Interlocking Composite Roof Beam Structure for Lighter Long Spans
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Solution Overview
Problem
Existing roof beams for temporary structures face a challenge in achieving a balance between strength and weight, particularly when spanning large areas without intermediate supports, as stronger materials tend to be heavier, and reinforcing methods increase weight without proportionate strength gain.
Innovation Solution
A roof beam design comprising two elongate members with hollow box sections connected through interlocking connectors, where one member's ribs fit into the channels of the other, forming a composite beam that is both stronger and lighter than traditional reinforcing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional reinforcing methods are used (sliding one profile inside another), then the strength of the beam is increased, but the weight increases without proportionate strength gain
Solution Approach 1:
The invention transitions from a nested configuration (one profile inside another) to a side-by-side configuration where the second profile is positioned adjacent to the first profile. This dimensional rearrangement allows the connectors to engage laterally through channels and ribs, creating a composite beam that achieves superior strength-to-weight ratio by utilizing spatial arrangement rather than simple mass addition.
Solution Approach 2:
The invention creates a composite beam structure by combining two different aluminium alloy profiles with distinct cross-sectional geometries. The first profile (U-shaped or channel section) and second profile (I-section or hat section) work together through mechanical connectors, forming a composite structure that leverages the geometric strengths of each component to achieve enhanced overall strength without proportional weight increase.
2Strength
If stronger materials are used to bridge large spans, then the strength is improved, but the weight increases
Solution Approach 1:
The invention changes the geometric parameters of the beam cross-section by combining two profiles with different shapes and orientations. Rather than using a single heavier material, the solution modifies the structural parameters through composite geometry, creating a configuration where the combined section modulus and moment of inertia provide the necessary strength for large spans while keeping the weight lower than traditional single-profile approaches.
3Strength
If a reinforcing profile is slid into a box section, then the strength is increased, but the complexity of assembly increases
Solution Approach 1:
The invention segments the beam into two distinct functional profiles that can be manufactured independently using standard extrusion processes. The first profile contains channels at its corners, and the second profile contains corresponding ribs, allowing each component to be produced separately and then assembled through straightforward lateral connection, reducing overall assembly complexity compared to nested configurations.
Data Source
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AI summary
A roof beam is shown for a temporary building in which the beam comprises a first elongate member and a second elongate member, each comprising a box section with a hollow centre having a length, a width and a depth. The first elongate member is provided at each of two adjacent corners of its box section with a first connector extending lengthwise and comprising a channel closed off from the hollow centre of the first elongate member and open outwards through a neck narrower than the channel. The second elongate member has at each of two adjacent corners of its box section a second connector extending lengthwise and comprising a rib projecting through the neck of a complementary first connector and a flange on the rib held within the channel of the complementary first connector. In addition, the first elongate member and the second elongate member are respectively configured and arranged so that the first and second connector interconnect, with the second connector being a close fit within the first connector, whereby the first and second elongate members are coupled together to form the roof beam.