FIELD
This application relates generally to the field of structural support members for use in structures, such as structural decking systems, roof systems, or other like framing systems, and more particularly, to improvements to the structural support members and manufacturing of the structural support members.
BACKGROUND
Structures (e.g., buildings, warehouses, plants, or the like) are used in commercial, residential, or industrial construction and may use different types of framing. As such, these structures may utilize structural decking systems, roof systems (e.g., standing seam roofs, or the like), or other like systems, such as wooden framing systems (e.g., wooden studs, plywood floors and walls, or the like). Alternatively, or additionally, structures may utilize other materials and/or substrates to form the structures. These structures all utilize structural support members to distribute loading throughout the structure.
In some embodiments the structures may include structural decking systems that utilize structural decking panels, which may typically be manufactured from steel sheets that may or may not be coiled. In order to increase the structural strength and the stiffness of the individual steel sheets, structural decking panels with longitudinal profiles are formed from the steel sheets via roll forming, break forming, bending, stamping, or other like processes. The structural decking panels are secured to each other in order to form a portion of the structural steel decking system when installed. These structural decking panels may be used as roof decking, floor decking, or wall panels. As such, corrugated structural decking panels may be used in a variety of building applications. The decking panels are connected to the other load resisting support members of a building, such as joists and/or beams, which are in turn connected to other support members, such as girders (e.g., joist girders, beams, or the like), walls, wall panels, columns (e.g., concrete, steel, or the like, or combinations thereof), or the like in order to create the structural decking systems. When the decking panels are connected to each other and the various support members in a secure manner for roof, floor, or wall applications, the assembled structural steel decking system provides considerable diaphragm (or membrane) strength, which is used to transfer horizontal loads to the vertical and lateral load carrying members of the building.
Additionally, or alternatively, structures that use roof decking (e.g., standing seam roofing, or the like) are typically large area, open floor steel frame buildings. The buildings typically are pre-engineered and are provided as kits of components for use in a wide range of industries, including agricultural, aircraft hangers, garages, riding arenas, indoor sports fields, warehouses, as well as commercial and governmental buildings. Steel buildings may feature open floor space, referred to as bays, and are commonly but not always, built on poured concrete slabs. These buildings may also include load resisting support members (e.g., columns, beams, rafters, purlins, joists, girts, bracing, or the like), as described above. Vertical columns may be operatively coupled to the concrete slabs and extend from the concrete. The vertical columns may be operatively coupled to and support elongated beams or trusses. Long bay support members (e.g., beams, joists, purlins) may be operatively coupled to the beams or trusses in a transverse orientation. A plurality of roof panels may be operatively coupled to the beams, joists, or purlins with clips, such as standing seam clips. Typically, the clips provide a gap between the beams, purlins, or joists and the roof panels. Frequently, the gap is filled with insulation components and/or other building components to reduce heat transfer through the roof panels.
Additionally, or alternatively, structures may utilize wooden structural framing and/or other materials, such as through the use of podium designs (e.g., concrete podiums, or the like). These types of wooden and/or concreate structures may provide cost savings, speed of installation, wind and seismic loading benefits, thermal benefits, sustainability, and/or other advantages.
Regardless of the type of structure and framing, all of these structures may utilize structural support members, such as girders, beams, joists, or other like structural support members to distribute the loading through the structure. There is a need for improved structural support members for these structures.
BRIEF SUMMARY
Various framing systems (e.g., structural or otherwise) often utilize joists (e.g., joists, girder joists, or the like), beams, and/or other structural support members for supporting studs (e.g., metal, wooden, or the like), steel decking panels, wooden panels, or the like. A joist typically comprises an upper chord, a lower chord, and web(s), which operatively couples the upper chord to the lower chord. The opposing ends of the joist (e.g., a proximal end and a distal end) may include a joist seat (otherwise described as a joist shoe). The upper chord, the lower chord, web(s), and joist seat(s) may be made of one or more components that are operatively coupled together and/or may be formed of any type of shape. The upper chord is operatively coupled to the lower chord and/or the joist seat through the use of one or more web members (e.g., single or multiple bars, rolled members, or the like). The upper chord and the lower chord (and the joist seat) may each be formed from L-shaped members (e.g., otherwise described as angle members, or the like), such as a first member operatively coupled to a second member and spaced apart using a spacer. The upper chord may have an upright T-shape formed from the two L-shaped members, while the lower chord may have an upside-down T-shape formed from the two L-shaped members. Other joists may utilize rolled chords (e.g., having u-shapes, w-shapes, or the like shape), which are coupled to each other through one or more web members (e.g., one or more bars, rolled members, or the like) that are welded and/or fastened to the rolled chords. Instead of and/or in combination with the joists, beams (e.g., I-beams, H-beams, castellated beams, or other like beams) may be used as structural support members. The castellated beam may be an I-beam (or H-beam) that is formed, then separated (e.g., longitudinally along the length of the beam) and reassembled using welding such that apertures are located in the center of the beam.
