A sheet metal

Abstract

A sheet metal (10) with a first and a second set of diagonal arrays (30a, 30b) is disclosed The diagonal arrays (30a, 30b) are such that they are oriented non-parallelly with a principal axis (X) and overlap with each other. The points of overlap in some embodiments comprise point of discontinuity (a). These diagonal arrays have an angle (Y) ranging between 60° to 100° between them and have rounded or sharp or V-shaped edges. A construction (100) is formed from the sheet metal comprising first and a second set of diagonal arrays (30a, 30b) wherein the diagonal arrays (30a, 30b) stiffens the material utilized in forming the construction element – it thereby helps reduce the flange bending.

Description

[0001] A SHEET METAL

[0002] Technical Field

[0003] The present disclosure relates, in general to a sheet metal, and specifically to sheet metal comprising two sets of diagonal arrays, and more specifically to sheet metal comprising two sets of diagonal arrays having a series of deformations, that find application as drywall stud or ceiling channel or floor channel.

[0004] Background

[0005] In the building industry, it is widely prevalent to make walls from plasterboard and suspended ceilings from ceiling tiles. But then for the plasterboards and the ceiling tiles to rest over, there is always a requirement of a framing structure - which is provided by studs and channels. The studs and channels are generally formed from sheet metal which provides dimensional stability, and ease of manufacturing, among other advantages. Usage of thin metal sheet for the formation of studs and channels is very common in recent times, with two prime objectives being material reduction and cost effectiveness. But there are several drawbacks from using thin sheet metals, including reduced strength and stiffness and higher sound transmission.

[0006] Thus, stiffness improvement has been a prime focus to further build on the advantages of using thin sheet metals for stud and channel manufacturing. Corrugated metal sheets are known to be an effective way of reducing material gauge while enhancing the performance of the product. The other associated advantages of corrugated pattern are higher screw retention, higher strength and stiffness due to the increased effective thickness of the sheet metal as well as improved load resistance. Corrugation is attained by intermeshing corrugated rollers that preferably have an involute toothing or have a similar toothing -this method of manufacturing is known as cold rolling. The advantages of corrugated metal sheets can be optimized through the design of the pattern, the positioning as well as dimensional features of the corrugation. For example, in the prior art US 2009 / 0038255A1, there is a presence of continuous longitudinal corrugation in the webs which helps in improved screw retention as well as helps in sound insulation. Nevertheless, due to the presence of corrugation only in a part of the sheet metal, the same would involve manufacturing complexity as well as lower stability as compared to any sheet metal having all- over corrugation.

[0007] Further, the fact that the corrugation is longitudinal results in a tendency of screw slippage along the longitudinal pattern of corrugation, thus making installation more difficult and potential reducing performance.

[0008] It is observed that angular pattern of corrugation, as in the prior art US20200087913A1 has improved screw retention, strength and also withstands quality issues such as waviness, twisting and bending. However, the angular pattern of corrugation, meeting at the center of the web is susceptible to cracks. Additionally, there is a possibility of screw slippage during the self-drilling process due to angular pattern of corrugation.

[0009] Thus, there has been a need for an improved angular pattern of corrugation which would not only be easy to manufacture, but also would have crack resistance, higher screw retention capacity as well as improved stiffness.

[0010] There is still need in the art to develop a corrugation pattern for sheet metal - which would thereafter be formed into studs or channels, having ease of manufacturability, higher stiffness, improved screw retention and gripping capacity, reduced flange bending and improved load resistance.

[0011] Hence, the objective of the present disclosure is to provide a sheet metal having diagonal arrays having angularities in the pattern. This pattern improves screw retention and twist resistance. Further, the diagonal pattern of arrays as in the present disclosure is capable of enhanced mechanical performance and provides ease of installation. Summary of the Disclosure

[0012] In one aspect of the present disclosure, a sheet metal is disclosed. The sheet metal comprises a first set of diagonal arrays of deformations and a second set of diagonal arrays of deformations, where each array comprises at least one deformation oriented along a straight line and where each deformation is a portion of the sheet metal which is raised or depressed compared to the main plane of the metal. The first and second set of diagonal arrays are oriented non-parallelly to a principal axis of the sheet metal and overlap with each other. In the overlapping region where an array from the first set of diagonal arrays overlaps with an array from the second set of diagonal arrays both arrays extend on both sides of the overlap. There is a first pre-defined spacing between each neighbouring array in the first set of diagonal arrays and a second pre-defined spacing between each neighbouring array in the second set of diagonal arrays. In some embodiments the first pre-defined spacing and the second pre-defined spacing are different. Preferably the first pre-defined spacing and the second pre-defined spacing are equal.

