WO2025083706A1

WO2025083706A1 - Sheet metal, construction element and method of manufacturing the sheet metal

Info

Publication number: WO2025083706A1
Application number: PCT/IN2024/052068
Authority: WO
Inventors: Shailendra SHINDE; Ganesh HOLKAR; Sunilkumar YADAV
Original assignee: Saint Gobain Placo SAS
Current assignee: Saint Gobain Placo SAS
Priority date: 2023-10-16
Filing date: 2024-10-15
Publication date: 2025-04-24
Anticipated expiration: 2026-04-16

Abstract

A construction element (900) formed from a sheet metal (100). The construction element (900) comprises a web (910) extending along a longitudinal axis (901) of the construction element (900) and at least one flange (920) extending transversely from the web (910). The web (910) comprises at least a first pattern (110) embossed thereon, and the flange (920) comprises at least a second pattern (150) embossed thereon. The first pattern (110) comprises at least one array of triangles (112). The second pattern (150) comprises at least one array of waves (152). Further, a portion (930) between the web (910) and the flange (920) comprises a combination of first and second patterns (110, 150) embossed thereon. The construction element (900) provides more structural strength and high rigidity compared to the conventionally known profile elements, by counter-balancing the forces and stresses applied form different directions.

Description

SHEET METAL, CONSTRUCTION ELEMENT AND METHOD OF MANUFACTURING THE SHEET METAL

TECHNICAL FIELD

[001] The present disclosure relates to the field of sheet metals. Particularly, the present disclosure relates to a sheet metal, a construction element formed from the sheet metal and a method and an apparatus of manufacturing the sheet metal that is adapted to be made into the construction element.

BACKGROUND

[002] The information in this section merely provides background information related to the present disclosure and may not constitute prior art(s) for the present disclosure.

[003] In today’s world, walls consisting of plaster boards are widely used. Said walls comprises a profile element, made of sheet metal, that serves as a carrier structure for the construction of walls. Typically, the profile element comprises a web region and at least one flange region such that the at least one flange region additionally comprises fixation means that can be brought into engagement with wall segments in order to fix the plaster boards/ walls. The profile element acts as a means through which most of the forces imposed on the wall are diverted away, generally along a longitudinal direction of the profile element.

[004] The force diversion property of the profile element is based on several factors, for example, material, cross-sectional dimensions and shape, length or height of the profile element. One such crucial factor that affects the force bearing capacity of the profile element includes the pattern, i.e., the geometric imperfections, defined on the profile element. The pattern defined on the web region of the profile element facilitates balancing transverse forces and the pattern defined on the flange region facilitates balancing moments of flexion.

[005] Typically, the profile elements are so arranged/ designed that the load applied on the profile element does not cause the wall to fail, i.e., break down or be bent away by more than a certain threshold. In other words, the profile element and the pattern defined thereon is so designed that the problem of excess buckling can be avoided under the load applied on the profile element. While there are different patterns known to manufacturers that addresses the problem of buckling, the existing pattern designs do not cater to the needs where the walls are subject to heavy loads. Thus, there remains a need for improvement in the design of the profile elements.

[006] Accordingly, there remains a need in the domain for an improved profile element or a construction element that comprises pattems(s) that has high strength (i.e., minimizes the chances of buckling) under heavy load conditions, and that improves mechanical strength without increasing the cost.

SUMMARY

[007] The one or more shortcomings of the prior art are overcome by the system/ assembly/ method as claimed, and additional advantages are provided through the provision of the system/ assembly/ method as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

[008] Pursuant to an aspect of the present disclosure, in an embodiment, a sheet metal adapted to be made into a construction element is disclosed. The sheet metal comprises at least one array of triangles embossed on the sheet metal. The sheet metal further comprises at least one array of waves embossed on the sheet metal. The at least one array of waves is embossed in regions around the at least one array of triangles.

[009] In another non-limiting embodiment of the present disclosure, each of the at least one array of triangles and the at least one array of waves is formed of corrugations comprising a combination of crests and troughs that merge into each other to form a continuous surface.

[010] In another non-limiting embodiment of the present disclosure, each array of triangles is formed by a plurality of pairs of triangles embossed consecutively on the sheet metal. Each pair of triangles comprises a first triangle having a first base and a first apex, and a second triangle having a second base and a second apex. The first triangle extends from the first base towards the first apex along a first direction. The second triangle extends from the second base towards the second apex along a second direction. The first direction and the second direction are bidirectional.

[OH] In another non-limiting embodiment of the present disclosure, the first direction and the second direction are unidirectional.

[012] In another non-limiting embodiment of the present disclosure, the at least one array of triangles is formed by a plurality of triangles embossed consecutively on the sheet metal. Each triangle comprises a base and an apex. The triangle extends from the base towards the apex along a longitudinal axis of the sheet metal.

[013] In another non-limiting embodiment of the present disclosure, the at least one array of triangles comprises at least one smaller triangle nested within a larger triangle. [014] In another non-limiting embodiment of the present disclosure, each triangle of the at least one array of triangles comprises curved edges and curved corners.

[015] In another non-limiting embodiment of the present disclosure, a ratio of a base to a height of each triangle of the at least one array of triangles falls within a range of 1 : 1 to 2: 1.

[016] In another non-limiting embodiment of the present disclosure, the at least one array of waves extends along a longitudinal axis of the sheet metal.

[017] In another non-limiting embodiment of the present disclosure, a first array of waves is defined on one side of the at least one array of triangles and a second array of waves is defined on the opposite side of the at least one array of triangles.

[018] In another non-limiting embodiment of the present disclosure, the at least one array of triangles and the at least one array of waves are embossed on the sheet metal by cold forming process.

[019] In another non-limiting embodiment of the present disclosure, the sheet metal comprises raised portions embossed around or within triangles of the at least one array of triangles.

[020] In another non-limiting embodiment of the present disclosure, the raised portions are embossed on the sheet metal by cold forming process.

[021] In another non-limiting embodiment of the present disclosure, at least one array of triangles and the at least one array of waves extend across 40% to 90% of the surface area of the sheet metal.