While traditional joists and/or beams satisfy various needs during construction, there is a need for alternate types of structural support members. The present disclosure relates to an improved structural support member, in the form of a cold formed beam that may be formed from a single sheet of steel (e.g., rolled, bent, cut, pressed, stamped, or the like from a single sheet of steel in the desired profile). In particular embodiments, as will be discussed herein, the cold formed beam may include an upper member and a lower member (e.g., square, rectangular, other shape) separated by a web. The web may include stamped apertures that strengthen the web, reduce weight, and/or allow building components to pass through the stamped apertures. The cold formed beam may include beam connections that operatively couple the ends of the steel sheet used to form the beam to a portion of the beam (e.g., the web). The beam connections may include deformation of the metal layers (e.g., clinching, or the like), such as two or more layers of the sheet together without having to weld the beam. As such, forming the cold formed beam from a single sheet, stamping of the web, and/or using deformation connections (e.g., clinching, or the like) of the ends of the sheet allows for the pre-coating (e.g., galvanized, painting, or the like) of the sheet before the forming (e.g., rolling, or the like), before stamping, and/or before installing the beam connectors. As will be described in further detail herein, the structure of the cold formed beam of the present disclosure reduces the weight, increases the speed of manufacture, reduces the need for bridging (e.g., between traditional support members), reduces the time to install, improves installation of the decking to the cold formed beam, and/or improves assembly of other building components to the cold formed beam.
One embodiment of the present disclosure is a cold-formed beam comprising an upper member, a lower member, and a web between the upper member and the lower member. The upper member, the lower member, and the web are formed from forming a sheet.
In further accord with embodiments, the sheet is a single sheet that is rolled to form the upper member, the lower member, and the web.
In other embodiments, the upper member comprises an upper web flange that extends over at least a portion of the web.
In still other embodiments, the lower member comprises a lower web flange that extends over at least a portion of the web.
In yet other embodiments, the upper web flange is operatively coupled to the web and the lower web flange is operatively coupled to the web through the use of a plurality of beam connectors.
In other embodiments, the plurality of beam connectors comprise an interference connector formed by deforming a portion of the upper web flange and the web, and a portion of the lower web flange and the web.
In further accord with embodiments, the plurality of beam connectors comprise welding the upper web flange to the web and the lower web flange to the web, or assembling fasteners through the upper web flange and the web and the lower web flange and the web.
In other embodiments, the plurality of beam connectors are formed between a range of 2 inches to 24 inches along the length of the beam.
In still other embodiments, the upper member or the lower member comprises a square member or a rectangular member.
In yet other embodiments, the square member or the rectangular member comprises a first flange extending from the web, a second flange extending from the first flange, a third flange extending from the second flange, and a fourth flange extending from the third flange. Moreover, a web flange extends from the fourth flange over at least a portion of the web.
In other embodiments, the web comprises a plurality of stamped apertures extending through the web.
In further accord with embodiments, the plurality of stamped apertures comprise circular apertures.
In other embodiments, the plurality of stamped apertures comprise triangular apertures, square, or diamond apertures.
In still other embodiments, the plurality of stamped aperture comprise polygonal apertures.
In yet other embodiments, at least a portion of the web around the plurality of stamped apertures comprise at least one embossment.
In other embodiments, the upper member comprises and upper extension member on at least one end, wherein the upper extension member extends past the web.
In other embodiments, the beam further comprises at least one seat support operatively coupled to the at least one upper extension member.
Another embodiment of the present disclosure is a structural system comprising a plurality of support members and a plurality of cold formed beams. The plurality of cold-formed beams comprise an upper member, a lower member, and a web between the upper member and the lower member. The upper member, the lower member, and the web are formed from forming a sheet. The ends of the plurality of cold formed beams are operatively coupled to two of the plurality of support members.
In further accord with embodiments, the sheet is a single sheet that is rolled to form the upper member, the lower member, and the web.
Another embodiments of the present disclosure is method of forming a cold formed beam. The method comprises rolling a steel sheet to form an upper member, a lower member, and a web between the upper member and the lower member. The method further comprises stamping the web to form a plurality of apertures in the web. Moreover, the method comprises forming a plurality of beam connectors between an upper flange and the web and a lower flange and the web.
