EMBOSSED STEEL SHEETS

Abstract

An embossed piece of sheet steel including a piece of sheet steel having a first side and an opposing second side, a first plurality of indentations formed on the first side of the piece of sheet steel and a second plurality of indentations formed on the opposing second side of the piece of sheet steel. The first plurality of indentations is formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns. The indentations of the first plurality of indentations are positioned along each row at alternating intersections with the columns and each adjacent row having the indentations at alternating intersections offset by one column. The second plurality of indentations is formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns. The indentations of the second plurality of indentations are positioned along each row at alternating intersections with the columns intermediate the indentations of the first plurality of indentations and each adjacent row having the indentations offset by one column.

Description

FILED OF THE INVENTION

This invention relates to sheet steel and more specifically to strengthened sheet steel.

BACKGROUND OF THE INVENTION

Sheet steel is a product used for many construction projects where strength of material is required. The strength of sheet steel depends on the thickness of the sheet. Generally, the thicker the sheet, the stronger it is. The problem presented here is that steel can be heavy, and while a thicker sheet is stronger, it is also true that a thicker sheet is heavier. So, a balance must be struck between the strength and the weight of the sheet steel. When applied to flooring panels or structural elements such as purlins, weight must be low but strength high. To strengthen sheet steel, various techniques have been employed. These techniques include forming strengthening beads (ridges) along edges of the sheet steel to inhibit flexing in a particular direction. For example, a longitudinal bead crimped in the sheet steel inhibits bending transverse to the bead. So, while beads strengthen sheet steel, they are limited to a specific axis and a limited area. Other techniques to lighten and strengthen sheet steel include cutting holes through the sheet steel, removing material and lightening the sheet. To add strength back to the sheet, the edges of the opening are crimped or otherwise deformed to form strengthening elements around the opening. While somewhat effective at lowering the weight, and maintaining strength, removal of material does generally weaken the sheet steel and does not give additional strength. Additionally, removing material from a large area of sheet steel can be very time consuming and expensive.

It would be highly advantageous, therefore, to remedy the foregoing and other deficiencies inherent in the prior art.

An object of the present invention is to provide sheet steel which stronger than its thickness warrants.

SUMMARY OF THE INVENTION

Briefly to achieve the desired objects and advantages of the instant invention in accordance with a preferred embodiment provided is an embossed piece of sheet steel including a piece of sheet steel having a first side and an opposing second side, a first plurality of indentations formed on the first side of the piece of sheet steel and a second plurality of indentations formed on the opposing second side of the piece of sheet steel. The first plurality of indentations is formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns. The indentations of the first plurality of indentations are positioned along each row at alternating intersections with the columns and each adjacent row having the indentations at alternating intersections offset by one column. The second plurality of indentations is formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns. The indentations of the second plurality of indentations are positioned along each row at alternating intersections with the columns intermediate the indentations of the first plurality of indentations and each adjacent row having the indentations offset by one column.

Also provided is a method of forming an embossed piece of sheet steel. The method includes the steps of providing a piece of sheet steel having a first side and an opposing second side. Providing a rotating roller die having protrusions extending from a surface thereof for forming indentations in the first side of the piece of sheet steel, the protrusions of the roller die formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the protrusions of the roller die are positioned along each row at alternating intersections with the columns and each adjacent row having the protrusions at alternating intersections offset by one column. Providing a complemental roller die having protrusions extending from a surface thereof for forming indentations in the second side of the piece of sheet steel, the protrusions of the complemental roller die formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the protrusions of the complemental roller die are positioned along each row at alternating intersections with the columns intermediate the protrusions of the protrusions of the roller die and each adjacent row having the protrusions offset by one column, the roller die rotatably mounted adjacent the complemental roller die and spaced to receive the piece of sheet steel therebetween. Passing the piece of sheet steel between the rotating roller die and the complemental roller die forming indentations in the pattern of the roller die protrusions on the first side, and forming indentations in the pattern of the complemental roller die protrusions on the second side.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific objects and advantages of the invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof, taken in conjunction with the drawings in which:

FIG. 1 is a top view of a piece of sheet steel embossed according the present invention and bent into an element;

FIG. 2 is an enlarged portion of the piece of sheet steel illustrated in FIG. 1 as indicated by section A;

FIG. 3 is a top schematic view of the indentation pattern embossed in the piece of sheet steel according to the present invention;

FIG. 4 is an enlarged portion of the piece of sheet steel illustrated in FIG. 3, as indicated by section B;

FIG. 5 is a schematic illustration of embossing rollers in an embossing device; and

FIG. 6 is an illustration of the forming rollers creating the embossing pattern in the piece of sheet steel.