[022] Pursuant to another aspect of the present disclosure, in an embodiment, a construction element formed from the sheet metal as described above, is disclosed. The construction element comprises a web extending along a longitudinal axis of the construction element. The web comprises at least a first pattern embossed thereon. The construction element comprises at least one flange extending transversely from the web. The at least one flange comprises at least a second pattern embossed thereon. The first pattern comprises the at least one array of triangles. The second pattern comprises the at least one array of waves. [023] In another non-limiting embodiment of the present disclosure, a portion of the first pattern is embossed on the at least one flange, and a portion of the second pattern is embossed on the web.

[024] In another non-limiting embodiment of the present disclosure, the construction element has two flanges extending transversely from the web. The construction element includes a ‘U-shaped’ profile or a ‘C-shaped’ profile, in a cross section of the construction element.

[025] In another non-limiting embodiment of the present disclosure, a joining portion between the web and a flange of the at one flange comprises a combination of the first pattern and the second pattern embossed thereon.

[026] In another non-limiting embodiment of the present disclosure, the construction element is a drywall channel, drywall stud or ceiling channel.

[027] In another non-limiting embodiment of the present disclosure, the construction element is formed as a unitary structure made of a metallic sheet in which the at least one flange is bent relative to the web.

[028] Pursuant to yet another aspect of the present disclosure, in an embodiment, a method of manufacturing a sheet metal that is adapted to be made into a construction element is disclosed. The method comprises feeding, by a feeder, a metallic sheet. The method further comprises embossing, by a combination of top and bottom rollers of a corrugation assembly, a first pattern and a second pattern on the metallic sheet. The first pattern comprises an array of triangles, and the second pattern comprises an array of waves.

[029] In another non-limiting embodiment of the present disclosure, the method further comprises the step of embossing raised portions, by the combination of the top and bottom rollers of the corrugation assembly, around or within triangles of the array of triangles.

[030] In another non-limiting embodiment of the present disclosure, the step of embossing the raised portions comprises a stamping operation, after the metallic sheet passes through the combination of the top and bottom rollers of the corrugation assembly.

[031] Pursuant to yet further aspect of the present disclosure, in an embodiment, an apparatus for manufacturing a sheet metal is disclosed. The apparatus comprises a feeder for feeding a metallic sheet. The apparatus further comprises a corrugation assembly disposed downstream of the feeder and adapted to emboss the metallic sheet. The corrugation assembly comprises a pair of rollers, at least one of which is driven by a rotating unit. The pair of rollers comprises a first roller having a first pattern and a second pattern defined thereon. The pair of rollers further comprises a second roller arranged below the first roller and has counterpart first and second patterns defined thereon. Upon rotation of the at least one of the first roller and the second roller, the metallic sheet passes between the first roller and the second roller such that an impression of the first pattern and the second pattern is embossed on the metallic sheet. The first pattern comprises an array of triangles, and the second pattern comprises an array of waves defined in regions around the array of triangles.

[032] Within the scope of the present disclosure, the sheet metal and the construction element formed from the sheet metal comprising the at least one array of triangles and the at least one array of waves provide more structural strength and high rigidity compared to the conventionally known profile elements, by counter-balancing the forces and stresses applied from different directions.

[033] Further, the continuous surface of the sheet metal and the construction element add aesthetic appeal to the construction element and is ergonomic with no sharp edges. Additionally, for the reason that there are no sharp edges, i.e., the surface is smooth and continuous, accumulation of stress and strain across the surface of the sheet metal and the construction element can be minimized, thereby improving the structural integrity and minimizing buckling of the construction element. Also, corrugation design facilitates smooth flow of material which allows only negligible surface coating damage resulting in more corrosion resistance performance of the sheet metal and the construction element.

[034] Furthermore, embossing the triangles and the waves, and additionally the raised portions, on the sheet metal and the construction element facilitates adding more surface area without adding material, thereby more strength is achieved without increasing the weight and cost of the material.

[035] Moreover, the first apex and the second apex of the first triangle and the second triangle, respectively, of the array of triangles facilitates counter-balancing the force/ stress acting in different direction, thus preventing tear-off of the sheet metal and the construction element.

[036] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form a further embodiment of the disclosure.

[037] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF FIGURES

[038] The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments are now described, by way of example only, with reference to the accompanying drawings wherein like reference numerals represent like elements and in which:

[039] FIG. 1 illustrates an exemplary sheet metal, in accordance with a first embodiment of the present disclosure;

[040] FIG. 2 illustrates an exemplary sheet metal, in accordance with a second embodiment of the present disclosure;

[041] FIG. 3 illustrates an exemplary sheet metal, in accordance with a third embodiment of the present disclosure;

[042] FIG. 4 illustrates an exemplary sheet metal, in accordance with a fourth embodiment of the present disclosure;

[043] FIG. 5 illustrates an exemplary sheet metal, in accordance with a fifth embodiment of the present disclosure;

[044] FIG. 6 illustrates an exemplary sheet metal, in accordance with a sixth embodiment of the present disclosure;

[045] FIG. 7 illustrates an exemplary sheet metal, in accordance with a seventh embodiment of the present disclosure;

[046] FIG. 8 illustrates a cross-sectional view of the sheet metal of FIG. 2, taken along a plane passing the sheet metal, in accordance with a first embodiment of the present disclosure; [047] FIG. 9 illustrates an exemplary construction element made from the sheet metal of FIG. 1, in accordance with a first embodiment of the present disclosure;

[048] FIG. 10 illustrates a method of manufacturing the sheet metal of FIGS. 1 to 9, in accordance with an embodiment of the present disclosure;

[049] FIG. 11 illustrates a method of manufacturing the sheet metal of FIGS. 1 to 9, in accordance with another embodiment of the present disclosure; and

[050] FIG. 12 illustrates a corrugation assembly of an apparatus for manufacturing the sheet metal, in accordance with an embodiment of the present disclosure.

[051] Skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure.

DETAILED DESCRIPTION

[052] While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the FIGS, and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure as defined by the appended claims.

