Cold-Formed Steel Beam With Clinched Web and Stamped Apertures

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing structural support members, such as traditional joists and beams, face challenges in terms of weight, manufacturing efficiency, bridging requirements, installation time, and compatibility with decking systems.

Innovation Solution

A cold-formed beam is developed, formed from a single sheet of steel, featuring an upper member, a lower member, and a web with stamped apertures. The beam uses deformation connections, such as clinching, to couple the ends of the sheet without welding, allowing for pre-coating and efficient manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If traditional joists and beams are used, then structural support is provided, but weight is excessive and manufacturing efficiency is low

Engineering Contradiction:

Improvebeam weightVSAvoidmanufacturing efficiency

Core Design Contradiction:

Weight of moving objectVSProductivity

Solution Approach 1:

The beam is segmented into multiple layers formed from a single sheet of material, with apertures creating discrete structural zones. This segmentation reduces material usage and weight while maintaining structural integrity through the layered configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The beam incorporates apertures throughout its structure, creating a porous configuration that reduces weight while maintaining structural strength. The apertures are strategically positioned to preserve load-bearing capacity while minimizing material consumption.

Inventive Principle:

Principle #31Porous materials

2Reliability

If welding is used to couple sheet ends, then structural integrity is achieved, but manufacturing complexity and time increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the welding process with a deformation connection system. Layers are coupled through mechanical deformation rather than thermal welding, eliminating the need for complex welding equipment and procedures while maintaining structural integrity through interlayer deformation bonds.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The deformation connection system allows the beam structure to self-couple its layers through mechanical deformation during the forming process itself, without requiring separate welding operations. The forming process simultaneously creates both the beam shape and the interlayer connections.

Inventive Principle:

Principle #25Self-service

3Strength

If bridging is added to traditional beams, then structural strength is improved, but device complexity and installation time increase

Engineering Contradiction:

Improvebeam strengthVSAvoidbridging requirements

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The invention merges the bridging function into the beam structure itself through the aperture configuration and layered design. The apertures and layer interactions provide inherent structural reinforcement that eliminates the need for separate bridging components, simplifying the overall device while maintaining strength.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If pre-coating is performed before forming, then corrosion protection is improved, but manufacturing process complexity increases

Engineering Contradiction:

Improvecorrosion protectionVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention performs the coating operation before the forming process, applying protective coating to the flat sheet material prior to deformation. This preliminary coating ensures complete coverage and adhesion while the material is still in its simplest state, and the coating withstands the subsequent forming and deformation processes.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The cold-formed beam reduces weight, increases manufacturing speed, minimizes bridging needs, accelerates installation, and enhances the assembly of decking and other building components, while maintaining structural integrity.

Implementation Method 1

A cold-formed beam is developed, formed from a single sheet of steel

Methodology Applied

Scientific EffectCold-forming: Cold-forming

Implementation Method 2

The beam uses deformation connections, such as clinching, to couple the ends of the sheet without welding

Methodology Applied

Scientific EffectDeformation: Deformation

Data Source

PatentUS20250043573A1Cold formed beam for structures and method of forming the cold formed beam

Publication Date: 2025.02.06 NUCOR CORP

AI summary

A cold formed beam formed from a single sheet of steel having an upper member and a lower member (e.g., square, rectangular, other shape) separated by a web. The web may include stamped apertures and/or embossments around at least a portion of the stamped apertures. The cold formed beam may include beam connections that operatively couple the ends of the steel sheet used to form the beam to a portion of the beam (e.g., the web). The beam connections may by interference connectors formed from deformation of two or more layers of beam (e.g., clinching, or the like). Among other benefits, forming the cold formed beam from a single sheet, stamping of the web, and/or the using deformation connections (e.g., clinching, or the like) of the ends of the sheet allows for the pre-coating (e.g., galvanized, painting, or the like) of the sheet before the forming.