly by a web, preferably positioned central to the pair of flanges.
As used throughout, substantially parallel indicates parallel with +/−10 degrees and substantially perpendicular indicates perpendicular with +/−10 degrees.
As used throughout, “hemming” is a forming operation in which the edges of the sheet are folded in order to improve the stiffness.
Thus, aiming at the reduction of the metal usage and reduction in the weight of the construction element, the present disclosure proposes structural and configurational modifications to the conventional construction element in order to provide a ‘lightweight construction element’ which enables reduced raw material usage and lower CO2 emission.
The present disclosure relates to a lightweight construction element. A lightweight construction element 100a (as depicted in
It is to be noted here, the closest points for measuring distance X there between the flange members 10, 20 lie at their respective edges or at their respective centers or at respective points lying between their edges and their centers. Further, as depicted in the Figures, the flange members 10, 20 of the embodiments of the present disclosure comprise a lip 55 as rising from the flange and directed in the inward direction towards the center of the web member 50. The angle of the lips 55 in the flange members 10, 20 can range from an angle of 15° to 90°. In any other optional embodiment, the lightweight construction element is devoid of the lip. Additionally, in other optional embodiments, as depicted in
The preferred dimensions of the lightweight construction element 100a or 100b are as follows: The length of the plate portion 51 of web members 50 ranges from 20 mm to 200 mm and the width ranges from 10 mm to 150 mm. The length of the first and second flanges ranges from 3.2 meter to 3.6 meter. Further, the spacing between the web members 50 ranges from 50 mm to 300 mm. It is to be noted, in some of the optional embodiments, the length and the width of the plate portion 51 are identical.
It is to be noted that the length of the web members 50 are not equal to the length of the flange members 10, 20. They are spaced at a predetermined interval such that together the plurality of web members 50 cover a small fraction of length with respect to the flange member 10 or 20. This design modification and configuration results in reduction of the weight of the lightweight framing component 100a or 100b and enables ease of installation due to the reduced weight. Further, it is to be noted the coupling process involves mere placing of the web members 50 along the flange members 10, 20 and coupling the same. The lightweight construction element of the present invention is equally efficient with respect to structural performance of deflection as compared to any conventional construction element. Moreover, as already mentioned, reduction in metal usage in turn results in reduction of CO2 emission by the reduced consumption of fuel required to melt and mold the metal sheet. Hence, this is a step towards sustainability and sustainable living without compromising on the quality.
In all embodiments, the lightweight construction element 100a or 100b comprises one or more materials from the list of metal, plastic, polymer, cardboard, wood, or other suitable material. The metal may be steel. The components of the lightweight framing element 100 can be manufactured as a whole or in parts taking into consideration the requirements and usages. The lightweight framing element 100 may be a drywall stud to which plasterboard is fixed as part of a drywall partition, but alternatively the framing element 100 may be a ceiling or a floor channel.
The disclosure also depicts a method of making a lightweight construction element 100a or 100b which involves: placing of the first and second flange members 10, 20 alongside each other spaced at a distance X measured between the closest points on each flange member 10, 20. Thereafter, the plurality of web members 50 are spaced at a predetermined distance either on the front surface 13, 23 or back surface 14, 24 of the flange members 10, 20 respectively with their first and second edge regions 52a, 52b respectively on the first and second flange members 10, 20. The predetermined distance ranges from 200 to 300 mm. Further, the plurality of web members 50 are coupled to the flange members 10, 20 along a predetermined attachment line 60. The coupling is done by screwing, riveting, bolting, nailing, welding, clinching or crimping and can be done on the front surface 13, 23 or the back surface 14, 24 of the flange members 10, 20. In one embodiment, the web members 50 are planar web members 50 and require bending of the web members 50 along the attachment line 60 at an angle ranging between 90-110 degrees. This is followed by coupling. The attachment line lies along the center of the flange members 10, 20 or the edges of the flange members 10, 20 respectively lying closest to each other. In an alternative embodiment, the plurality of web members 50 are pre-formed and the first and second edge regions 52a, 52b are at an angle ranging from 90 to 110 degrees to the plate portion 51. Such an embodiment does not involve an additional step of bending of the web members 50. Such pre-formed web members 50 may be formed by 3D printing, molding or other suitable methods for forming non-planar elements.
Weight reduction and Deflection Testing:
A weight reduction and deflection testing was done for the lightweight construction element 100 of the present disclosure. A first and second flange member 10, 20 with a plurality of consecutive web members 50 physically coupled to the front surface 13, 23 of the first and second flange members 10, 20 was obtained by simulation modeling using ANSYS software. The spacing between the web member 50 was taken as 250 mm and the total length of the flanges were taken as 3200 mm. Further, for simulation purpose, three construction elements 100 were placed at an equidistant range of 600 mm and fitted into the celling channel 110 and floor channel 120 at the top and bottom, respectively. The ceiling channel 110 was fixed to the ceiling and the floor channel 120 was fixed to the floor (as illustrated in
It can be understood from the above values that the lightweight construction element 100 results in 32% weight reduction as compared to a conventional construction element. Further, the resulting deflection in the lightweight construction element 100 in spite of having a spaced plurality of web members 50, retains the structural stability as that of the conventional construction element. The increase in deflection of 2.9 mm of the lightweight construction element 100 of the present disclosure can be overcome by 3% reduction in the height of the partition board. Further, the difference in partition board height also can be matched with conventional arrangement by adding an additional screw at the bottom between the construction element and floor channel interface.
Thus the lightweight construction element 100a or 100b of the present disclosure is lightweight (in terms of eliminating the need of a continuous web) and results in reduction of CO2 emission during its manufacture. In addition, the lightweight construction element 100a or 100b herein possesses the following advantages:
The lightweight construction element 100a or 100b of the present disclosure finds application in building constructions not limiting to commercial and residential spaces. The structural modification as in the present disclosure eliminates the usage of a continuous web to connect the flanges of a drywall lightweight construction element or channel component. It provides ease of manufacture, is sustainable, easy to transport and assemble and is also cost effective. Further, no additional assembly tools or accessories are required for the assembly of the web members in the lightweight construction element as described in the present disclosure.
Having thus described the disclosure with particular reference to the preferred forms thereof, it will be obvious that various changes and modifications can be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims. Therefore, the embodiments described in the specification and the drawings shown in the drawings are only the most preferred embodiment of the present disclosure and do not represent all of the technical ideas of the present disclosure, various modifications that can be replaced at the time of the present application It should be understood that there may be equivalents and variations.
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 disclosure. 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.
51: Plate portion
100
a, 100b: Lightweight construction element
| Number | Date | Country | Kind |
|---|---|---|---|
| 202141059748 | Dec 2021 | IN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IN2022/050999 | 11/14/2022 | WO |