[053] Before describing detailed embodiments, it may be observed that the novelty and inventive step that are in accordance with the present disclosure resides in a sheet metal, a construction element adapted to be formed from the sheet metal, a method of manufacturing the sheet metal, and an apparatus of manufacturing the sheet metal. It is to be noted that a person skilled in the art can be motivated from the present disclosure and modify the various constructions of the sheet metal, the construction element, the method, and the apparatus. However, such modification should be construed within the scope of the present disclosure. Accordingly, the drawings are showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

[054] In the present disclosure, the term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment or implementation of the present subject matter described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments.

[055] The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusions, such that a device that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such setup or device. In other words, one or more elements in a system or apparatus proceeded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

[056] The terms like “at least one” and “one or more” may be used interchangeably or in combination throughout the description.

[057] Pursuant to an embodiment, a sheet metal adapted to be made into a construction element is disclosed. The sheet metal comprises at least one array of triangles embossed on the sheet metal. The sheet metal further comprises at least one array of waves embossed on the sheet metal. The at least one array of waves is embossed in regions around the at least one array of triangles. Each of the at least one array of triangles and the at least one array of waves is formed of corrugations comprising a combination of crests and troughs that merge into each other to form a continuous surface. Each triangle of the at least one array of triangles comprises curved edges and curved corners. The at least one array of waves extends along a longitudinal axis of the sheet metal. A first array of waves is defined on one side of the at least one array of triangles and a second array of waves is defined on the opposite side of the at least one array of triangles. The at least one array of triangles and the at least one array of waves are embossed on the sheet metal by cold forming process. At least one array of triangles and the at least one array of waves extend across 40% to 90% of the surface area of the sheet metal.

[058] In one embodiment, each array of triangles is formed by a plurality of pairs of triangles embossed consecutively on the sheet metal. Each pair of triangles comprises a first triangle having a first base and a first apex, and a second triangle having a second base and a second apex. The first triangle extends from the first base towards the first apex along a first direction. The second triangle extends from the second base towards the second apex along a second direction. The first direction and the second direction are bidirectional. In some embodiments, the first direction and the second direction are unidirectional. In other embodiments, the at least one array of triangles is formed by a plurality of triangles embossed consecutively on the sheet metal. Each triangle comprises a base and an apex. The triangle extends from the base towards the apex along a longitudinal axis of the sheet metal. The at least one array of triangles comprises at least one smaller triangle nested within a larger triangle. A ratio of a base to a height of each triangle of the at least one array of triangles falls within a range of 1 : 1 to 2: 1.

[059] In some embodiments, the sheet metal comprises raised portions embossed around or within triangles of the at least one array of triangles. The raised portions do not overlap with the corrugations which form the array of triangles or the array of waves. The raised portions are embossed on the sheet metal by cold forming process. [060] Pursuant to another embodiment, a construction element formed from the sheet metal as described above, is disclosed. The construction element comprises a web extending along a longitudinal axis of the construction element. The web comprises at least a first pattern embossed thereon. The construction element comprises at least one flange extending transversely from the web. The at least one flange comprises at least a second pattern embossed thereon. The first pattern comprises the at least one array of triangles. The second pattern comprises the at least one array of waves. A portion of the first pattern is embossed on the at least one flange, and a portion of the second pattern is embossed on the web. The construction element has two flanges extending transversely from the web. The construction element includes a ‘U-shaped’ profile or a ‘C-shaped’ profile, in a cross section of the construction element. A joining portion between the web and a flange of the at one flange comprises a combination of the first pattern and the second pattern embossed thereon. The construction element is a drywall channel, drywall stud or ceiling channel. The construction element is formed as a unitary structure made of a metallic sheet in which the at least one flange is bent relative to the web.

[061] Pursuant to yet another embodiment, a method of manufacturing a sheet metal that is adapted to be made into a construction element is disclosed. The method comprises feeding, by a feeder, a metallic sheet. The method further comprises embossing, by a combination of top and bottom rollers of a corrugation assembly, a first pattern and a second pattern on the metallic sheet. The first pattern comprises an array of triangles, and the second pattern comprises an array of waves. The method further comprises the step of embossing raised portions, by the combination of the top and bottom rollers of the corrugation assembly, around or within triangles of the array of triangles. The step of embossing the raised portions comprises a stamping operation, after the metallic sheet passes through the combination of the top and bottom rollers of the corrugation assembly.

[062] Pursuant to yet further embodiment, an apparatus for manufacturing a sheet metal is disclosed. The apparatus comprises a feeder for feeding a metallic sheet. The apparatus further comprises a corrugation assembly disposed downstream of the feeder and adapted to emboss the metallic sheet. The corrugation assembly comprises a pair of rollers, at least one of which is driven by a rotating unit. The pair of rollers comprises a first roller having a first pattern and a second pattern defined thereon. The pair of rollers further comprises a second roller arranged below the first roller and has counterpart first and second patterns defined thereon. Upon rotation of the at least one of the first roller and the second roller, the metallic sheet passes between the first roller and the second roller such that an impression of the first pattern and the second pattern is embossed on the metallic sheet. The first pattern comprises an array of triangles, and the second pattern comprises an array of waves defined in regions around the array of triangles.

[063] Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals will be used to refer to the same or like parts. Embodiments of the disclosure are described in the following paragraphs with reference to FIGS. 1 to 12. In FIGS. 1 to 12, the same element or elements which have same functions are indicated by the same reference signs.

[064] Referring to FIG. 1, a sheet metal (100) in accordance with the present disclosure is disclosed. Without limiting the scope of protection of the present disclosure, the sheet metal (100) is adapted to be made into a construction element, including, but not limited to, a dry wall channel, dry wall stud or ceiling channel.

