Abstract:
The present invention generally relates to a beam suitable for providing support to, for example, an automobile body. More specifically, the present invention relates to a steel boxed I-beam structure having compound curves, formed without use of a dedicated fixture or jig. Typically, the steel boxed I-beam structure provides a strong support that can be manufactured with a minimum of effort, and without the use of heavier shop machinery.

Description:
BACKGROUND  
       [0001]    Steel support beams have many applications. They may be used to support architectural forms and building structures. Steel support beams may also be used in building vehicles or rebuilding damaged vehicles. 
         [0002]    Typically, a support beam, whether constructed of steel or another support material, is constructed of pieces joined at angular intersections. For example, two portions of a steel beam may be welded at a 45-degree angle, or a 90-degree angle, or another angle appropriate to the final use of the beam. Beams made of other materials may be adhered to one another, or may be bolted together with brackets, etc. 
         [0003]    A beam that includes smooth curves will often require the use of a jig or fixture and heavy tools to form its final structure. For example, placing a beam in a jig and bending it progressively to a final structure may result in construction of a curved beam. Alternatively, first portions of a beam may be removed so that other portions may be bent, with the first portions (or replacement portions) of the beam then being placed in their final configuration. 
         [0004]    Because standard support beams are limited in their ability to assume nonstandard shapes (such as a beam with smooth curves, or a beam with one or more broadened portions), and because support beams often require heavy tools to form, it would be desirable to make a beam with complex shapes and/or with a minimum of tooling and reshaping. The described support beams, and the method of making those beams, have such characteristics. It should be appreciated that the disclosed beams and methods may be constructed of a variety of materials, as desired for a given application, and used in many situations. 
         [0005]    Typical steel support beams and their methods of manufacture are found in U.S. Pat. Nos. 2,794,650, 2,844,864, 5,210,921, 6,058,673, 6,092,864, 6,305,136, 6,557,930, 6,733,040, 6,896,320, and 7,156,422, the disclosures of which are incorporated herein by reference. 
       SUMMARY  
       [0006]    The present disclosure relates generally to a beam for providing support to a vehicle body, an architectural structure, or any other structure needing support. More specifically, it relates to a steel beam manufactured without the use of extensive machinery, and containing compound curves made without a dedicated fixture or jig. 
         [0007]    One method of manufacturing a support beam may include providing a first piece and a second piece of beam material, arranging the first and second pieces of beam material in close spatial relation, and securing to each other the first and second pieces of beam material to form the support beam. A support beam formed by the method may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, where the length dimension is measured from a first end to a second end of the support beam, and the second end of the beam may be displaced from the first end along both the first and second axes. 
         [0008]    The pieces of beam material used in the manufacturing method may be cut or otherwise formed from material stock, and the stocks for the first and second pieces may be substantially the same material (such as steel, wood, plastic, or another material) or they may be of different materials (such as one of steel and one of a plastic). Typically, for pieces made from a stock material, such as steel, the pieces may be cut by water jet cutting or laser cutting, but any appropriate method of cutting or forming the component pieces of a beam may be used. 
         [0009]    An extension of the method described above may further include providing a third piece of beam material, and arranging the third piece of beam material in close spatial relation to the first and second pieces of beam material such that the first, second, and third pieces of beam material form an I-shaped support beam. In some embodiments, the I-shaped support beam may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, with the length dimension measured from a first end to a second end of the I-shaped support beam, and the second end of the I-shaped support beam may be displaced from the first end along both the first and second axes of the I-shaped support beam. 
         [0010]    A further extension of the method described above may include providing fourth and fifth pieces of beam material, arranging the fourth and fifth pieces of beam material in close spatial relation to the first, second and third pieces of beam material, and securing the fourth and fifth pieces of beam material to the first, second, and third pieces of beam material to form a boxed, I-shaped support beam. In some embodiments, the boxed, I-shaped support beam may have a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, with the length dimension measured from a first end to a second end of the boxed, I-shaped support beam, and the second end of the boxed, I-shaped support beam may be displaced from the first end along both the first and second axes of the boxed, I-shaped support beam. 
