Augmented I-Beam Level with Box-Side Reinforcement
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Solution Overview
Problem
Conventional level and straight edge tools in the building trades lack a balance between strength, rigidity, and weight, with I beam styles being too flimsy and box styles being too heavy and costly, while requiring improved durability and accuracy to withstand adverse conditions.
Innovation Solution
Designing I beam style level and straight edge tools with augmented strength by incorporating a closed or box-shaped side that adds rigidity, potentially made from lightweight materials like aluminum or magnesium, and using extrusion processes or varying geometrical shapes such as triangles or 'g' cross-sections to enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If I beam style level is made from lightweight materials in thin sections, then weight is reduced and cost is lowered, but strength and rigidity are insufficient causing the tool to be bent or twisted under impact or torque
Solution Approach 1:
The level tool combines aluminum extrusion with a plastic insert/molded portion to create a composite structure. The aluminum provides lightweight strength while the plastic insert adds rigidity and protects against twisting under impact, resolving the contradiction between lightweight construction and structural strength.
Solution Approach 2:
The plastic insert is strategically positioned at the center of the I beam structure where it provides maximum rigidity support. This localized reinforcement addresses the specific weakness of the thin-walled aluminum sections without adding weight throughout the entire tool.
2Strength
If box style level is used, then strength and rigidity are improved, but weight and manufacturing cost increase
Solution Approach 1:
The level tool is divided into two functional segments: an aluminum extrusion providing the basic lightweight structure and a plastic insert providing targeted reinforcement. This segmentation allows the tool to achieve box-level strength in critical areas while maintaining the weight advantages of thin-walled construction elsewhere.
Solution Approach 2:
By combining aluminum and plastic materials in a composite construction, the tool achieves the strength characteristics of a box level while maintaining the weight benefits of an I beam design, effectively resolving the weight-strength tradeoff.
Data Source
AI summary
The present invention is directed generally to tools that are lightweight, high quality, durable, rigid and strong. For example, various tools used to level items and/or as a straight edge for aligning or drawing lines on items may be designed in an improved or augmented beam style so that they are lightweight, strong, durable and rigid so as to hold their shape under stress or return to their original shape after being stressed. In various exemplary embodiments, the beam style level and/or straight edge may have a first main elongated side to which two elongated perpendicular sides are connected or coupled. At least one or more higher strength elongated sides, for example a second elongate side, may be comprised of a closed or generally rectangular shaped. For example, the second elongated side may be, for example, a generally rectangular shaped construction with at least one curved side.