[065] Still referring to FIG. 1, the sheet metal (100) is formed by cold forming process using an apparatus, for example, a press-die assembly, for manufacturing the sheet metal. The sheet metal (100) comprises different patterns formed and/ or embossed thereon. In accordance with the present disclosure, the sheet metal (100) comprises a first pattern (110) and a second pattern (150) embossed thereon such that the second pattern (150) does not overlap with the first pattern (110). Embossing the first pattern (110) and the second pattern (150) on the sheet metal (100) increases the surface area of the sheet metal (100) that facilitates dissipating and/ or minimizing the stress concentration within the sheet metal (100), and thus enhances the structural integrity of the sheet metal (100). In the illustrated exemplary embodiment of FIG. 1, the first pattern (110) may comprise at least one array of triangles (112) embossed on the sheet metal (100). Further, the second pattern (150) may comprise at least one array of waves (152) embossed on the sheet metal (100). Without limiting the scope of the present disclosure, the at least one array of waves (152) is embossed in regions on the sheet metal (100) that is around the at least one array of triangles (112). In other words, the at least one array of waves (152) is embossed on the sheet metal (100) such that the at least one array of waves (152) does not overlap with the at least one array of triangles (H2).

[066] In an embodiment, as shown in FIGS. 1 to 5, the at least one array of triangles (112) comprises only one array of triangles (112). Although, FIGS. 1 to 5 illustrates that the sheet metal (100) comprises only one array of triangles (112); however, it can be contemplated that without deviating from the scope of the present disclosure, the sheet metal (100) may comprise more than one array of triangles (112), each of which may be arranged or embossed in a vertical and/ or horizontal direction with respect to each other. Referring to FIGS. 1 to 5, the array of triangles (112) comprises a plurality of pairs of triangles (114) embossed consecutively on the sheet metal (100). In an embodiment of the present disclosure, the plurality of pairs of triangles (114) are embossed consecutively on the sheet metal (100) along a longitudinal direction (101) of the sheet metal (100).

[067] Each pair of triangles (114) comprises a first triangle (120) and a second triangle (130) embossed consecutively to the first triangle (120). The first triangle (120) may have a first base (122) and a first apex (124) formed by the intersection of the two remaining sides of the first triangle (120) (i.e., the two sides of the first triangle (120) other than the first base (122) of the first triangle (120)). Similarly, the second triangle (130) may have a second base (132) and a second apex (134) formed by the intersection of the two remaining sides of the second triangle (130) (i.e., the two sides of the second triangle (130) other than the second base (132) of the second triangle (130)). In accordance with the embodiments of the present disclosure, the first triangle (120) may extend from the first base (122) towards the first apex (124) in a first direction (121). Similarly, the second triangle (130) may extend from the second base (132) towards the second apex (134) in a second direction (131). For instance, in an embodiment (not illustrated), the sheet metal (100) may comprise the first triangle (120) in which the first base (122) is aligned along the longitudinal direction (101) of the sheet metal (100) and the first apex (124) of the first triangle (120) is directed downwardly. Also, the sheet metal (100) may comprise the second triangle (130) in which the second base (132) is aligned along the longitudinal direction (101) of the sheet metal (100) and the second apex (134) of the second triangle (130) is directed upwardly such that the pair of triangles (114) comprises an upwardly pointed second triangle (130) embossed adjacent or consecutive to the downwardly pointed first triangle (120).

[068] In accordance with the present disclosure, the first triangle (120) illustrated in FIGS. 1 to 5 has the first base (122) substantially perpendicular to the longitudinal direction (101) of the sheet metal (100). Also, the first apex (124) of the first triangle (120) is directed along the longitudinal direction (101) of the sheet metal (100) such that the first direction (121) of the first triangle (120) is along the longitudinal direction (101) of the sheet metal (100). Similarly, the second triangle (130) illustrated in FIGS. 1 to 5 has the second base (132) substantially perpendicular to the longitudinal direction (101) of the sheet metal (100). Also, the second apex (134) of the second triangle (130) is directed along the longitudinal direction (101) of the sheet metal (100) such that the second direction (131) of the second triangle (130) is along the longitudinal direction (101) of the sheet metal (100). Without limiting the scope of protection of the present disclosure, the first direction (121) of the first triangle (120) and the second direction (131) of the second triangle (130) are bidirectional.

[069] For instance, in an embodiment, the second direction (131) of the second triangle (130) may extend in a direction opposite to the first direction (121) of the first triangle (120) such that the second apex (134) of the second triangle (130) is directed towards or away from the first apex (124) of the first triangle (120). As shown in FIGS. 1 and 4, the first apex (124) of the first triangle (120) is directed in a left direction (when seen in the top view of the sheet metal (100)) and the second apex (134) of the second triangle (130) is directed in a right direction (when seen in the top view of the sheet metal (100)) such that the second apex (134) of the second triangle (130) is directed away from the first apex (124) of the first triangle (120). In other embodiments, as shown in FIGS. 2 and 5, the first apex (124) of the first triangle (120) is directed in a right direction (when seen in the top view of the sheet metal (100)) and the second apex (134) of the second triangle (130) is directed in a left direction (when seen in the top view of the sheet metal (100)) such that the second apex (134) of the second triangle (130) is directed towards the first apex (124) of the first triangle (120). [070] In some embodiments, the first direction (121) of the first triangle (120) and the second direction (131) of the second triangle (130) are unidirectional. As shown in the illustrated embodiment of FIG. 3, the first base (122) of the first triangle (120) and the second base (132) of the second triangle (130) are substantially perpendicular to the longitudinal direction (101) of the sheet metal (100). Also, the first apex (124) of the first triangle (120) and the second apex (134) of the second triangle (130) are directed along the longitudinal direction (101) of the sheet metal (100) such that the first direction (121) of the first triangle (120) is along the second direction (131) of the second triangle (130), i.e., both the first triangle (120) and the second triangle (130) extend in the same direction. For instance, as shown in FIG. 3, the first apex (124) of the first triangle (120) and the second apex (134) of the second triangle (130) extend in a left direction (when seen in the top view of the sheet metal (100)). In other embodiments (not shown), the first apex (124) of the first triangle (120) and the second apex (134) of the second triangle (130) may be directed in a right direction (when seen in the top view of the sheet metal (100)).