         [0011]    Another method of manufacturing a support beam may include providing first and second pieces of beam material, arranging the first and second pieces of beam material in close spatial relation, and aligning into an aligned spatial relation the first and second pieces of beam material with an alignment apparatus, where the alignment apparatus is configured reversibly to embrace the first and second pieces of beam material. 
         [0012]    This may further include securing to each other the aligned pieces of beam material such that the first and second pieces of beam material remain in an aligned spatial relation upon removal of the alignment apparatus. 
         [0013]    An extension of this method may further include providing a third piece of beam material, and arranging the third piece of beam material in close spatial relation to the first and second pieces of beam material, where the first, second, and third pieces of beam material may be aligned with the alignment apparatus, which may reversibly embrace the first, second, and third pieces of beam material. The alignment apparatus may have a number of alignment, or support, openings having shapes complementary to the pieces of beam material, and the openings may be adjustable in position to each other and the body of the alignment apparatus. 
         [0014]    A further extension of this method may include securing to each other the aligned pieces of beam material such that the first, second, and third pieces of beam material remain in an aligned spatial relation upon removal of the alignment apparatus. 
         [0015]    A support beam fashioned according to this method may assume an I-beam form, or any other appropriate form for a given structural function. 
         [0016]    The present disclosure also provides for a support beam having a width dimension on a first axis, a height dimension on a second axis, and a length dimension on a third axis, where the length dimension may be measured from a first end to a second end of the beam, and where the second end of the beam is displaced from the first end along both the first and second axes of the beam. The beam may also include at least one smooth curve between the first end and the second end. 
         [0017]    To provide structural support, the beam may have at least a partial I-beam shape, having a first flange with first and second edges and a midline between the first and second edges, and a first web with first and second edges, where the web is secured to the flange such that either the first or second edge of the web is coupled to the midline of the first flange. The beam may also include a second flange having first and second edges and a midline between the first and second edges, where the second flange is secured to the first web such that a first or second edge of the web is coupled to the midline of the second flange. 
         [0018]    In this structure, the first flange and the first web of the support beam may be configured to be held reversibly in alignment by an alignment tool including first and second support openings having shapes complementary to the first flange and the first web. In some embodiments, the alignment tool may be adjustable, allowing adjustment of the relative locations of the first and second support openings and, thus, the relative orientations of the flange(s) and web. 
         [0019]    To further provide structural support, the I-beam shape may be boxed, with the beam including first and second walls each having first and second edges, where the first edges of the first and second walls are secured to the first flange, and where the second edges of the first and second walls are secured to the second flange. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0020]      FIG. 1  is a left perspective view of a first embodiment of a steel beam according to the present disclosure. 
           [0021]      FIG. 2  is a right perspective view of the steel beam of  FIG. 1 . 
           [0022]      FIG. 3  is a side view of the steel beam of  FIG. 1 . 
           [0023]      FIG. 4  is a front view of a first embodiment of the steel beam of  FIG. 1 . 
           [0024]      FIG. 5  is a right perspective view of components used to form a second embodiment of a steel beam according to the present disclosure. 
           [0025]      FIG. 6  is a perspective view of a first embodiment of an alignment tool according to the present disclosure. 
           [0026]      FIG. 7  is a front view of an operational relationship between the alignment tool of  FIG. 6  and the steel beam of  FIG. 1 , according to the present disclosure. 
           [0027]      FIG. 8  is a plan cutaway view of a third embodiment of a steel beam according to the present disclosure. 
           [0028]      FIG. 9  is a plan cutaway view of a fourth embodiment of a steel beam according to the present disclosure. 
           [0029]      FIG. 10  is a partial left perspective view of an intermediate step in a method of constructing a first embodiment of a steel beam according to the present disclosure. 
       
    
    
     DETAILED DESCRIPTION  
       [0030]    The present disclosure describes a support beam. The support beam is typically a steel beam, and it may be used as, for example, a structural support beam in a vehicle frame. Alternatively, the support beam may be used in any application requiring a strong structural support beam including nonstandard shapes (i.e. other than a typical cylinder, tube, typical combinations of those shapes, etc.). The illustrated support beam of the present disclosure is a beam having a roughly rectangular cross-section but also having complex curves along its length, which can be manufactured by a straightforward process requiring only a minimum of effort. In other embodiments, the support beam may follow a semicircular path, may include multiple curves, or take another non-standard shape. 
