Rollformed Beam with Pre-formed Scoring for Soffit Angles
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Solution Overview
Problem
The existing methods for forming suspended drywall ceilings and ceiling soffits are time-consuming and non-uniform, as beams need to be cut and bent individually in the field, leading to poor fitment and increased labor costs.
Innovation Solution
The beams are pre-formed into 10 ft. or 12 ft. lengths with configured features such as T-shaped holes, flattened segments, and scoring, allowing for precise bending and fixing at desired angles at the job site to create uniform and strong frameworks for ceiling soffits without distortion during shipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If straight beams are individually cut and bent in the field to form ceiling soffits, then the beams can be adapted to create curved or angled frameworks, but the process becomes time-consuming and non-uniform, resulting in poor fitment
Solution Approach 1:
The beam configurations are pre-formed during continuous rollforming to include T-shaped holes, flattened segments, and scoring at predetermined locations. This preliminary preparation allows the beams to be quickly assembled and bent at the job site without time-consuming field modifications, resolving the contradiction between adaptability and installation speed
2Adaptability or versatility
If straight beams are individually cut and bent in the field, then the beams can be shaped for soffit frameworks, but the work is non-uniform and parts do not fit well together
Solution Approach 1:
Scoring is formed in the flanges at predetermined bend locations during manufacturing, and T-shaped holes with flattened segments are pre-configured. These preliminary actions ensure that when beams are assembled and bent in the field, they achieve uniform, precise angles and fitment, eliminating the non-uniformity associated with field bending
Solution Approach 2:
The beam design incorporates localized features (T-shaped holes, flattened segments, scoring) at specific locations that enable bending only at those predetermined points. This local quality control ensures uniformity and precision while maintaining the ability to adapt beam shapes for different soffit configurations
3Strength
If beams are made strong and intact for shipping, then they can be handled without distortion, but they cannot be easily bent at the job site
Solution Approach 1:
The beam is segmented into a strong overall structure with localized flexible regions. The T-shaped holes with flattened segments create controlled weak points that allow bending at specific locations while the rest of the beam remains strong and intact for handling and shipping
Solution Approach 2:
Flattened segments are created at specific locations in the bulb of the beam, making those local areas more flexible and easier to bend. The rest of the beam maintains its full structural strength, resolving the contradiction between overall strength and local bendability
Data Source
AI summary
A straight rollformed beam made for use in a suspended horizontal drywall ceiling is modified so that it can be used in a drywall ceiling underhang known as a drywall ceiling soffit. The beam is made with repetitive configurations along the length of the beam that are selectively cut, in the field, so that the beam can be bent to, and then fixed at, a desired angle. Drywall panels are secured to a plurality of such beams that form a framework for the soffit.