[071] Further, in accordance with the present disclosure, referring to FIGS. 6 and 7, in some embodiments, the array of triangles (112) may be formed as a plurality of triangles (140) embossed consecutively on the sheet metal (100). Each triangle (140) of the plurality of triangles (140) may comprise a base (142) and an apex (144) formed by the intersection of the two remaining sides of the triangle (140) (i.e., the two sides of the triangle (140) other than the base (142) of the triangle (140)). The triangle (140) may extend from the base (142) towards the apex (144) in a first direction (141). In an embodiment, the apex (144) of the triangle (140) is directed along the longitudinal direction (101) of the sheet metal (100). For instance, as shown in FIGS. 6 and 7, the apex (144) of the triangle (140) is directed in a left direction (when seen in the top view of the sheet metal (100)) such that the apex (144) of the triangle (140) is directed along the longitudinal direction (101) of the sheet metal (100). In other embodiments (not shown), the apex (144) of the triangle (140) may be directed in a right direction (when seen in the top view of the sheet metal (100)).

[072] Further, in an embodiment of the present disclosure, the at least one array of triangles (112) may comprise at least one smaller triangle (116) nested within a larger triangle (118). For example, in the illustrated embodiments of FIGS. 1, 2 and 7, the array of triangles (112) is embossed as a smaller triangle (116) embossed within another larger triangle (118). In an embodiment, the array of triangles (112) may comprise said combination of smaller triangles (116) nested with the larger triangles (118) in all the triangles (as shown in FIGS. 1, 2 and 7) or in alternate triangles (not shown). Without deviating from the scope of the present disclosure, the smaller triangles (116) and the larger triangles (118) may have structural and functional configuration similar to those of first triangle (120), the second triangle (130) or the triangle (140).

[073] Within the scope of the present disclosure, each triangle of the at least one array of triangles (112) comprises curved edges and curved comers so as to avoid stress concentration on the sheet metal (100). Also, without limiting the scope of the present disclosure, a ratio of a base to a height of each triangle of the at least one array of triangles (112) falls within a range of 1 : 1 to 2: 1. In an embodiment, a radius of curvature of the corners of the triangle may vary within a range of 2 mm to 3 mm, preferably 2.5 mm.

[074] Referring to FIGS. 1 to 7, the second pattern (150) embossed on the sheet metal (100) comprises the at least one array of waves (152). In the illustrated embodiments of FIGS. 1 to 7, the at least one array of waves (152) comprises two arrays of waves (152), each of which extends at either side of the at least one array of triangles (112). For example, referring to FIGS. 1 and 2, a first array of waves (152-1) is embossed on one side of the at least one array of triangles (112), i.e., an upper region of the at least one array of triangles (112) and a second array of waves (152-2) is embossed on the opposite side of the at least one array of triangles (112), i.e., a lower region of the at least one array of triangles (112). Without limiting the scope of the present disclosure, in an embodiment, each of the at least one array of waves (152) extends along the longitudinal direction (101) of the sheet metal (100).

[075] In accordance with the present disclosure, each of the at least one array of triangles (112) and the at least one array of waves (152) is formed of corrugations comprising a combination of crests (102) and troughs (104) that merge into each other to form a continuous surface so as to minimize stress concentration on the sheet metal (100). Referring to FIG. 8 that illustrates a side cross-sectional view of the sheet metal (100) (of FIG. 2) taken along the plane (P-P’) that passes through the embossed regions of the sheet metal (100), the crests (102) may be understood as the peaks formed by the embossed patterns on the sheet metal (100) and the troughs (104) may be understood as the grooves (or valleys) formed by the embossed patterns on the sheet metal (100). Within the scope of the present disclosure, said crests (102) and troughs (104) are formed of curved geometry and merge into each other such that a seamless continuous surface on the sheet metal (100) is formed. With reference to FIG.8, each of the crests (102) and the troughs (104) merge with each other at a junction (106) that is also formed of a curved geometry. The junction (106) may be understood as a curved plane that defines contours, for example, concave shaped cylindrical contours along a width of the sheet metal (100) that facilitates seamless and uninterrupted, i.e., without creases, transition of the first and second patterns (110, 150) between the crests (102) and the troughs (104). The seamless continuous surface of the sheet metal (100) avoids any stress concentration on the sheet metal (100) under load. Also, the increased surface area of the sheet metal (100) facilitates increasing the strength and the load bearing capacity of the sheet metal (100). Further, without limiting the scope of protection of the present disclosure, the at least one array of triangles (112) and the at least one array of waves (152) extend across 40% to 90% of the surface area of the sheet metal (100). [076] Referring to FIGS. 1, 2, 4 and 7, the sheet metal (100) further comprises raised portions (108) embossed thereon. In an exemplary embodiment of the present disclosure, the raised portions (108) may be embossed on the sheet metal (100) by a process of stamping. In other embodiments, the raised portions (108) may be embossed on the sheet metal (100) by any known techniques in the art, for example, press-dies, etc. Within the scope of the present disclosure, the raised portions (108) embossed at a first surface (for example, an upper surface) of the sheet metal (100) forms a depression at a second surface (for example, a lower surface) of the sheet metal (100). In accordance with the present disclosure, the raised portions (108) may be embossed in the regions (of the sheet metal (100)) around or within the triangles of the at least one arrays of triangles (112). For example, with reference to FIG. 1, the raised portions (108) embossed around the at least one array of triangles (112) may correspond to those raised portions (108) that are formed on the sheet metal (100) between the first pattern (110) and the second pattern (150). Further, with reference to FIG. 1, the protuberances (108) embossed within the at least one array of triangles (112) may correspond to those raised portions (108) that are nested within the triangles of the at least one array of triangles (112). The raised portions (108) are embossed on the sheet metal (100) such that the raised portions (108) do not overlap with corrugations which form the at least one array of triangles (112) and the at least one array of waves (152). In an embodiment, without deviating from the scope of protection of the present disclosure, the raised portions (108) may overlap with the corrugations which form the at least one array of triangles (112) and the at least one array of waves (152). Said raised portions (108) embossed on the sheet metal (100) may correspond to, but not limited to, dots, protrusions, indentations, or the like not limiting to its shape.

[077] In an embodiment of the present disclosure, the at least one array of triangles (112) and the at least one array of waves (152) are embossed on the sheet metal (100) by cold forming process. Also, in an embodiment, the raised portions (108) are embossed on the sheet metal (100) by cold forming process.