DETAILED DESCRIPTION

Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is directed to FIG. 1 which illustrates an element, generally designated 10, formed of embossed sheet steel. Element 10 includes a piece 12 of sheet steel having indentations 14 formed on one side and indentations 15 formed on an opposing side, as can be seen with additional reference to FIG. 2. Embossing to form indentations 14 and 15 is accomplished by cold pressing indentations 14 on one side and 15 on the opposing side of piece 12 of sheet steel, as will be described presently. Piece 12 of sheet steel can be bent into different shapes for flooring, and structural elements such as beams and purlins, forming element 10. Piece 12 can be bent into shape using conventional methods known to those skilled in the art.

Referring now to FIGS. 3, a pattern of indentations 14 embossed on one side of piece 12 of sheet steel is illustrated. The pattern of indentations 14 is in the form of a diamond patterns. Specifically, with additional reference to FIG. 4, indentations are formed along rows 20 and columns 22. An indentation 14 is formed at alternating intersections of rows columns 20 and columns 22. Indentations 15 are formed from the opposing side at the un-used intersections. As can be seen in FIG. 4, an enlarged partial view of a pattern is illustrated as an example, with rows 20a-20e and columns 22a-22e. In this example, indentations 14 are formed along row 20a at the intersection with column 22a, 22c and 22e. In other words, indentations 14 along row 20a are spaced with a column between each indentation 14. Indentations 14 are formed along row 20b, offset from 20a, at the intersection with column 22b and 22d. In other words, indentations 14 along row 20b are spaced with a column between and offset one column from adjacent row 20a. Row 20c is offset from row 20b, and matches row 20a, with indentations 14 at the intersection with column 22a, 22c and 22e. Rows 20d match row 20b, and row 20e matches row 20c and 20a. This pattern is carried out across the entire surface of piece 12 of sheet steel, illustrating one side. The opposing side of piece 12 has an identical but offset pattern. The opposing side of piece 12 has indentations 15 (shown by broken lines) formed in the intersections of rows 20 and columns 22 not having indentations 14. In other words, indentations 15 are formed along row 20a at the intersection with column 22b, and 22d. Thus, indentations 15 along row 20a are spaced with a column (having indentations 4) between each indentation 15. Indentations 15 are formed along row 20b, offset from 20a, at the intersection with column 22a, 22c and 22e. Thus, indentations 15 along row 20b are spaced with a column between and offset one column from adjacent row 20a. Row 20c is offset from row 20b, and matches row 20a, with indentations 15 at the intersection with column 22b, and 22d. Rows 20d match row 20b, and row 20e matches row 20c and 20a. Another way of describing the pattern is alternating indentations 14 and reverse indentions 15 along rows 20. It can be seen that this same alternating pattern extends along columns 22.

Referring back to FIG. 3, piece 12 of sheet steel having the embossed pattern of indentations is illustrated. Indentations 14 and 15 formed in piece 12 of sheet steel interact to create what is essentially strengthening beads in every direction. This provides strength to piece 12 in substantially every direction. Specifically, indentations form strengthening beads indicated by longitudinal lines 25, transverse lines 26, diagonal lines 27 and diagonal lines 28. These lines transect the entire piece 12 with only a few lines being indicated in FIG. 3 as examples. Each of these lines of indentations strengthens the piece of sheet steel in a transverse direction similar to a strengthening bead, but the pattern of indentations 14 and 15 results in strengthening in all directions increasing strength in tension and compression.

The formation of the pattern of indentations 14 and 15 results in a lengthening of the piece of sheet steel longitudinally (length), due to the method of forming the indentations, but also a narrowing of the width. The thickness of piece 12 is virtually increased by the depth of the embossed indentations, the thickness of piece 12 and depth of indentations 14 and 15 depending on the end use. For a specific example, using element 10 as a floor panel, a 0.012 inch-thick (30-gauge) piece 12 is embossed with indentations 14 and 15 being 0.060 inches deep. The embossed pattern of piece 12 results in piece 12 having strength characteristics of a 0.060-inch-thick (16-gauge) sheet of steel while retaining the weight of a 30-gauge sheet. As another example, such as a structural member like a purlin, piece 12 of sheet steel is a thicker 0.040 inches (19-gauge). Indentations 14 and 15 can be formed 0.060 inches deep to result in a virtual thickness of 0.100-0.110 inch-thick (12-gauge). In this example, a pound of steel is saved per linear foot when the width of the piece is 48 inches versus a true 12-gauge piece of sheet steel. That is a large savings in weight and cost of material.