         [0031]      FIGS. 1-4  show an illustrated first embodiment of a support beam  10  according to the present disclosure. The illustrated embodiment is a steel beam having a boxed I-beam shape. As such, the central portion of the beam includes a number of support elements, such as a web  12 , a first flange  14 , and a second flange  16 . To “box” this central I-beam backbone, the illustrated beam might include a first wall  18  and a second wall  20 . As illustrated, the support beam has, essentially, three vertical portions (web  12 , wall  18 , and wall  20 ) bracketed by two horizontal portions (flange  14  and flange  16 ). Although illustrated in this manner, it is understood that the beam may be constructed with fewer walls, fewer flanges, more webs, or any other desired combination of these support elements. 
         [0032]    Initially, the illustrated beam can be described as having a first leg  22  and a second leg  24  at either end of a curved midportion  26 . The midportion can be any shape necessary as needed for a particular application of the support beam, but the illustrated embodiment includes a first curve  28  and a second curve  30 . Each of the first and second legs  22 ,  24  of the support beam may follow a short, substantially linear path. As such, a length edge  32  of the first leg  22  may define an axis L along which a length of a support beam may be measured. A length edge  34  of the second leg  24  may be parallel to edge  32  and, as such, may be parallel to the axis L. Typically, the length of the illustrated support beam may be measured as the distance along axis L from a first end  36  to a second end  38  of the beam. 
         [0033]    The illustrated support beam may also have height and width dimensions. A height edge  40  may follow a substantially linear path so as to define an axis H along which a height of a support beam may be measured. In the same way, a width edge  42  may follow a substantially linear path and define an axis W along which a width of a support beam may be measured. As with the length edges  32 ,  34 , height edge  40  of the first end  36  may have an analogous height edge  44  at the second end  38 , and width edge  42  of first end  36  may have an analogous width edge  46  at the second end  38 . 
         [0034]    As is apparent from the Figures, the length, height, and width of a support beam may be measured in multiple ways. For example, the length of a support beam could be measured as the distance from the first end to the second end along the axis L. As an alternative, if the first and second ends were located closely in space (as in a support beam having a horseshoe shape, or following a semicircular path), then the length might be measured as the separation distance along axis L between the two most-separated points on the support beam. 
         [0035]    As another example, the width of the support beam could be measured as the distance from the first wall to the second wall along the axis W (this could correspond to the width of a first or second flange, depending on construction of the beam). An alternative width could be measured as the separation distance along axis W between the two most-separated points on the support beam. In the illustrated embodiment, for example, the greatest separation on the width axis W is not the width of the first or second flanges because the illustrated support beam is not a linear structure, and the second end is displaced along the W axis from the first end (seen most clearly in  FIG. 3 ). 
         [0036]    As another exemplary measurement, the height of the support beam could be measured as the distance from the first flange to the second flange along the axis H (this could correspond to the width of the web, or first or second wall, depending on construction of the beam). An alternative height could be measured as the separation distance along axis H between the two most-separated points on the support beam. In the illustrated embodiment, for example, the greatest separation on the height axis H is not the height of web  12 , or first wall  18  or second wall  20  because the illustrated support beam does not lie on a planar surface, the second end being displaced along the H axis from the first end (seen most clearly in  FIG. 4 ). 
         [0037]    The illustrated steel beam has a non-standard shape which can be described relative to a set of axes defined by the beam. In the illustrated embodiment of a support beam, the second end  38  of the support beam is displaced from the first end  36  along both the W and H axes at its location on the L axis. This three-dimensional displacement of one end from the other in the illustrated beam is the result of the presence of the first curve  28  and the second curve  30  in the midportion  26  of the beam. In other words, moving along the L axis of the beam, a comparison of the first end of the beam to the second end of the beam shows that the second end of the beam is displaced upward along the H axis and rightward on the W axis from the first end (if the point of origin of the axes is considered to be the first end of the beam). 