[078] Within the scope of the present disclosure, FIG. 9 illustrates a construction element (900) that is formed from the sheet metal (100) as described above. The construction element (900) may comprise, but not limited to, drywall channel, drywall stud or ceiling channel. Referring to FIG. 9, the construction element (900) may comprise a web (910) and at least one flange (920). The web (910) may be understood as a region of the construction element (900) that extends along a longitudinal axis (901) of the construction element (900). Further, the at least one flange (920) may be understood as a region/ component of the construction element (900) that extends transversely from the web (910). In an embodiment of the present disclosure, when seen in a top view of the construction element (900), the construction element (900) may be formed by bending at least one of a lower region and an upper region of the sheet metal (100) relative to a central region of the sheet metal (100), such that the central region of the sheet metal (100) corresponds to the web (910) of the construction element (900) and the bent upper and/ or lower regions corresponds to the flange(s) (920) extending substantially transverse to the web (910). Accordingly, the construction element (900) may be formed as a unitary structure made of a metallic sheet in which the at least one flange (920) is bent relative to the web (910). In the illustrated embodiment of FIG. 9, the construction element (900) comprises two flanges (920) extending transversely to the web (910) such that the construction element (900) includes a ‘U-shaped’ profile or a ‘C-shaped’ profile, in a cross section of the construction element (900).

[079] In accordance with the present disclosure, in an embodiment, the web (910) of the construction element (900) comprises at least the first pattern (110) embossed thereon. Also, the at least one flange (920) of the construction element (900) may comprise at least the second pattern (150) embossed thereon. In other words, the web (910) of the construction element (900) comprises the at least one array of triangles (112) embossed thereon. Also, the at least one flange (920) of the construction element (900) comprises the at least one array of waves (152) embossed thereon. In an embodiment, a joining portion (930) between the web (910) and the flange (920) of the at least one flange (920) comprises a combination of the first pattern (110) and the second pattern (150) embossed thereon. For instance, in the illustrated embodiment of FIG. 9, the web (910) of the construction element (900) comprises the first pattern (110) and a portion of the second pattern (150) embossed therein and the at least one flange (920) of the construction element (900) comprises the second pattern (150) and a portion of the first pattern (110) embossed thereon. In other words, the web (910) of the construction element (900) may comprise the at least one array of triangles (112) and a portion of the at least one array of waves (152) embossed therein and the at least one flange (920) of the construction element (900) may comprise the at least one array of waves (152) and a portion of the at least one array of triangles (112) embossed thereon.

[080] Without limiting the scope of protection of the present disclosure, the at least one array of triangles (112) embossed on the construction element (900) may structurally and functionally correspond to the at least one array of triangles (112) embossed on the sheet metal (100). Similarly, the at least one array of waves (152) embossed on the construction element (900) may structurally and functionally correspond to the at least one array of waves (152) embossed on the sheet metal (100). [081] Referring to FIG. 9, the construction element (900) may further comprises raised portions (108) embossed thereon. In an exemplary embodiment of the present disclosure, the raised portions (108) may be embossed on the construction element (900) by a process of stamping. The raised portions (108) may be embossed in the regions around or within the triangles of the at least one arrays of triangles (112). The raised portions (108) are embossed on the construction element (900) such that the protuberances (108) do not overlap with corrugations which form the at least one array of triangles (112) and the at least one array of waves (152). Said raised portions (108) embossed on the sheet metal (100) may correspond to, but not limited to, dots, protrusions, indentations, or the like.

[082] Referring to FIGS. 10 and 11, in a further aspect of the present disclosure, a method (1000) of manufacturing the sheet metal (100) is disclosed. In an embodiment, the sheet metal (100) formed by the method (1000) may be made into the construction element (900). Without deviating from the scope of the present disclosure, the method (1000) may be performed by an apparatus (not shown) for manufacturing the sheet metal (100), which comprises a feeder (not shown) and a corrugation assembly (1200), as shown in FIG. 12, disposed downstream of the feeder. Referring to FIG. 12, the corrugation assembly (1200) may comprise a pair of rollers (1202) adapted to emboss one or more patterns on a sheet of metal fed by the feeder.

[083] The pair of rollers (1202) of the corrugation assembly (1200) may be driven or rotated by a rotating unit (not shown). The rotating unit may comprise, but not limited to, a motor. In an embodiment, one roller of the pair of rollers (1202) may be driven by the rotating unit. In another embodiment, both the rollers of the pair of rollers (1202) may be driven by the rotating unit. In accordance with the present disclosure, the pair of rollers (1202) may comprise a first roller (1210) and a second roller (1220) arranged vertically below the first roller (1210). The first roller (1210), i.e., atop roller, may have a first pattern (1204) and a second pattern (1206) defined thereon. Further, the second roller (1220), i.e., a bottom roller, may have a counterpart first and second patterns (1204, 1206) defined thereon. For instance, in case where the first roller (1210) has the first and second patterns (1204, 1206) defined in form of peaks above the curved surface of the first roller (1210), the second roller (1220) has the first and second patterns (1204, 1206) defined in form of valleys/ grooves so that the peaks of the first rollers (1210) can be received in the corresponding grooves of the second roller (1220). Without limiting the scope of protection of the present disclosure, the first pattern (1204) and the second pattern (1206) defined on the first roller (1210) and the second roller (1220) of the corrugation assembly (1200) may correspond to the at least one array of triangles (112) and the least one array of waves (152), respectively, embossed on the sheet metal (100).

[084] Referring again to FIG. 10, the method (1000) of manufacturing the sheet metal comprise a step (1010) of feeding a metallic sheet by the feeder of the apparatus for manufacturing the sheet metal (100). The feeder may comprise one or more spools of the metallic sheet that are adapted to feed the apparatus with the metallic sheet. In an embodiment, the apparatus may comprise a set of rollers (not shown) disposed downstream of the feeder. The set of rollers may be adapted to unwind the spool of metallic sheet and supply the unwound metallic sheet towards the corrugation assembly (1200) for embossing the patterns (1204, 1206) on the metallic sheet.

