A lightweight construction element

Abstract

A lightweight construction element is disclosed comprising a first and a second flange member 10, 20 each having front face 13, 23 facing each other and back face 14, 24 non-facing each other. The first flange member and the second flange member 10, 20 are aligned alongside each other at a distance X. Further, the lightweight construction element comprises a plurality of web members 50, whereby, the length of the plate portion 51 of web members 50 defines the spacing between the first flange member 10 and the second flange member 20. The plurality of web members 50 are physically coupled to the first and second flange members 10, 20 by attaching to either the front surface 13, 23, or the back surface 14, 24 of each flange member 10, 20, and are bent at an angle ranging between 90-110 degrees to the plate portion 51 along the the attachment line 60. The plurality of web members 50 eliminate the need of a full length web and which results in reduction of metal usage and thus in turn reduced CO2 emission.

1 . A lightweight construction element comprising:
 a first and second flange members  10 ,  20 , each having a front surface  13 ,  23  facing each other and a back surface  14 ,  24  non-facing each other;   
       wherein the first flange member  10  and second flange member  20  are aligned alongside each other spaced at a distance X measured between the closest points on each flange member  10  and  20 ; and
 a plurality of web members  50 , each having plate portion  51  with a length, a width, a first edge region  52   a , a second edge region  52   b , a third edge region  53   a  and a fourth edge region  53   b , the first edge region  52   a  and the second edge region  52   b  lying across the width of the plate portion  51 , the third edge region  53   a  and the fourth edge region  53   b  across the length of the plate portion  51 , the width of the plate portion  51  defines the spacing between the first flange member  10  and the second flange member  20 , 
 
       characterized in that the plurality of web members  50  are physically coupled to the first and second flange members  10 ,  20  by attaching to either the front surface  13 ,  23 , or the back surface  14 ,  24  of each flange member  10 ,  20 , and the plurality of web members  50  are bent so that that the plate portion  51  lies at an angle ranging between 90 and 110 degrees with the first flange member  10  and second flange member  20 . 
     
     
         2 . The lightweight construction element as claimed in  claim 1 , wherein the web members  50  are spaced at a distance of 50-300 mm. 
     
     
         3 . The lightweight construction element as claimed in  any of the preceding claims , the web members are bent along an attachment line  60  between the flange members and web members. 
     
     
         4 . The lightweight construction element as claimed in  any of the preceding claims , wherein the attachment line  60  lies along the center of the flange members  10 ,  20 . 
     
     
         5 . The lightweight construction element as claimed in  any of the preceding claims , wherein the attachment line  60  lies along the edges of the flange members  10 ,  20 , respectively lying closest to each other. 
     
     
         6 . The lightweight construction element as claimed in  any of the preceding claims , is I-shaped or U-shaped. 
     
     
         7 . (canceled) 
     
     
         8 . The lightweight construction element as claimed in any of the preceding claims, wherein the width of the plate portion  51  is equal or greater than to the distance X measured between the closest points on each flange member  10  and  20 . 
     
     
         9 . (canceled) 
     
     
         10 . The lightweight construction element as claimed in any of the preceding claims, wherein the closest points for measuring distance X there between the flange members  10 ,  20  lies at their respective edges or at their respective centers or at respective points lying between their edges and their centers. 
     
     
         11 . The lightweight construction element as claimed in any of the preceding claims, wherein the web members  50  are spaced such that length of the web member  50  is not equal to the length of the flange members  10 ,  20 . 
     
     
         12 . The lightweight construction element as claimed in  claim 1 , comprises plastic, polymer, cardboard, wood, steel or other metals. 
     
     
         13 . (canceled) 
     
     
         14 . The lightweight construction element as claimed in  claim 1 , is manufactured in whole or in parts. 
     
     
         15 . The construction element as claimed in  claim 1  is a drywall stud. 
     
     
         16 . A method of making a lightweight construction element as claimed in  claim 1 , the method comprising the steps of:
 placing the first and second flange members  10 ,  20  alongside each other spaced at a distance X measured between the closest points on each flange member  10  and  20 ;   placing a plurality of web members  50  spaced at a predetermined distance either on the front surface  13 ,  23  or back surface  14 ,  24  of the flange members  10 ,  20 , respectively with their first and second edge regions  52   a ,  52   b  respectively on the first and second flange members  10 ,  20 ; and   coupling the plurality of web members  50  to the flange members  10 ,  20  along a predetermined attachment line  60 .   
     
     
         17 . The method as claimed in  claim 16 , wherein the web members  50  are planar web members  50  and require bending of the web members  50  along the attachment line  60  at an angle ranging between 90-110 degrees. 
     
     
         18 . The method as claimed in  claim 16 , wherein the plurality of web members  50  are pre-formed and the first and second edge regions  52   a ,  52   b  are at an angle ranging from 90 to 110 degrees to the plate portion  51 . 
     
     
         19 . The method as claimed in  claim 16 , wherein the predetermined distance ranges between 50-300 mm. 
     
     
         20 . The method as claimed in  claim 16 , wherein the coupling is done by screwing, riveting, bolting, nailing, welding, clinching or crimping. 
     
     
         21 . The method as claimed in  claim 16 , wherein the coupling is done on the front surface  13 ,  23  or back surface  14 ,  24  of the flange members  10 ,  20 . 
     
     
         22 . The method as claimed in  claim 19 , wherein the attachment line  60  lies along the center of the flange members  10 ,  20  or the edges of the flange members  10 ,  20 , respectively lying closest to each other.