[0013] In another aspect of the present disclosure, a construction element formed with the sheet metal is disclosed. The construction element comprises a web member and at least one flange member, the at least one flange member is positioned at an angle ranging from 90° to 130° with the web member. The at least one web member or the at least one flange member comprises the first set of diagonal arrays and the second set of diagonal arrays.

[0014] In yet another aspect of the present disclosure a drywall partition having a framing assembly is disclosed. The framing assembly comprises: a floor channel fixed to the floor; a ceiling channel substantially parallel to and spaced from the floor channel and fixed to the ceiling; a plurality of construction elements spaced horizontally and mounted to the floor channel member at its bottom end and to the ceiling channel at its top end; and at least one construction panel. The construction element abuts and support the surface of the construction panel at positions outside the diagonal arrays in the first set and second set. Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

[0015] Brief Description of the Drawings

[0016] Embodiments are illustrated by way of example and are not limited to those shown in the accompanying figures.

[0017] FIG. 1A illustrates a top view of a sheet metal, according to one embodiment of the present disclosure;

[0018] FIG. IB illustrates a top view of a sheet metal, according to one other embodiment of the present disclosure;

[0019] FIG. 2A illustrates a perspective view of a construction element, according to an embodiment of the present disclosure;

[0020] FIG. 2B illustrates a perspective view of a construction element, according to another embodiment of the present disclosure;

[0021] FIG. 2C illustrates a perspective view of a construction element, according to yet another embodiment of the present disclosure;

[0022] FIG. 3 illustrates an apparatus for forming a sheet material, according to one embodiment of the present disclosure;

[0023] FIG. 4A and FIG. 4B illustrate the top view of the first and second roller of the apparatus for forming a metal sheet, according to one embodiment of the present disclosure;

[0024] FIG. 5 illustrates a perspective view of a dry wall partition framing assembly in accordance with one embodiment of the present disclosure.

[0025] 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.

[0026] 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.

[0027] Detailed Description

[0028] 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.

[0029] 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.

[0030] 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.

[0031] As used throughout, “hemming” is a forming operation in which the edges of the metal sheet are folded in order to improve the stiffness.

[0032] FIG. 1A and FIG. IB illustrate top view of a sheet metal (10), in accordance with one embodiment of the present disclosure. The sheet metal (10) comprises a first set of diagonal arrays (30a) and a second set of diagonal arrays (30b). The first and second sets of diagonal arrays (30a, 30b) are such that they are oriented non-parallelly with a principal axis (X) of the sheet metal (10) and overlap with each other, so that in the overlapping region where an array from the first set of diagonal arrays (30a) overlaps with an array from the second set of diagonal arrays (30b) both array extends on both sides of the overlap. Each array in the first set of diagonal arrays (30a) overlaps with each array of the second set of diagonal arrays (30b) and at each overlapping region(s) only one array from the first set of diagonal arrays (30a) and only one arrays from the second set of diagonal arrays (30b) overlap. Each array in the first and second sets of diagonal arrays (30a, 30b) is comprised of at least one deformation oriented along a straight line. The deformations of the first and second sets of diagonal arrays (30a, 30b) may be continuous, therefore each array comprises a single deformation oriented along a straight line, as illustrated in the said embodiment shown in Fig. 1A. In alternate embodiments of the present invention, the deformations of the first and second sets of diagonal arrays (30a, 30b) may be discontinuous, therefore each array comprises multiple deformations oriented along a straight line, as shown in FIG. IB.

[0033] In the present embodiments shown in Fig. 1 A and FIG. IB, the first set of diagonal arrays (30a) and the second set of diagonal arrays (30b) run across all portions of the sheet metal. In some other embodiments, there are specified portions of the sheet metal through which the first and second set of diagonal arrays (30a, 30b) would run and further portions through which the first and second set of diagonal arrays (30a, 30b) would not run.