         [0038]      FIGS. 2-4  show other views of the support beam of  FIG. 1 , making clear the complex structure of the illustrated embodiment and the two-dimensional displacement (along axes W and H) of the first and second ends of the beam. Though showing a very similar beam,  FIG. 4  illustrates a beam having reverse curvature to the beams of  FIGS. 1-3  (the second end of the beam of  FIG. 4  is displaced to the left relative to the first end of the beam). 
         [0039]      FIG. 5  shows two component parts, a web  12 ′ and a flange  16 ′, used in making a second embodiment of a steel beam according to the present disclosure.  FIG. 5  shows that the component parts used in making a beam can each have multiple curves in the plane of the component material, each curve having different characteristics, to form a final beam having multiple complex curves rather than a pair of relatively simple curves (as shown in  FIGS. 1-4 ). 
         [0040]      FIG. 6  is an illustration of an alignment tool  50  according to the present disclosure, which can be used in a method of manufacturing the illustrated beams of  FIGS. 1-5 , and other beams according to the present disclosure. The alignment tool may generally be constructed of a relatively stiff material, being configured to hold portions of the illustrated support beam in alignment during a support beam manufacturing process. However, other materials appropriate for performing the manufacturing method described below may be used. In some embodiments, the support beam  10  and alignment body  50  are of substantially the same materials, while in other embodiments the support beam and alignment body are of substantially or somewhat different materials. 
         [0041]    The exemplary alignment tool  50  of  FIG. 6  has a roughly rectangular alignment body  52  supporting a pair of alignment legs  54 ,  56 . In the illustrated embodiment, the alignment legs are somewhat longer than the central portion of the alignment body, thus forming an alignment surface  58  between the alignment legs. The illustrated alignment body also includes alignment openings  60 ,  62 , formed by the close, but not complete, abutment between the alignment surface and the alignment legs. 
         [0042]    As is apparent from the Figures, the alignment tool can be placed into an operative relationship with elements of the support beam, facilitating the manufacture of the beam.  FIG. 7  is an illustration of one possible operational relationship between the alignment tool of  FIG. 6  and the steel beams of  FIGS. 1-5 , according to the present disclosure.  FIG. 7  makes clear that a given alignment tool may be useful for making a given embodiment of a support beam, since the various alignment portions of the tool may be designed to place components of the support beam into a close, temporarily fixed relationship. The temporary alignment of the elements of the support beam can then be made more permanent by, for example, welding the elements of the support beam to one another. 
         [0043]      FIG. 7  shows an aligning relationship between alignment tool  50  and portions of a support beam  10 , partway through a method of manufacturing the support beam (described in more detail below). In  FIG. 7  one can see that a first flange  14  and a second flange  16  can each be slidingly inserted into alignment openings  60  and  62 , respectively. As well, web  12  can be placed between the flanges so that it lays against the alignment surface  58 . In this way, the central spine of the boxed I-beam can be laid out, with the three components of the central spine in temporary alignment with one another. As seen in  FIG. 7 , the web is aligned with the two flanges so that the web is positioned roughly along the midline of the two flanges (i.e. about midway between the two edges of each flange). Other arrangements or alignments are possible depending on the use or desired construction of the beam. For example, in some embodiments, the web may be positioned away from the midline of each flanges, such that it lies closer to one side or the other of each flange. 
         [0044]    As is clear from the Figures, the illustrated embodiment of alignment tool  50  in  FIGS. 6 and 7  is uniquely suited to making the illustrated embodiment of a support beam  10  in  FIGS. 1-5  because of the placement of the alignment legs, surface, and openings. In like manner, another embodiment of alignment tool  50  could be uniquely suited for making a subtly different, or substantially different, embodiment of a support beam. For example, the alignment tool could have alignment openings that are placed at angles relative to each other, forming a beam with flanges or walls that are angled relative to each other or the web. Another embodiment might have shallower alignment openings, to accommodate or align narrower flanges. As another example, an alignment tool might be adjustable, where the alignment legs, surface, and/or openings could be moved relative to one another and then temporarily fixed in place (for example, with a series of nuts and bolts). Such an alignment tool could allow a manufacturer to make multiple types of beams with a single tool. 
