Roll-Formed Reinforcement Rib for Overhead Structures

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Solution Overview

Problem

Conventional reinforcement ribs for overhead structures are difficult to bend, expensive to manufacture due to extrusion processes, and limited in size, failing to provide adequate support and flexibility for large span applications.

Innovation Solution

A reinforcement rib design featuring a pair of sidewalls with a top wall bridging one end of each sidewall and a lower flange extending from the opposite end, secured to the overhead structure's crests, allowing for end-to-end arrangement or nesting of ribs, and formed using roll-forming to reduce costs and enable larger sizes, with optional shear studs and structural elements like I-beams for enhanced support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional reinforcement ribs are used, then they provide structural support, but they are difficult to bend and limited in size

Engineering Contradiction:

Improvestructural supportVSAvoidbendability and size flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The reinforcement rib is divided into multiple segments that can be connected together. Each segment can be individually formed and then joined to create larger, more flexible reinforcement structures that can adapt to different span requirements and conform to curved surfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcement rib segments are designed to nest within each other during transportation and storage, allowing compact handling of large-sized components. The segments can be inserted into one another like nested dolls, reducing logistics complexity while maintaining full structural capability when assembled.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If extrusion process is used to manufacture reinforcement ribs, then structural integrity is maintained, but manufacturing cost increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The extrusion process is replaced with roll-forming technology. Instead of forcing material through a die under high pressure, the metal strip is progressively bent and shaped into the desired cross-sectional profile using rolling stands. This substitution significantly reduces manufacturing complexity and cost while maintaining structural integrity of the reinforcement ribs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If more fasteners are used to secure ribs, then connection strength increases, but installation complexity and cost increase

Engineering Contradiction:

Improveconnection strengthVSAvoidfastener quantity and installation complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple fastening functions are merged into integrated connection elements. The reinforcement rib segments incorporate built-in connection features such as welded plates or formed attachment points that combine securing, alignment, and structural integration functions into single components, reducing the number of separate fasteners needed.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection system utilizes composite construction combining the reinforcement rib material with integrated connection plates or welded joints. This creates a unified structural element that achieves high connection strength without requiring multiple discrete fasteners, simplifying both the connection system and installation process.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS9163392B2Reinforcement rib and overhead structure incorporating the same

Publication Date: 2015.10.20 AIL INT

AI summary

A reinforcement rib for an overhead structure comprises a pair of sidewalls and a top wall that bridges one end of each sidewall. A lower flange extends outwardly from an opposite end of each sidewall. Each lower flange is adapted to be secured to the overhead structure.