[0034] In some embodiments, as depicted in FIG. IB, the first set of diagonal arrays (30a) and the second set of diagonal arrays (30b) comprise a plurality of points of discontinuity (a) in the regions of overlap. An angle of intersection (Y) between each of the diagonal arrays in the first set and second set (30a, 30b) ranges between 60° to 100°. Further, each diagonal arrays in the first set of diagonal arrays (30a) and the second set of diagonal arrays (30b) are separated by a flat metal portion.

[0035] In all embodiments of the present invention and the two specific embodiments shown in Fig. 1A and FIG. IB, the first and second set of diagonal arrays (30a, 30b) overlap with each other to form a rhombic structure. According to multiple embodiments of the present invention, the rhombic structure formed by the first and second sets of diagonal arrays can be a closed structure (closed completely by the deformations of the first and second arrays) as shown in FIG. 1 A or can be an open structure (not closed completely by the deformations of the first and second array) as shown in FIG. IB. According to additional, optional embodiments as shown in FIG. 1A, the flat metal portion therebetween the rhombic structure further comprises one or more embossed portions (40). The embossed portion (40) is preferably circular in shape however can be designed to have any other compatible shape without limitation. An enlarged view of the portion A marked in Fig. 1 A illustrates more vividly the two sets of diagonal arrays 30a, 30b and the embossed portion 40 therebetween the rhombic structures formed by the overlapping of the two sets of diagonal arrays 30a, 30b, the overlap extending on both sides of the diagonal arrays 30a and 30b.

[0036] The first and second sets of diagonal arrays (30a, 30b) as taught by the present invention results in improved mechanical performance for example, improved self-stiffness of the sheet metal. The added circular embossed portions (40) further increase the overall sheet metal surface area and thus adds up to the strengthening of the sheet metal (10). Further, the presence of circular embossed portions (40) reduces the sagging tendency of the construction element made from the sheet metal (10). Additionally, in some other embodiments of the present invention, the sheet metal (10) further comprises cuboid stampings which further increases the sheet metal stiffness. Such cuboid stampings are done on the portions of the sheet metal bearing the first set and second set of diagonal arrays (30a, 30b). While in some other embodiments, the cuboid stampings are done on portions of the sheet metal not bearing the first set and second set of diagonal arrays (30a, 30b). In other embodiments the stampings can be in any other compatible shapes. The overall pattern results in upgrading the aesthetics of a sheet metal (10) as well.

[0037] There is a first pre-defined spacing between each neighbouring array in the first set of diagonal arrays (30a) and a second pre-defined spacing between each neighbouring array in the second set of diagonal arrays (30b). In some embodiments the first pre-defined spacing and the second pre-defined spacing are different. Preferably the first pre-defined spacing and the second pre-defined spacing are equal. In an example embodiment, the first pre-defined spacing and the second pre-defined spacing are equal and said pre-defined spacing ranges between 8 mm and 25 mm. The spacing is such that it ensures that the first and second set of diagonal arrays cover a surface area of 50% to 75% of the sheet metal area. In some other embodiment, the first and second set of diagonal arrays covers 25% to An effective thickness of the sheet metal (10) is twice the thickness of the sheet metal (10). This increased effective thickness results in higher sound insulation properties and thus overall acoustic performance is enhanced. The usual thickness of the sheet metal (10) ranges from 0.3 to 2 mm. Further, the thicker pattern edges near the stress concentration regions results in a marked improvement in stress concentration in the concerned regions.

[0038] FIG. 2A, illustrates a perspective view of a construction element (100) according to an embodiment of the present disclosure. The construction element (100) comprises a web member (10) and a pair of flange members (20) wherein the first set of diagonal arrays (30a) and the second set of diagonal arrays (30b) extend over the entire surface of the web and the pair of flanges. The flange members (120) are positioned at an angle of 90° to 130° relative to the web member (110). According to some embodiments of the present invention, the pair of flange members (120) raise from the points of discontinuity (a) of the first set of diagonal arrays (30a) and the set of diagonal arrays (30b), not shown in figures. However, in alternative embodiments, the pair of flange members (120) arise from points away from the points of discontinuity (a) of the first set of diagonal arrays (30a) and the set of diagonal arrays (30b).

