Cold Rolled Steel Beam With Double-Layered Web And Flanges
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Solution Overview
Problem
Existing structural steel members, particularly I, S, and W shapes, are costly due to high material and labor expenses for manufacturing and finishing, especially for small sections and custom applications, and there is a need for lighter weight options to conserve energy and reduce handling costs.
Innovation Solution
Cold rolled steel beams with double-layered steel webs and flanges, featuring orthogonally positioned end connectors and a prefinished surface treatment, are produced from a unitary piece of coil material using a roll forming process, which reduces material usage and labor costs by incorporating spaced apart physical connections and a method for efficient surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hot rolled steel beams are used for small sections, then structural strength is achieved, but manufacturing cost and material expense increase significantly
Solution Approach 1:
The steel beam is divided into multiple layers (typically three layers) that are joined together through roll forming. This segmentation allows the use of thinner, more cost-effective material while achieving the required structural strength through the combined layers, directly addressing the high cost of traditional hot-rolled small sections.
Solution Approach 2:
The invention transitions from traditional hot-rolled single-piece beams to cold-formed multi-layer rolled beams. By adding the dimensional aspect of multiple layers joined together, the beam achieves equivalent or superior strength to hot-rolled beams while using less material and reducing manufacturing costs.
2Weight of moving object
If traditional hot rolled beams are used, then structural integrity is maintained, but weight is excessive increasing energy consumption and handling costs
Solution Approach 1:
Different regions of the beam cross-section have different thicknesses and layer configurations optimized for their specific functional requirements. The multi-layer construction allows local variation in material distribution, providing sufficient structural integrity where needed while minimizing weight in less critical areas.
Solution Approach 2:
The beam is constructed as a composite structure with multiple steel layers joined together. This composite approach allows the beam to achieve high structural integrity through the combined strength of multiple layers while using less total material than a solid hot-rolled beam, thereby reducing weight.
3Ease of manufacture
If custom connections and protective coatings are added to structural steel members, then functionality and durability are improved, but cost per unit weight increases significantly
Solution Approach 1:
The connection elements and protective coatings are integrated into the roll forming process itself rather than being added as separate post-fabrication steps. End connectors and surface treatments are applied during manufacturing, which reduces labor costs and eliminates the need for separate handling operations, thereby reducing cost per unit weight while maintaining adaptability.
Solution Approach 2:
Connections and surface treatments are prepared in advance during the roll forming process. End connectors are formed and positioned, and protective coatings are applied before the beam leaves the manufacturing line. This preliminary action eliminates the need for costly post-fabrication customization and reduces overall manufacturing costs.
4Ease of operation
If heavy hot rolled beams are used, then structural strength is sufficient, but handling and installation labor requirements increase
Solution Approach 1:
The beam design incorporates integrated connection features and end connectors that are self-aligning and self-installing. The orthogonal end connectors are designed to fit into corresponding receptacles without requiring complex alignment or additional fastening operations, making the beam self-sufficient during installation and reducing labor requirements.
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 rolled steel beams offer a cost-effective and lightweight solution for structural applications, reducing material usage and labor costs by up to 50% compared to traditional hot rolled methods, while maintaining structural integrity and allowing for efficient installation and finishing.
Implementation Method 1
The spaced apart physical connections are preferably chosen from the group consisting of weld, rivet, clinch material fold, screw, bolt and a combination thereof. The spaced apart physical connections preferably fasten the two layers of steel in the web together.
Data Source
AI summary
The present invention relates to a cold rolled steel beam comprising: a web having two layers of steel, the web having a top end and a bottom end; a pair of bottom flanges extending outwardly from the bottom end of the web; and a pair of top flanges extending outwardly from the top end of the web, each top flange having two layers of steel. Preferably, a portion of each bottom flange has two layers of steel, and the cold rolled steel beam includes a pair of end connectors extending generally orthogonally from the web and positioned generally orthogonally to the bottom flanges and the top flanges. Preferably, the cold rolled steel beam is cold formed from a unitary piece of sheet steel.