Referring now to FIG. 5, an embossing device 30 is illustrated. Embossing device 30 includes a roller die 32 and a complemental roller die 34 rotatably mounted one above the other and spaced appropriately to receive piece 12 of sheet steel therebetween. With additional reference to FIG. 6, roller die 32 and complemental roller die 34 are illustrated. Roller die 32 has protrusions 36 extending from a surface 37 thereof to form indentations 14. Complemental roller die 34 has protrusions 38 offset from protrusions 36 in the pattern previously described extending from a surface 39 thereof to form indentations 15. Roller die 32 and complemental roller die 34 are rotatably mounted one above the other and spaced appropriately to receive the piece of sheet steel therebetween. Protrusions 36 and protrusions 38 are set in a pattern identical to indentations 14 and 15, respectively. As roller die 32 and complemental roller die 34 are rotated, piece 12 of sheet steel is drawn between and embossed with the described pattern of indentations 14 and 15.

Thus described is a piece of sheet steel embossed with a specific pattern of indentation on both sides to mimic a thicker piece of sheet steel for increase strength while maintaining the weight of the thinner sheet steel.

The present invention is described above with reference to illustrative embodiments. Those skilled in the art will recognize that changes and modifications may be made in the described embodiments without departing from the nature and scope of the present invention. Various changes and modifications to the embodiments herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof.

Claims

1. An embossed piece of sheet steel comprising: a piece of sheet steel having a first side and an opposing second side;a first plurality of indentations formed on the first side of the piece of sheet steel;a second plurality of indentations formed on the opposing second side of the piece of sheet steel;the first plurality of indentations formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the indentations of the first plurality of indentations are positioned along each row at alternating intersections with the columns and each adjacent row having the indentations at alternating intersections offset by one column; andthe second plurality of indentations formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the indentations of the second plurality of indentations are positioned along each row at alternating intersections with the columns intermediate the indentations of the first plurality of indentations and each adjacent row having the indentations offset by one column.

2. The embossed piece of sheet steel as claimed in claim 1 wherein the first plurality of indentations and the second plurality of indentations are round.

3. The embossed piece of sheet steel as claimed in claim 1 wherein the entire piece is embossed.

4. The embossed piece of sheet steel as claimed in claim 1 wherein the embossed piece is a floor panel.

5. The embossed piece of sheet steel as claimed in claim 1 wherein the embossed piece is a structural element.

6. An embossed piece of sheet steel comprising: a piece of sheet steel having a first side and an opposing second side;a plurality of indentations formed on the first side of the piece of sheet steel in a pattern; andthe pattern having equally spaced parallel rows and equally spaced perpendicular intersecting columns, the indentations of the plurality of indentations being positioned along each row at alternating intersections with the columns and each adjacent row having the indentations at alternating intersections offset by one column.

7. The embossed piece of sheet steel as claimed in claim 6, further comprising: a second plurality of indentations formed on the second side of the piece of sheet steel in a second pattern; andthe second pattern having equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the indentations of the second plurality of indentations are positioned along each row at alternating intersections with the columns intermediate the indentations of the plurality of indentations and each adjacent row having the indentations of the second plurality if indentations offset by one column.

8. The embossed piece of sheet steel as claimed in claim 6 wherein the entire piece is embossed.

9. The embossed piece of sheet steel as claimed in claim 6 wherein the embossed piece is a floor panel.

10. The embossed piece of sheet steel as claimed in claim 6 wherein the embossed piece is a structural element.

11. A method of forming an embossed piece of sheet steel comprising the steps of: providing a piece of sheet steel having a first side and an opposing second side,providing a rotating roller die having protrusions extending from a surface thereof for forming indentations in the first side of the piece of sheet steel, the protrusions of the roller die formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the protrusions of the roller die are positioned along each row at alternating intersections with the columns and each adjacent row having the protrusions at alternating intersections offset by one column;providing a complemental roller die having protrusions extending from a surface thereof for forming indentations in the second side of the piece of sheet steel, the protrusions of the complemental roller die formed in a pattern along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the protrusions of the complemental roller die are positioned along each row at alternating intersections with the columns intermediate the protrusions of the protrusions of the roller die and each adjacent row having the protrusions offset by one column;mounting the roller die rotatably adjacent the complemental roller die and spaced to receive the piece of sheet steel therebetween; andpassing the piece of sheet steel between the rotating roller die and the complemental roller die forming indentations in the pattern of the roller die protrusions on the first side, and forming indentations in the pattern of the complemental roller die protrusions on the second side.

12. The method as claimed in claim 11 wherein the step of forming indentations in the pattern of the roller die protrusions on the first side includes the indentations formed along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the indentations are positioned along each row at alternating intersections with the columns and each adjacent row having the indentations at alternating intersections offset by one column.

13. The method as claimed in claim 12 wherein the step of forming indentations in the pattern of the complemental roller die protrusions on the second side includes the indentations formed along equally spaced parallel rows and equally spaced perpendicular intersecting columns, wherein the indentations are positioned along each row at alternating intersections with the columns intermediate the indentations formed by the protrusions of the roller die, and each adjacent row having the indentations offset by one column.