To the accomplishment of the foregoing and the related ends, the one or more embodiments of the invention comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings illustrate some of the embodiments of the invention and are not necessarily drawn to scale, wherein:
FIG. 1A illustrates a perspective view of a structural decking system utilizing a cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 1B illustrates a perspective view of a portion of a structural decking system that may utilize the cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 1C illustrates a side view of a portion of a roof system that may utilize the cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 1D illustrates a perspective view of a portion of roof system that may utilize the cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 2A illustrates a perspective view of a cold formed beam having square shaped upper and lower members, in accordance with embodiments of the present disclosure;
FIG. 2B illustrates an enlarged perspective view of an end of the cold formed beam of FIG. 2A, in accordance with embodiments of the present disclosure;
FIG. 2C illustrates an end view of the cold formed beam of FIG. 2A, in accordance with embodiments of the present disclosure;
FIG. 3A illustrates a perspective view of a cold formed beam having rectangular shaped upper and lower members, in accordance with embodiments of the present disclosure;
FIG. 3B illustrates an end view of the cold formed beam of FIG. 3A, in accordance with embodiments of the present disclosure;
FIG. 4A illustrates a perspective view of a cold formed beam having rectangular shaped upper and lower members with a rib, in accordance with embodiments of the present disclosure;
FIG. 4B illustrates an end view of the cold formed beam of FIG. 4B, in accordance with embodiments of the present disclosure;
FIG. 4C illustrates a perspective view of a cold formed beam having rectangular shaped upper and lower members with multiple ribs, in accordance with embodiments of the present disclosure;
FIG. 4D illustrates an end view of the cold formed beam of FIG. 4C, in accordance with embodiments of the present disclosure;
FIG. 5A illustrates a side view of an end a cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 5B illustrates an end view of the cold formed beam of FIG. 5A, in accordance with embodiments of the present disclosure;
FIG. 5C illustrates a cross-sectional view of the cold formed beam of FIG. 5B, in accordance with embodiments of the present disclosure;
FIG. 6A illustrates a side view of an end a cold formed beam operatively coupled to a girder support member, in accordance with embodiments of the present disclosure;
FIG. 6B illustrates a side view of two ends cold formed beams operatively coupled to a girder support member, in accordance with embodiments of the present disclosure;
FIG. 6C illustrates a side view of an end of a cold formed beam operatively coupled to a support member, in accordance with embodiments of the present disclosure;
FIG. 7A illustrates a perspective view of a cold formed beam with extension members extending from the upper member and bearing seats attached to the extension members, in accordance with embodiments of the present disclosure;
FIG. 7B illustrates a side view and a partial enlarged view of the cold formed beam of FIG. 7A, in accordance with embodiments of the present disclosure;
FIG. 7C illustrates an end view of the cold formed beam of FIG. 7A, in accordance with embodiments of the present disclosure;
FIG. 7D illustrates a perspective view of a cold formed beam with extended extension members extending from the upper member and a coped end with a bearing seat attached to the extension members, in accordance with embodiments of the present disclosure;
FIG. 7E illustrates a side view of the cold formed beam of FIG. 7D, in accordance with embodiments of the present disclosure;
FIG. 7F illustrates an end view of the cold formed beam of FIG. 7D, in accordance with embodiments of the present disclosure;
FIG. 8A illustrates a perspective view of a cold formed beam with beam connectors, in accordance with embodiments of the present disclosure;
FIG. 8B illustrates an end view of a cold formed beam with beam connectors, in accordance with embodiments of the present disclosure;
FIG. 9A illustrates a cross-sectional view of dies and layered sheets of a cold formed beam for forming a clinching beam connection in the cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 9B illustrates a cross-sectional view of a first die forming the clinching beam connection in layered sheets of the cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 9C further illustrates a cross-sectional view of a second rotating die for forming the clinching beam connection in layered sheets of the cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 9D further illustrates a cross-sectional view of the first die retracting from the clinching beam connection in the cold formed beam, in accordance with embodiments of the present disclosure;
FIG. 9E further illustrates a cross-sectional view of the cold formed beam and/or the dies moving to a different location of the cold formed beam to form another clinching beam connection, in accordance with embodiments of the present disclosure;
FIG. 10A illustrates an end view of cold formed beams with cross-bracing, in accordance with embodiments of the present disclosure;
FIG. 10B illustrates a side view of the cold formed beam with cross-bracing of FIG. 10A, in accordance with embodiments of the present disclosure;
FIG. 10C illustrates an end view of cold formed beams with cross-bracing, in accordance with embodiments of the present disclosure;
FIG. 10D illustrates a side view of the cold formed beam with cross-bracing of FIG. 10C, in accordance with embodiments of the present disclosure;
FIG. 10E illustrates an end view of cold formed beams with cross-bracing, in accordance with embodiments of the present disclosure;
FIG. 10F illustrates a side view of the cold formed beam with cross-bracing of FIG. 10E, in accordance with embodiments of the present disclosure;
FIG. 10G illustrates an end view of cold formed beams with cross-bracing, in accordance with embodiments of the present disclosure;
FIG. 10H illustrates a side view of the cold formed beam with cross-bracing of FIG. 10G, in accordance with embodiments of the present disclosure;
FIG. 10I illustrates an end view of cold formed beams with cross-bracing and bearing seats, in accordance with embodiments of the present disclosure;
FIG. 10J illustrates an end view of cold formed beams with cross-bracing, in accordance with embodiments of the present disclosure;
FIG. 10K illustrates a side view of the cold formed beam with cross-bracing of FIG. 10J, in accordance with embodiments of the present disclosure;
FIG. 10L illustrates an end view of cold formed beams with cross-bracing, in accordance with embodiments of the present disclosure;
FIG. 10M illustrates an end view of cold formed beams with cross-bracing, in accordance with embodiments of the present disclosure;
FIG. 11A illustrates a side view of an end a cold formed beam having a web with circular stamped apertures, in accordance with embodiments of the present disclosure;
FIG. 11B illustrates a side view of an end a cold formed beam having a web with polygonal stamped apertures, in accordance with embodiments of the present disclosure;
FIG. 11C illustrates a side view of an end a cold formed beam having a web with square stamped apertures, in accordance with embodiments of the present disclosure;
FIG. 11D illustrates a side view of an end a cold formed beam having a web with triangular stamped apertures in a back-to-back configuration, in accordance with embodiments of the present disclosure;
FIG. 11E illustrates a side view of an end a cold formed beam having a web with triangular stamped apertures in a clover configuration, in accordance with embodiments of the present disclosure; and
FIG. 12 illustrates a method of forming a cold-formed beam with stamped apertures, in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
Embodiments of the present invention now may be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure may satisfy applicable legal requirements. Like numbers refer to like elements throughout.