[085] The method (1000) further comprises a step (1020) of passing the metallic sheet between the first (top) roller (1210) and the second (bottom) roller (1220) of the corrugation assembly (1200), and upon rotation of at least one roller of the first roller (1210) and the second roller (1220), embossing the first pattern (1204) and the second pattern (1206) on the metallic sheet. Upon passing the metallic sheet between the rollers (1210, 1220) and rotating the rollers (1210, 1220), an impression of the first and second patterns (1204, 1206) defined on the first and second rollers (1210, 1220) is embossed on the metallic sheet and a portion of the metallic sheet disposed between the peaks and grooves of the first and second rollers (1210, 1220) curves to the shape of the peaks and grooves defined on the first and second rollers (1210, 1220). As discussed above, the first pattern (1204) and the second pattern (1206) defined on the first roller (1210) and the second roller (1220) of the corrugation assembly (1200) may correspond to the at least one array of triangles (112) and the least one array of waves (152), respectively, embossed on the sheet metal (100).

[086] In an embodiment, the first roller (1210) of the corrugation assembly (1200) may additionally define protrusions (1208) on the curved surface thereof. Further, the second roller (1220) may additionally define the counterpart blind hole (1209) on the curved surface thereof, such that upon synchronous rotation of the first and second rollers (1210, 1220), the protrusions (1208) and the counterpart blind holes (1209) form raised portions (108) on the metallic sheet passed between the first and second rollers (1210, 1220). Referring to FIG. 11, the method (1000) may further comprise a step (1030) of embossing the raised portions (108) on the metallic sheet, by the combination of the first (top) roller (1210) and the second (bottom) roller (1220) of the corrugation assembly (1200), around or within triangles of the array of triangles (112). In an embodiment, the step (1030) of embossing the raised portions may comprise a stamping operation after the metallic sheet has passed through the combination of the first (top) roller (1210) and the second (bottom) roller (1220) of the corrugation assembly (1200). Said raised portions (108) embossed on the metallic sheet metal may correspond to, but not limited to, dots, protrusions, indentations, or the like not limiting its shape.

[087] Further, within the scope of the present disclosure, the sheet metal (100) and the construction element (900) may comprise an additional stamping (199) (as shown in FIGS. 1 to 7 and 9), for example, in shape of a rectangle, defined between the triangles of the first pattern (110). Said additional stamping (199) may provide further increased surface area of the sheet metal (100) and the construction element (900) and provide a space for including logos/ branding information of the sheet metal (100) and the construction element (900).

[088] Within the scope of the present disclosure, the sheet metal (100) and the construction element (900) formed from the sheet metal (100) comprising the at least one array of triangles (112) and the at least one array of waves (152) provide more structural strength and high rigidity compared to the conventionally known profile elements, by counter-balancing the forces and stresses applied form different directions. [089] Further, the continuous surface of the sheet metal (100) and the construction element (900) add aesthetic appeal to the construction element (900) and is ergonomic with no sharp edges. Additionally, for the reason that there are no sharp edges, i.e., the surface is smooth and continuous, accumulation of stress and strain across the surface of the sheet metal (100) and the construction element (900) can be minimized, thereby improving the structural integrity and minimizing buckling of the construction element (900). Also, corrugation design facilitates smooth flow of material which allows only negligible surface coating damage resulting in more corrosion resistance performance of the sheet metal (100) and the construction element (900).

[090] Furthermore, embossing the triangles (112) and the waves (152), and additionally the raised portions (108), on the sheet metal (100) and the construction element (900) facilitates adding more surface area without adding material, thereby more strength is achieved without increasing the weight and cost of the material.

[091] Moreover, the first apex (124) and the second apex (134) of the first triangle (120) and the second triangle (130), respectively, of the array of triangles (112) facilitates counter-balancing the force/ stress acting in different direction, thus preventing tear-off of the sheet metal (100) and the construction element (900).

[092] Inventive Example

[093] Simulations of flange bending and deflection under lateral load condition were performed for the construction element (viz. a ceiling channel) of the present invention. In the simulation, a load of 50 N was applied on one side of one of the flanges of the construction elements having a length of 200 mm and a sheet thickness of 0.3 mm and 0.5 mm. The results are shown in Table 1.

Table 1 : Simulation Results of Inventive Example

[094] Comparative Example

[095] For the purpose of comparison, simulations of flange bending and deflection under lateral load condition were carried out for a conventional ceiling channel made from a plain metal sheet. In the simulation, a load of 50 N was applied on one side of one of the flanges of the conventional ceiling channel having a length of 200 mm and a sheet thickness of 0.3 mm and 0.5 mm. The results are shown in Table 2.

Table 2: Simulation Results of Comparative Example

[096] The results show that the construction element of the present disclosure has least deflection values in the above-mentioned tests and hence is stronger. The least deflection values are attributed to the presence of the first and second pattern present across the plane of the construction element that act as a stiffener rib for improving the frame deflection performance.

[097] The various embodiments of the present disclosure have been described above with reference to the accompanying drawings. The present disclosure is not limited to the illustrated embodiments; rather, these embodiments are intended to fully and completely disclose the subject matter of the disclosure to those skilled in this art. In the drawings, like numbers refer to like elements throughout. Thicknesses and dimensions of some components may be exaggerated for clarity. [098] Herein, the terms “attached”, “connected”, “interconnected”, “contacting”, “mounted”, “coupled” and the like can mean either direct or indirect attachment or contact between elements, unless stated otherwise.

[099] Well-known functions or constructions may not be described in detail for brevity and/or clarity. As used herein the expression “and/or” includes any and all combinations of one or more of the associated listed items.

[100] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including” when used in this specification, specify the presence of stated features, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, operations, elements, components, and/or groups thereof.

[101] While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

REFERENCE NUMERALS

EQUIVALENTS:

[102] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[103] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[104] Any discussion of documents, acts, materials, devices, articles and the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

[105] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

Claims

1. A sheet metal (100) adapted to be made into a construction element (900), the sheet metal (100) comprising: at least one array of triangles (112) embossed on the sheet metal (100); and at least one array of waves (152) embossed on the sheet metal (100), wherein the at least one array of waves (152) is embossed in regions around the at least one array of triangles (112).