[0039] The flange members (20) are made to raise from the point of discontinuity (a) or at points away from the point of discontinuity (a) so as to stiffen the flange members and reduce bending of the flange members (20) relative to the web member (10). In one embodiment as depicted in FIG. 2A, the first and second set of diagonal arrays (30a, 30b) are present in the web member (110) as well as the pair of flange members (120). The first and second set of diagonal arrays (30a, 30b) increases the overall surface area and have the same impact as that of conventional rib structures offering strength at the joining area between the flange members (20) and the web member (10).

[0040] In some other embodiment as in FIG. 2B, the first and second set of diagonal arrays (30a, 30b) are present only in the web member (10), while in yet other embodiment as in FIG. 2C, the plurality of first and second set of diagonal arrays (30a, 30b) are present only in the flange members (20). Embodiments showed in FIG. 2B and FIG. 2C illustrate first and second set of diagonal arrays 30a, 30b that are continuous without points of discontinuity (a). According to additional embodiments of the present invention, the web member (10) has cuboid stampings (50) as illustrated in FIG. 2C. The overall pattern results in upgrading the aesthetics of a sheet metal (10) as well.

[0041] In the embodiment as in FIG. 2A, the first and second flange member (120) terminate with inwardly pointing return edge (130) comprising first and second set of diagonal arrays (30a, 30b) - resulting in a construction element having a C-shape. Whereas in some other embodiment, the inwardly pointing return edge (130) is without the diagonal arrays taught by the present invention. In the embodiment as in FIG. 2B and FIG. 2C, the first and second flange member (120) terminate with outwardly pointing return edge (130) comprising first and second set of diagonal arrays (30a, 30b). Whereas in some other embodiment, the outwardly pointing return edge (130) is without the diagonal arrays taught by the present invention. The embodiment pertaining to construction elements devoid of return edge results in a U-shaped construction element. The inward or outward return edges (130) are hemmed in the present embodiments which avoid injury during installation and also add strength to return edges (130) against twisting during handling and transportation. But, in some other embodiment, the return edges (130) can be without hemming as well.

[0042] Further, in any of the embodiments as depicted in FIGs. 2A to 2C, there can be a flat portion which is devoid of arrays and is used to emboss a trademark, a name of a product or other information related to the construction element (not shown in the figures). Additionally, the construction element (100) in some embodiments comprise lateral or longitudinal ribs (140, 150) in the web (110) and / or flanges (120) which further improves the strength of the construction element (as in FIG. 2A and 2C). In some other embodiments, a plurality of equidistant conventional gussets are present at the region of intersection of the pair of flanges (120) with the web (110) - which provides additional strength to the construction element (100) (not in FIG.). The construction elements (100) are made from metal which in some embodiments is steel or iron or aluminum - depending on the requirement. Further, this construction element (100) so formed can be used both drywall stud as well as floor or ceiling channel.

[0043] The present invention further discloses an apparatus comprising a pair of rollers 610 and 620 for making the sheet metal (10) illustrated in FIG. 1A or Fig. IB FIG. 3 illustrates the apparatus (600) according to one embodiment of the present invention. The apparatus 600 comprises a first roller 610 and a second roller 620 that mate with each other contra rotating about their respective axes. The first roller 610 comprises a plurality of projections 60 on its surface, while the second roller 620 comprises a plurality of depressions 70 on its surface aligned with the projections 60 on the surface of the first roller 610. FIG. 4A illustrates the top view of the first roller 610 having the plurality of projections 60 and FIG. 4B illustrates the top view of the second roller 620 having the plurality of depressions 70. The projections 60 on the surface of the first roller 610 form the first and second diagonal arrays 30a, 30b and the depressions 70 on the surface of the second roller 620 allows for the projected sheet metal 10 to slowly transition into the diagonal arrays.

[0044] The plurality of projections 60 on the surface of the first roller 610 press into the sheet metal 10 to form the diagonal arrays on the surface of the sheet metal 10. The plurality of depressions 70 on the surface of the second roller 620 aligned with the plurality of projections 60 on the surface of the first roller 610 allow for the diagonal arrays formed by the first roller 610 not to be flattened out by the second roller 620.