The present disclosure relates to an improved structural support member in the form of a cold formed-beam 100 that may be formed from a single sheet of steel (e.g., rolled from a single sheet of steel in the desired profile, or the like). In particular embodiments, as will be discussed herein, the cold formed beam 100 may include an upper member 120 and a lower member 140 (e.g., square, rectangular, other shape) separated by a web 160. The upper member 120 and the lower member 140 may otherwise be described as an upper chord 120 and a lower chord 140. The web 160 may include stamped web apertures 170 (otherwise described as punched, pressed, sheared, or the like apertures) that strengthen the web 160, reduce weight, and/or allow building components to pass through the web apertures 170. The cold formed beam 100 may include beam connectors 190 (otherwise described as beam connections) that operatively couple the ends of the sheet to a portion of the beam 100 (e.g., a portion of the web 160, a portion of the upper member 120, and/or the lower member 140). The beam connectors 190 may include interference connectors 192 (otherwise described as interference connections) formed by deforming two or more metal layers (e.g., clinching connections, punched, pressed, sheared, or the like connections) in which two or more layers of the sheet within the cold formed beam 100 are deformed together such that welding is not required. As such, the stamping of the web 160 to form the web apertures 170 and/or the deformed metal connections of the ends of the sheet that form the cold formed beam 100 allows for the pre-coating (e.g., galvanized, painting, or the like) of the sheet before forming (e.g., cold rolling, bending, stamping, or the like) and/or before installing the beam connectors 190. As will be described in further detail herein, the structure of the cold formed beam 100 of the present disclosure reduces the weight, increases the speed of manufacture, reduces the need for bridging (e.g., when compared to traditional structural support members, such as joists, or the like), reduces the time to install, improves installation of the decking (e.g., otherwise described as panels, decking panels, or the like) to the cold formed beam 100, and/or improves assembly of other building components.
As illustrated in FIGS. 1A and 1B, the cold formed beam 100 may be utilized in structural decking systems 1 (otherwise described as structural panel systems, structural decking panel systems, or the like). The structural decking system 1 of FIG. 1A comprises vertical support members 2 (e.g., steel beams, concrete columns, structural walls, concrete walls, other support members). In some embodiments, girder support members 4 (e.g., joist girders, or the like) may be operatively coupled between the vertical support members 2. The cold-formed beam 100 of the present disclose may be operatively coupled between the support members (e.g., vertical support members 2, girder support members 4, or the like). Thereafter, decking panels 70 are operatively coupled to the cold-formed beams 100, as will be described in further detail herein.
As illustrated in FIG. 1B, the decking panels 70 of the structural decking system 1 may be operatively coupled to the cold-formed beams 100 through the use of one or more decking connectors 90. It should be understood that the structural decking panels 70 may have profiles that include top flanges 74 (otherwise described as peaks, upper flanges, outer flanges, or the like), bottom flanges 76 (otherwise described as troughs, lower flanges, inner flanges, or the like), and panel webs 78 (e.g., the portions of the panel that are sloped, perpendicular, or generally perpendicular with the flanges 74, 76) that operatively couple the top flanges 74 to the bottom flanges 76. The combination of top and bottom flanges 74, 76, and the panel webs 78 create a flute for the decking panels 2 that may be described as profiles. The profiles may be referred to as “fluted profiles,” “hat profiles”, “flat-bottomed profiles”, “triangular profiles,” “trapezoidal profiles,” “dovetail profiles,” or other like profiles depending on the shape of the profiles. The distance from the top of the top flange 74 and the bottom of the bottom flange 76 may generally range from a ½ inch to 3, 3½, 4, 4½, 5, 5 1/2, or the like inches in depth; however, other ranges of depths within these ranges, overlapping these ranges, or outside of these ranges may be used in the profiles. For example, in some embodiments the distance may range from ½ inch to 12 inches in depth, or the like. The decking panels 70 may or may not include longitudinal ribs, bends, or cutouts that impact the moment of inertia and section modulus of the decking panels 70 (e.g., profile dimensions, ribs, cutouts, or the like that are used to target different performance characteristics, such as but not limited to strength and/or stiffness). Depending on the material thickness, the length and width of the decking panels 70, and the height of the top flanges 74 and bottom flanges 76, the decking panels 70 may weigh between 100 and 420 lbs. In other embodiments, the weight of the decking panels 70 may be within, overlap, or be located outside of this range. Each decking panel 70 may be formed (e.g., roll-formed, or the like) into the desired profile.