2. The sheet metal (100) as claimed in claim 1, wherein each of the at least one array of triangles (112) and the at least one array of waves (152) is formed of corrugations comprising a combination of crests (102) and troughs (104) that merge into each other to form a continuous surface.

3. The sheet metal (100) as claimed in claim 1, wherein each array of triangles (112) is formed by a plurality of pairs of triangles (114) embossed consecutively on the sheet metal (100), each pair of triangles (114) comprises a first triangle (120) having a first base (122) and a first apex (124), and a second triangle (130) having a second base (132) and a second apex (134), the first triangle (120) extending from the first base (122) towards the first apex (124) along a first direction (121), and the second triangle (130) extending from the second base (132) towards the second apex (134) along a second direction (131), wherein the first direction (121) and the second direction (131) are bidirectional.

4. The sheet metal (100) as claimed in claim 1, wherein the first direction (121) and the second direction (131) are unidirectional.

5. The sheet metal (100) as claimed in claim 1, wherein the at least one array of triangles (112) is formed by a plurality of triangles (140) embossed consecutively on the sheet metal (100), each triangle (140) comprising a base (142) and an apex (144), wherein the triangle (140) extends from the base (142) towards the apex (144) along a longitudinal axis (101) of the sheet metal (100).

6. The sheet metal (100) as claimed in claim 1, wherein the at least one array of triangles (112) comprises at least one smaller triangle (116) nested within a larger triangle (118).

7. The sheet metal (100) as claimed in claim 1, wherein each triangle of the at least one array of triangles (112) comprises curved edges and curved corners.

8. The sheet metal (100) as claimed in claim 1, wherein a ratio of a base to a height of each triangle of the at least one array of triangles (112) falls within a range of 1 : 1 to 2: 1.

9. The sheet metal (100) as claimed in claim 1, wherein the at least one array of waves (152) extends along a longitudinal axis (101) of the sheet metal (100).

10. The sheet metal (100) as claimed in claim 1, wherein a first array of waves (152- 1) is defined on one side of the at least one array of triangles (112) and a second array of waves (152-2) is defined on the opposite side of the at least one array of triangles (112).

11. The sheet metal (100) as claimed in claim 1, wherein the at least one array of triangles (112) and the at least one array of waves (152) are embossed on the sheet metal (100) by cold forming process.

12. The sheet metal (100) as claimed in claim 1, wherein the sheet metal (100) comprises raised portions (108) embossed around or within triangles of the at least one array of triangles (112).

13. The sheet metal (100) as claimed in claim 12, wherein the raised portions (108) are embossed on the sheet metal (100) by cold forming process.

14. The sheet metal (100) as claimed in claim 1, wherein the at least one array of triangles (112) and the at least one array of waves (152) extend across 40% to 90% of the surface area of the sheet metal (100).

15. A construction element (900) formed from the sheet metal (100) as claimed in any one of claims 1 to 14, the construction element (900) comprising: a web (910) extending along a longitudinal axis (901) of the construction element (900), the web (910) comprising at least a first pattern (110) embossed thereon; and at least one flange (920) extending transversely from the web (910), the at least one flange (920) comprising at least a second pattern (150) embossed thereon, wherein, the first pattern (110) comprises the at least one array of triangles (112), and the second pattern (150) comprises the at least one array of waves (152).

16. The construction element (900) as claimed in claim 15, wherein, a portion of the first pattern (110) is embossed on the at least one flange (920), and a portion of the second pattern (150) is embossed on the web (910).

17. The construction element (900) as claimed in claim 15, wherein the construction element (900) has two flanges (920) extending transversely from the web (910), and the construction element (900) includes a ‘U-shaped’ profile or a ‘C- shaped’ profile, in a cross section of the construction element (900).

18. The construction element (900) as claimed in claim 15, wherein a joining portion (930) between the web (910) and a flange of the at one flange (920) comprises a combination of the first pattern (110) and the second pattern (150) embossed thereon.

19. The construction element (900) as claimed in claim 15, wherein the construction element (900) is a drywall channel, drywall stud or ceiling channel.

20. The construction element (900) as claimed in claim 15, wherein the construction element (900) is formed as a unitary structure made of a metallic sheet in which the at least one flange (920) is bent relative to the web (910).

21. A method (1000) of manufacturing a sheet metal (100) that is adapted to be made into a construction element (900), the method (1000) comprising: feeding, by a feeder, a metallic sheet; and embossing, by a combination of top and bottom rollers (1210, 1220) of a corrugation assembly (1200), a first pattern (110) and a second pattern (150) on the metallic sheet, wherein the first pattern (110) comprises an array of triangles (112), and the second pattern (150) comprises an array of waves (152).

22. The method (1000) as claimed in claim 21, comprising the step of embossing raised portions (108), by the combination of the top and bottom rollers (1210, 1220) of the corrugation assembly (1200), around or within triangles of the array of triangles (112).

23. The method (1000) as claimed in claim 22, wherein the step of embossing the raised portions (108) comprises a stamping operation, after the metallic sheet passes through the combination of the top and bottom rollers (1210, 1220) of the corrugation assembly (1200).

24. An apparatus for manufacturing a sheet metal (100), the apparatus comprising: a feeder for feeding a metallic sheet; and a corrugation assembly (1200) disposed downstream of the feeder and adapted to emboss the metallic sheet, wherein the corrugation assembly (1200) comprises a pair of rollers (1202), at least one of which is driven by a rotating unit, the pair of rollers (1202) comprises a first roller (1210) having a first pattern (1204) and a second pattern (1206) defined thereon; and a second roller (1220) arranged below the first roller (1210) and having counterpart first and second patterns (1204, 1206) defined thereon, wherein upon rotation of the at least one of the first roller (1210) and the second roller (1220), the metallic sheet passes between the first roller (1210) and the second roller (1220) such that an impression of the first pattern (1204) and the second pattern (1206) is embossed on the metallic sheet, and wherein the first pattern (1204) comprises an array of triangles (112), and the second pattern (1206) comprises an array of waves (152) defined in regions around the array of triangles (112).