[0045] According to multiple embodiments of the present invention, the projections 60 on the first roller 610 and the depressions 70 on the second roller 620 can be discontinuous with points of discontinuity (a) therebetween the series of raised and rebated portions oriented along a straight line spaced apart and overlapping with each other (not shown in figures). According to few other embodiments of the present invention, the projections 60 on the first roller 610 and the depressions 70 on the second roller 620 can be continuous with no points of discontinuity (a) therebetween the series of raised and rebated portions oriented along a straight line spaced apart and overlapping with each other (shown in figures).

[0046] The number, size and spacing of the projections 60 is selected to provide the desired reinforcement to the sheet material from which the stud or track will be formed. The distribution of the projections 60 are designed to provide the diagonal arrays 30a, 30b as taught by the present invention. The pair of rollers 610 and 620 stretch the sheet material angularly and effectively increases (doubles) the thickness of the sheet material.

[0047] FIG. 5 of the present disclosure illustrates a perspective view of a drywall partition framing assembly (1000) in accordance with one embodiment of the present disclosure. The partition framing assembly comprises: a floor channel, a ceiling channel (not shown in the Fig.) substantially parallel to and spaced from the floor channel, a plurality of construction element (100) and at least one construction panel (200). The floor channel is fixed to a floor, ceiling channel is fixed to a ceiling, the construction element (100) is spaced vertically and mounted to the floor channel member at its bottom end and to the ceiling channel at its top end. Further, the floor channel and the ceiling channel are made from the construction element (100) and the construction element (100) abut and support the surface of the construction panel (200) at positions outside the diagonal arrays of in the first set and second set (30a, 30b).

[0048] The construction panel (200) can be attached to one or both sides of the partition framing assembly (1000). Any suitable fastening mechanisms, for example, screws, adhesives etc. may be used to accomplish the coupling between the studs and the partition boards, as applicable. Further, a suitable jointing method may be used to attach the partition boards to each other.

[0049] The construction panel (200) are generally gypsum boards. The construction panel (200) 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 panel (200) may include any other materials such as, but not limited to, MDF, plywood, glass, metal sheet, cement, fiber cement, plastic sheet or a combination thereof.

[0050] The construction panel (200) may also include a subsequently placed one or more layers of insulation elements (not shown). The insulation element may include a foam material or other materials to provide any of acoustic properties, strength or other properties to the drywall partition system. Alternatively, the drywall partition system may be configured without the insulation element.

[0051] Various parameters related to the construction elements, such as, the number of the construction elements to be used in a partition framing assembly, the width of the construction element, vertical length of the construction element, crosssection of the construction element, spacing of the construction element may suitably vary based on the type of application. For example, the parameters related to the construction elements may depend on the size of the partition board required for the application, strength of the partition board etc.

[0052] Comparative Example

[0053] Simulations of deflection under lateral load condition were compared for a conventional construction element and the construction elements described above. In the simulation, a load of 50 N was applied on one side of one of the flanges of the conventional construction element and the construction element describes in the present invention. The results are shown in Table 1. The results show that the construction element of the present disclosure has lower flange bending value and hence is stronger than the conventional construction element available in the marketplace.

[0054] Table 1 : Flange bending during deflection Industrial Applicability

[0055] Thus, the usage of the sheet metal according to the present disclosure for the construction elements like studs or ceiling channel or floor channel results in improved screw retention property of the construction elements. In addition, the sheet metal according to the present disclosure possesses the following advantages: Improved load resistance of the construction elements formed from the sheet metals,

[0056] - Pattern of diagonal arrays stiffens the construction element and thereby reduces flange bending,

[0057] Improved sound insulation due to the increased effective thickness and reduced contact between the boards and the construction element- thus resulting in improved acoustic comfort,

[0058] - Reduced material gauge and therefore lower carbon impact while keeping or even enhancing the performance of the product,

[0059] The pattern of diagonal arrays facilitate smooth flow of material which allows only negligible surface coating damage, resulting in more corrosion resistance performance.

[0060] Having thus described the disclosure with 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. Such changes and modifications include combinations of compatible features from different embodiments of the present disclosure. 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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).

[0066] 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.

[0067] 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.