Decking edges 79 (e.g., the opposite longer sides of the structural decking panel 70) may be formed into lips that couple a first decking panel 70 to an adjacent second decking panel 70. The lips on opposite edges 79 of a decking panel 70 may create sidelaps between the decking panels 70. The sidelaps may be overlapping in-plane sidelaps, out of plane sidelap seams (e.g., male and female standing lips that create a standing sidelap seam), in-plane nested sidelaps, or the like. The sidelaps may have two, three, four, or more layers, or the like. Decking connectors 90 (connectors may also be described herein as joints, connections, attachments, couplings, or the like) may be formed in the sidelap of the structural decking panels 70 to couple adjacent decking panels 70 to each other. The decking connectors 90 may be fasteners (e.g., bolts, rivets, screws, or the like), welds (e.g., top sidelap welds, side sidelap welds, or the like), interference connections (e.g., clenched cut, sheared, punched, deformed, or the like) in which two of the layers of the edges 79 of adjacent decking panels 70 are deformed, or the like as discussed herein.
In order to couple two adjacent structural decking panels 70 together, a first edge 79 of a first structural decking panel 70 may receive a second edge 79 of a second structural decking panel 70. The first edge 79 may be placed over the second edge 79 to create an un-joined sidelap along the length of adjacent structural decking panel edges 79. The purpose of the sidelap formed after using the connector 90 (e.g., utilizing a fastener, interference clench connection, weld, or the like) is to couple two adjacent structural decking panels 70 securely to each other in order to prevent one decking panel 70 from separating transversely from another decking panel 70 (e.g., lifting vertically off another panel in a horizontal roof or floor installation), preventing in-plane movement (e.g., shifting of the panels 70 along the sidelap) between the adjacent structural panels 70, and providing the desired shear strength of the structural decking system 1.
The structural decking panels 70 may be secured to the cold-formed beams 100, after the decking panels 70 have been placed over the cold-formed beams 100, through one or more connectors 90 as previously discussed herein. In some embodiments, it should be understood that connectors 90 may be one or more fasteners (e.g., bolts, rivets, screws, stand-off fasteners, anchors, or the like) that operatively couple the decking 70 to the upper member 120 of the cold formed beams 100 (e.g., upper member connectors). For example, a fastener may extend through the decking 70 (e.g., bottom flange 76 of the decking) and to the upper member 120 of the cold formed beam 100. Concreate 98 may be placed over the decking panels 70 to create a floor or roof.
FIGS. 1C and 1D illustrate another type of decking system, such as a roof decking system 10 (e.g., standing seam roof systems, or the like). Roof decking systems 10 may be utilized in new construction and/or as retrofitting on current roofs of structures (e.g., buildings, or the like). The roof systems 10 may utilize decking panels 70 that are operatively coupled to beams, such as the cold formed beam 100 described herein, or to purlins that are operatively coupled to beams. The beams may be operatively coupled to beam girders 4, or directly to vertical support members 2. The decking panels 70 are typically operatively coupled to the support members (e.g., beams, or the like) through the use of seam clips 30, as illustrated in Figure 1C, or through seam clips 30 and a bridge member 40, as illustrated in FIG. 1D.
The seam clips 30 may be installed to the support member (e.g., purlin 6, cold formed beam 100, or the like) directly, or through the use of another member 40 (e.g., a bridge member, or other member). The seam clips 30 may comprise a base clip portion and a connector clip portion. The base clip portion and the connector clip portion may move with respect to each other in order to allow the connector clip portion to move with the decking panels 70 as the base clip portion stays static with the support members. As such, the seam clips 30 allow the roof panels to move due to thermal expansion and contraction. The decking panels 70 of the roof systems 10 may be thinner and/or have different profiles than the structural decking panels 70 described with respect to the structural decking systems 1 of FIGS. 1A and 1B. In the roof systems 10, the decking panel edges 79 may be operatively coupled to each other by placing a portion of a folded edge of one panel under an edge of the panel clips 30, and by placing a folded edge of an adjacent panel over the clip 30 and/or by placing a folded portion of the edge of one panel over the edge of another panel where the clips 30 are not located. Then the edges of the panels 70 and/or the clips 30 (e.g., edge of connector clip portion) where the clips 30 are located are seamed together. The seeming of the edges of the panels 70 (including the clips 30) may create a watertight seam (or water-resistant seam) in order to resist the flow of water between panels 70. As such, in some embodiments, portions of the edges 79 of the panels 70 and/or the clips 30 (e.g., connector clip portion edges) are further folded, bent, and/or sheared (e.g., cut, or the like) together in order to operatively couple the panels 70 and the clips 30 to each other. In other embodiments, other connectors may be utilized to operatively couple the adjacent panels edges 79 to each other and/or to the clips 30. In some embodiments, the seam clips 30 and/or the bridging members 50 may provide space for insulation 50 for the roof systems 10.