         [0045]    It bears repeating that the illustrated beam is simply one embodiment of a non-standard beam shape possible to be constructed with the method of manufacture described below. For example, the beam might follow a semi-circular path; it might contain more than two curves; and so on. Also, although the beam of the present disclosure is shown as a boxed I-beam with a web that is continuous from the first end to the second end, other designs are possible, such as a beam with a discontinuous web, or flanges with projections (as seen in  FIG. 5 ), etc. 
         [0046]    It also bears noting that a unique feature of the illustrated beam is the ability of the beam to embody complex curves with a minimum of effort on the part of a manufacturer of the beam. As is clear from the description of the above Figures, each of the pieces forming the central I-beam structure is a substantially planar element cut out of a substantially planar stock material. Each substantially planar element embodies a curve in a single dimension (i.e. in the plane of the stock material from which the element was cut). However, when brought together into an I-beam structure, the combination of two substantially planar elements, each having a curve in a single dimension, results in a non-planar I-beam embodying at least one complex curve (i.e. a curve having components in at least two dimensions). In the illustrated embodiment, for example, the central I-beam structure has complex curves embodying both the substantially one-dimensional “upward” (along the H axis) curve of web  12  (or  12 ′) and the substantially one-dimensional “sideways” (along the W axis) curve of flanges  14 ,  16  (or  16 ′). 
         [0047]    An exemplary embodiment of a beam containing more than one continuous or discontinuous web within an otherwise uniform exterior is shown in cross-section in  FIG. 8 . Such a design may allow a beam to have a relatively shallow side profile (i.e. a small dimension along axis H) while still providing increased strength relative to the beams illustrated in  FIGS. 1-5 . In the embodiment of  FIG. 8 , the beam  10  may include a midportion  26  that is broader than the beam&#39;s first and second legs. The midportion may be broadened to include multiple webs  12  spaced from each other. Though the illustrated beam embodiment includes two walls  18 ,  20  and three webs (two continuous webs  12   a ,  12   b  passing from end-to-end, and one discontinuous web  12   c  only in the midportion), other numbers of webs are possible according to the desired performance parameters of the support beam. 
         [0048]    An exemplary embodiment of a beam having a relatively broader midportion between two relatively narrower portions, with the broader portion housing multiple webs or a web having a nonlinear portion is shown in cross-section in  FIG. 9 . Like the embodiment of  FIG. 8 , this beam embodiment may allow increased strength with a shallow side profile. 
         [0049]    In the embodiment of  FIG. 9 , the walls may extend outward along the midportion  26  of the support beam, much like the embodiment of  FIG. 8 . Rather than housing multiple webs, however, the larger midportion of the beam of  FIG. 9  may house a nonstandard central web  12 . The central web of the embodiment of  FIG. 9  may be configured as a single-thickness plate at either of its ends. The central portion, however, of the web of this embodiment may be “split” in the middle (i.e. configured with two web arms  63  extending from the web toward the sides of the beam) such that the central portion of the web is configured as a roughly hexagonal web loop  64 . As an alternative, loop  64  could be configured as a rectangular, pentagonal, ovoid, or other appropriate shape for providing structure within the larger midportion  26  of the illustrated beam. 
         [0050]    Having described exemplary embodiments of support beams and an alignment tool, there follows a description of a method of making a typical support beam with a typical tool. The described method does not require heavy shop equipment unless heavy-gauge steel (or other material that is difficult to manipulate) is utilized in the construction. For example, 12-gauge and 10-gauge (about ⅛ inch) plate steel can be worked by hand, while ¼-inch plate steel may need to be worked with machinery, powered or otherwise. 
         [0051]    The method may include a first step and a second step of providing a first piece of beam material; for example, providing pieces of steel from steel stock. One way of providing these pieces of steel is to cut (by, for example, laser or water jet cutting) shaped pieces of steel from a steel sheet. As noted, for easier working, the steel may be about  1 / 8  of an inch in thickness. 