[0068] 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. List of Elements

[0069] TITLE: A SHEET METAL

[0070] 10: Sheet Metal

[0071] 30a: First Set of Diagonal Arrays

[0072] 30b: Second Set of Diagonal Arrays

[0073] 40: Embossed portion

[0074] 50: Cuboid Stamping

[0075] 100: Construction element

[0076] 110: Web

[0077] 120: First and Second Flange Members

[0078] 130: Return Edge

[0079] 140: Lateral Rib

[0080] 150: Longitudinal Rib

[0081] 200: Construction Panel

[0082] 1000: Partition Framing Assembly a: Point of Discontinuity

[0083] X: Principal Axis

[0084] Y: Angle of Intersection

[0085] 600: Apparatus

[0086] 610: First Roller

[0087] 620: Second Roller

[0088] 60: Projections

[0089] 70: Depressions

Claims

Claims1. A sheet metal (10) comprising: a first set of diagonal arrays (30a) and a second set of diagonal arrays (30b), oriented non-parallelly with a principal axis (X) and overlapping with each other, wherein each array comprises at least one deformation oriented along a straight line, and in the overlapping region where an array from the first set of diagonal arrays (30a) overlaps with an array from the second set of diagonal arrays (30b) both arrays extend on both sides of the overlap, characterised in that each deformation of the first and second sets of diagonal arrays (30a, 30b) is a portion of the sheet metal that is raised or depressed from the main plain of the sheet metal.

2. The sheet metal (10) as claimed in Claim 1, wherein, the first set of diagonal arrays (30a) and the second set of diagonal arrays (30b) comprise a plurality of points of discontinuity (a) in the regions of overlap.

3. The sheet metal (10) as claimed in Claim 1 , wherein, the first set of diagonal arrays (30a) and the second set of diagonal arrays (30b) comprise no points of discontinuity (a) in the regions of overlap.

4. The sheet metal (10) as claimed in Claim 1, wherein each diagonal arrays in the first set of diagonal arrays (30a) and the second set of diagonal arrays (30b) are separated by a flat metal portion.

5. The sheet metal (10) as claimed in Claim 1, wherein, the first set of diagonal arrays (30a) and second set of diagonal arrays (30b) cover a surface area of 50% to 75% of the sheet metal.

6. The sheet metal (10) as claimed in Claim 1, wherein the first and second sets of diagonal arrays (30a, 30b) overlap at an angle of intersection (Y) ranging between 60° to 100°.

7. The sheet metal (10) as claimed in Claim 1, wherein a thickness t of the sheet metal (10) ranges from 0.3mm - 2 mm.

8. The sheet (10) metal as claimed in Claim 7, wherein an effective thickness f of the sheet metal (10) is twice the thickness t of the sheet metal (10).

9. The sheet metal (10) as claimed in Claim 1, is made from material selected from steel or iron or aluminium.

10. A construction element (100) formed from the sheet metal (10) as claimed in Claim 1, comprising: a web member (110) and at least one flange member (120), the flange member (120) positioned at an angle ranging from 90° to 130° with the web member (110), at least one web member (110) or flange member (120) comprising the first and second set of diagonal arrays (30a, 30b) .

11. The construction element (100) as claimed in claim 10 is a drywall stud or a ceiling channel or a floor channel or ceiling angle.

12. A drywall partition framing assembly (1000) comprising: a floor channel fixed to a floor; a ceiling channel substantially parallel to and spaced from the floor channel and fixed to a ceiling;a plurality of construction element (100) as claimed in claim 11 spaced vertically and mounted to the floor channel member at its bottom end and to the ceiling channel at its top end; and at least one construction panel (200), characterized in that: the construction element (100) abut and support the surface of the construction panel at positions outside the arrays of angular array in the first set and second set (30a, 30b).

13. An apparatus 600 for forming the sheet metal as claimed in claim 1, the apparatus comprising: a first roller 610 comprising a plurality of projections on its surface; and a second roller 620 comprising a plurality of depressions on its surface, wherein the plurality of depressions is aligned with the plurality of projections on the surface of the first roller 610, characterised in that the plurality of projections on the first roller 610 comprise a first series of raised portions oriented along a straight line spaced apart and overlapping with a second series of raised portions oriented along a straight line; and the plurality of depressions on the second roller 620 comprise a first series of rebated portions oriented along a straight line spaced apart and overlapping with a second series of rebated portions oriented along a straight line.

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