Alternatively, or additionally, structures may utilize other framing systems (not illustrated), that may utilize wood or other materials for distributing loads throughout the structure. Regardless of the type of structure (e.g., structural decking systems, roof deck systems, standing seam roofing, wooden framing systems, or the like), these structures utilize conventional joists (e.g., chords and/or open webs) and/or beams (e.g., beams that are formed from separate members, such as upper members, lower members, and webs that are formed separately, or from I-beams or H-beams that are spliced and rejoined, machined, or the like to form a beam with apertures therein). Unlike conventional structural support members, the structural support members of present disclosure, as will be described herein, may be formed from a single sheet of steel (e.g., roll forming, or the like) and the edges of the steel sheet are operatively coupled using beam connectors 190, as will be described in further detail herein. Moreover, web apertures 170 are stamped into the webs 160 of the cold formed beams 100 to reduce the weight, provide additional structural strength, and/or allow for building components (e.g., HVAC ducts, pipes, electrical wiring, networking wires, or the like) to extend through the apertures 170.
FIGS. 2A through 4D illustrate embodiments of the cold formed beam 100 of the of the present disclosure. As illustrated, the cold formed beam 100 may comprise an upper member 120, a lower member 140, and a web 160 formed between the upper member 120 and the lower member 140. As previously described herein, the upper member 120, the lower member 140 and the web 160 may be formed by rolling a single sheet of steel into the cold formed beam 100. For example, a first portion of the steel sheet adjacent a first edge of the steel sheet may become the upper member 120, while a second portion of the steel sheet adjacent a second edge of the steel sheet may become the second member 140. Moreover, a central portion of the steel sheet may become the web 160 of the cold formed beam 100. The cold formed beam 100 may have a first end 102 and a second send 104, which are used to operatively couple the cold formed beam 100 to other structural support members. In some embodiments, as will be described in further detail herein, the first end 102 and/or second end 104 of the cold formed beam 100 may have stiffeners 200, brackets 250, an attachment assembly 40, and/or the like for operatively coupling with other structural support members.
The cold formed beam 100 may have a length of 20, 25, 30, 35, 40, 45, 50, 55, 60, or the like feet. Generally, the cold formed beam 100 may range from 30 to 45 feet in length; however, it should be understood that the length of the cold-formed beam 100 may be less than or greater than the values described above, and as such may range in a length that overlaps, falls between, or falls outside of any of the values described above. Furthermore, the depth (or height) of the cold-formed beam 100 may be 10, 12, 14, 15, 16, 18, 20, 22, 24, 25, 26, 28, 30, 32, 34, 35, 36, 38, 40, or the like inches. Generally, the cold-formed beam 100 may have a depth that ranges from 20 to 30 inches; however, it should be understood that the depth of the cold-formed beam 100 may be less than or greater than the values described above, and as such may have a depth that overlaps, falls between, or falls outside of any of the values described above.
In particular embodiments, the cold formed beam 100 may be formed from a single sheet coil that ranges between 36 to 60 inches wide and/or has an average thickness of 0.089, 0.099, 0.105, 0.120, 0.125, or the like inches. Moreover, the steel sheet used to form the cold formed beam 100, and thus a single layer of the cold formed beam 100, may have a thickness of 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.20, or the like inches. Generally, the sheet used to form the cold-formed beam 100, and thus a single layer of the cold formed beam 100, may have a thickness that ranges from 0.06 to 0.125 inches; however, it should be understood that the thickness of a single layer of the cold-formed beam 100 may be less than or greater than the values described above, and as such may range in a thickness that overlaps, falls between, or falls outside of any of the values described above. Moreover, portions of the beam 100, such as at the locations of the beam connectors 190, may be formed of two or more layers of the steel sheet, and thus, may comprise two or more layers of the steel sheet, and thus, may have a thickness that is two or more times the thickness of the steel sheet.
As illustrated in FIGS. 2C, 3B, 4B, and 4D, the upper member 120 may be formed from a first upper flange 122 extending from the web 160 (e.g., generally perpendicular to the web 160); a second upper flange 123 extending from the first upper flange 122 (e.g., generally perpendicular to the first upper flange 122 and/or parallel with the web 160); a third upper flange 124 extending from the second upper flange 123 (e.g., generally perpendicular to the second upper flange 123 and/or the web 160); a fourth upper flange 125 extending from the third upper flange 124 (e.g., generally perpendicular to the third upper flange 124 and/or parallel with the web 160); a fifth upper flange 126 extending from the fourth upper flange 125 (e.g., generally perpendicular to the fourth upper flange 125 and/or the web 160); and an upper web flange 128 extending from the fifth upper flange 126 (e.g., generally perpendicular to the fifth upper flange 126 and/or parallel with the web 160). As such, the upper member 120 may comprise of a square and/or rectangular shaped member that is formed from a first portion of the steel sheet (e.g., adjacent a first edge of the steel sheet). Moreover, the upper web flange 128 may be operatively coupled to the web 160 using beam connectors 190, as will be described in further detail herein, in order to secure the portion of the steel sheet adjacent the first edge to the cold formed beam 100.