         [0052]    For making a boxed I-beam structure of the types illustrated in  FIGS. 1-5 , a user may require five pieces of shaped steel: one piece for the central web, two pieces each for the first and second flanges, and two pieces each for the first and second walls. The pieces may be held individually or as a group at one end, with the other end of each piece being manipulated by a user, or a group of cooperating users, making a support beam. Typically, a pair of users may work together to align the pieces of the support beam before fastening them into place. 
         [0053]    The one or more users may arrange first and second pieces of the beam material into close spatial relation. One way to do this would be to align the pieces using an alignment tool  50  like the one illustrated in  FIGS. 6 and 7 . Initially, a user may slide an edge of one flange  14  into one of the alignment openings  60  on the alignment tool. The user may then place a web piece  12  on the alignment surface  58  of the alignment tool. In this way, an edge of the web piece may abut a midline of the adjacent flange. When one piece “abuts” another, the pieces may actually be in contact or they may merely be in sufficiently close spatial relation so that they may be connected later with a minimum of further adjustment in their positions (i.e. they may be close enough that they could be welded, glued, or otherwise fastened). 
         [0054]    The user or cooperating users may then secure to each other the first and second pieces of beam material to form all or a portion of the support beam. To secure the first and second pieces of beam material, the user may simply tack-weld the pieces to each other as they are held in place by the alignment tool. Alternative methods of attachment may be used according the desired use of the beam or further work to be done in finishing the beam. If, for example, a simple support beam is desired, it may be enough to form the beam by securing a single flange and a single web by welding. As another example, a user or group of users may align the components of the beam with the alignment tools, and then use a series of clamps to hold the components in place. A final tack welding may then be performed along the whole length of the beam in one step. 
         [0055]    If the support beam will have a central I-beam structure, the user may add another flange  16  to the arrangement of pieces, for example by sliding an edge of the flange  16  into an unoccupied alignment opening  62  of alignment tool  50 . In this way, a relatively simple alignment tool like the one in  FIGS. 6 and 7  may align two flange pieces  14 ,  16  and a web  12  so that each edge of the central web abuts a midline of a different flange. The web may then be tack-welded to the flange pieces or completely welded to the flange pieces, depending on the performance requirements of the beam. 
         [0056]    An exemplary arrangement during the process described above is shown in  FIG. 10 , where two flanges  14 ,  16  and a central web  12  are in operative association with alignment tools  50 . In the Figure, first and second alignment tools  50  are closely positioned, with each tool&#39;s alignment opening supporting a flange and the alignment surface contacting the web (as in  FIG. 7 ); thus, the alignment tools may be said to “bracket” the central I-beam structure. As illustrated in the Figure, a user may use the pair of tools  50  to initially align two flanges and a web at a given point. The user may then secure the pieces in place with a clamp  66 , allowing the alignment tools to be moved to the next location along the nascent beam that has flanges and a web to be aligned. Alternatively, the user could tack weld  68  the aligned portion of the I-beam before moving the alignment tools. In either case, using a pair of alignment tools at the same time can allow a user to precisely align the components of the I-beam before tack welding or clamping the aligned arrangement before moving to and aligning the next section of the beam. 
         [0057]    To form a beam like the one illustrated in  FIGS. 1-5 , the central “I” structure may only be tack-welded in place, as walls will be added to the final structure. In this case, the central “I” structure may act as a pattern for the final boxed I-beam. Once the central spine of the boxed I-beam is formed, the side walls, also cut or otherwise formed as pieces from stock material, may be lined up with the edges of the flanges. Once in final placement, the walls may be welded into place, securing them firmly with the flanges. 
         [0058]    The alignment tool may not be necessary for the final step of securing the walls to the I-beam spine, but it may be necessary to hold the walls in place with clamps or other tools while the final fixing occurs. Typically, final placement could be done with two users and a series of clamps, with no requirement for heavy tools or machinery. 
         [0059]    Although the present invention has been shown and described with reference to the foregoing operational principles and preferred embodiments, it will be apparent to those skilled in the art that various changes in form and detail can be made without departing from the spirit and scope of the invention. The present invention is intended to embrace all such alternatives, modifications and variances. The subject matter of the present invention includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed through presentation of claims in a subsequent application.