As further illustrated in FIGS. 2C, 3B, 4B, and 4D, the lower member 140, lower member 140 may be formed from a first lower flange 142 extending from the web 160 (e.g., generally perpendicular to the web 160); a second lower flange 143 extending from the first lower flange 142 (e.g., generally perpendicular to the first lower flange 142 and/or parallel with the web 160); a third lower flange 144 extending from the second lower flange 143 (e.g., generally perpendicular to the second lower flange 143 and/or the web 160); a fourth lower flange 145 extending from the third lower flange 144 (e.g., generally perpendicular to the third lower flange 144 and/or parallel with the web 160); a fifth lower flange 146 extending from the fourth lower flange 145 (e.g., generally perpendicular to the fourth lower flange 145 and/or the web 160); and a lower web flange 148 extending from the fifth lower flange 146 (e.g., generally perpendicular to the fifth lower flange 146 and/or parallel with the web 160). As such, the lower member 140, like the upper member 120, may comprise of a square and/or rectangular shaped member that is formed from a second portion of the steel sheet (e.g., adjacent a first edge of the steel sheet). Moreover, the lower web flange 148 may be operatively coupled to the web 160 using beam connectors 190, as will be described in further detail herein, in order to secure the portion of the steel sheet adjacent the second edge to the cold formed beam 100.
In some embodiments, the upper member 120 and the lower member 140 have a height of 1, 1.5, 2.0, 2.5, 3, 3.5, 4.0, 4.5, 5, or the like inches, and a width of 2.0, 2.5, 3, 3.5, 4.0, 4.5, 5, 5.5, 6, or the like inches. In some embodiments, the upper member 120 and the lower member 140 may have heights of 3 inches and a widths of 4 inches. In some embodiments, the upper member 120 and the lower member 140 may have heights of 3 inches and a widths of 5 inches. The dimensions of the upper member 120 and the lower member 140 may be the same or different from each other. Moreover, it should be understood that the web flanges 128, 148 may have lengths of 1, 1.5, 2.0, 2.5, 3, 3.5, 4.0, 4.5, 5 or the like inches, which may be the same or different from each other. In some embodiments, the web flanges 128, 148 may have lengths of 2.375 inches. It should be understood that the upper member 120 and/or the lower member 140 (including the individual flanges thereof) may have dimensions that may be less than or greater than the values described above, and as such may have ranges of dimensions that overlap, fall between, or fall outside of any of the values described above.
While the upper member 120 and the lower member 140 may be illustrated as four-sided members (e.g., generally square, rectangular, or the like), it should be understood that the members may have different shapes, such as triangular (e.g., an inverted upper triangle, lower triangle, or the like), any polygonal shape (e.g., 5, 6, 7, 8, 9 sided) shape, T-shape, uniform shape, non-uniform shape, or other like shape. In some embodiments at least a portion of the sheet may be folded back upon itself to create a flange with two or more layers (e.g., three or more layers at the web flanges 128, 148). In some embodiments at least a portion of the upper member 120 may require an upper flange (e.g., illustrated as the third flange 124) that may be parallel with a lower flute 76 of the decking 70 such that the decking connectors 90 may be used to operatively couple the decking panels 70 to the cold-formed beam 100 (e.g., through the lower flute 76 and the upper flange of the upper member 120).
Moreover, as illustrated in FIGS. 4A through 4D, the upper member 120 and/or the lower member 140 may have chord embossments (e.g., chord ribs, grooves, cuts, punches, louvers, apertures, or the like). As such, one or more flanges of the upper member 120 and/or the lower member 140 may include one or more structural chord embossments (e.g., structural chord ribs, grooves, embossments, cuts, punches, louvers, apertures, or the like) that may provide additional structural strength for the upper member 120 and/or lower member 140, and thus, the cold formed beam 100. In the illustrated embodiments, the structural chord embossments are illustrated as one or more chord ribs 180, such as one or more upper flange chord ribs 182 and/or one or more lower flange chord ribs 184. While the one or more upper flange chord ribs 182 and/or lower flange chord ribs 184 are illustrated as being located on the outer flanges and/or side flanges, it should be understood that the one or more chord ribs 180 may be located on the flanges of the upper member 120 and lower member 140 adjacent the web 160. Furthermore, while the chord ribs 180 are illustrated as v-shaped chord ribs 180, it should be understood that the chord ribs 180 may be any type of shape, such as u-shaped, y-shaped, c-shaped, or other like shaped ribs. Moreover, instead of the chord ribs 180 extending inwardly, the chord ribs 180 may extend outwardly, although inwardly extending upper chord ribs 182 on the upper flange 124 may be preferred due to the decking panels 70 and/or other components being located on top of the upper member 120. Furthermore, inwardly extending chord ribs 180 may be preferred in the upper member 120 and/or the lower member 140 due to attachment of other components to the side flanges of the upper member 120 and/or the lower member 140. Additionally, while the chord ribs 180 are illustrated as being continuous along the length of the upper member 120 and/or lower member 140, the chord ribs 180 may be discontinuous and only extend over a portion (e.g., uniformly or non-uniformly) of the length, width, and/or height of the upper member 120 and/or the lower member 140 (e.g., in any orientation). Finally, while the embossments are illustrated chord ribs 180, as discussed above, other embossments may replace the chord ribs 180 and/or be utilized along with the chord ribs 180.
As further illustrated in FIGS. 2A through 4D, the web 160 may include a plurality of web apertures 170. The plurality of web apertures 170 may be formed in the steel sheet before forming the upper member 120 and/or the lower member 140, and/or may be formed in the web 160 during or after the forming of the upper member 120 and/or the lower member 140. As illustrated in FIGS. 2A through 4D, at least a portion of the web 160 around the plurality of web apertures 170 may have at least one web embossment 172 (or may have a web embossment 172 that extends around the entirety of the web apertures 170). As such, at least a portion of the web embossment 172 may end in a lip 174 that defines the web apertures 170. The one or more web embossments 172 may provide additional structural support to the web 160. While FIGS. 2A through 4D illustrate a single web embossment 170, as illustrated in FIGS. 10A through 10E, and as will be described in further detail herein, in some embodiments multiple web embossments 172 may be formed in the web 160 around at least a portion of the web apertures 170, which may provide additional structural strength for the web 160, and thus, the cold formed beam 100. The multiple web embossments 170 may be progressive web embossments 172, such that each progressive embossment 172 is further away from the plane of the web 160.
In some embodiments, the plurality of apertures 170 may have an opening that is 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 24, 26, 28, 30, 35, 40, or the like inches in height, width, diagonal, and/or diameter. Generally, the plurality of web apertures 170 have a diameter of 8, 9, 10, 12, 14, 16, 18, 20, or the like inches; however, it should be understood that the plurality of web apertures 170 may have dimensions that may be less than or greater than the values described above, and as such, may have a range that overlaps, falls between, or falls outside of any of the values described above.
The plurality of web apertures 170 (e.g., a center of a web aperture, a center point within a group of two or more apertures 170 as illustrated in FIGS. 11D or 11E, or the like) within the web 160 may be spaced every 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 32, 36, 48, 60, or the like inches (e.g., center-to-center). Generally, the plurality of web apertures 170 are spaced 15, 20, or 30 inches (e.g., on center) apart; however, it should be understood that the spacing of the plurality of web apertures 170 may be less than or greater than the values described above, and as such may have a range that overlaps, falls between, or falls outside of any of the values described above. The plurality of web apertures 170 reduce the weight, provide additional structural strength, and/or allow for budling components (e.g., HVAC ducts, pipes, electrical wiring, networking wires, or the like) to extend through the apertures 170.
As further illustrated in FIGS. 5A through 5C, one or more stiffeners 200 may be utilized to provide additional structural strength to the cold-formed beam 100 and/or provide a location adjacent the ends (e.g., at or near the ends 102, 104) of the cold formed beam 100 in order to provide a location for operatively coupling the cold formed beam 100 to other support members of the decking systems described herein. In other embodiments, the stiffeners 200 may be located between adjacent web apertures 170 and/or extend at least partially over a web aperture 170 (e.g., on the flat side of the web 160, or the like). In some embodiments, the stiffener 200 may be a rectangular stiffener as illustrated in the cross-sectional view in FIG. 5C. However, it should be understood that the stiffener 200 may be any type of stiffener 200 having any shape, such as square, circular, oval, triangular, any polygonal shape, I-shaped, H-shaped, T-shaped, uniform, non-uniform, hollow, solid, or the like. As Illustrated in FIGS. 6A and 6B, the stiffeners 200 may be one or more end stiffeners 210. The end stiffeners 210 may include first end stiffeners 212, such as two first end stiffeners located on each side adjacent the first end 102 of the cold formed beam 100. Moreover, the end stiffeners 210 may be one or more second end stiffeners 214, such as two second end stiffeners 214 located on each side adjacent the second end 104 of the cold formed beam 100.
The one or more stiffeners 200 may be utilized to provide additional strength to the cold-formed beam 100; however, additionally or alternatively, it should be understood that the one or more stiffeners 200 may be used to provide a location for operatively coupling the cold-formed beam 100 to another support member (e.g., a vertical support member, horizontal support member, or the like). For example, as illustrated in FIGS. 6A and 6B, the cold formed beam 100 may utilize a bracket 250 (e.g., hanger bracket, or the like) that may be used to operatively couple the cold-formed beam 100 to another support member (e.g., illustrated in FIGS. 6A and 6B as an I-beam). In some embodiments, the hanger bracket 252 may extend around the lower member 140, around at least a portion of the end stiffeners 210, such as the one or more first end stiffeners 212 or second end stiffeners 214. The hanger bracket 252 may comprise a base hanger flange 254 that extends around the lower flange of the lower member 140. The base flange 254 may be operatively coupled to side hanger flanges 256, 258 that extend around the side flanges of the lower member 140 and/or the one or more end stiffeners 200. The side hanger flanges 256, 258 may be operatively coupled to a support hanger flange 260. The support hanger flange 260 may extend over the support member, as illustrated in FIGS. 6A and 6B. In other embodiments (not illustrated), the side hanger flanges 256, 258 may be operatively coupled to a flange of the upper members 120. It should be understood that the base flange 254 and/or the side hanger flanges 256, 258 may be operatively coupled to the lower member 140, the end stiffeners 210, and/or the upper member 120 through the use of bracket connectors 290 (e.g., welds, deformation the metal layers, fasteners, such as bolts and nuts, screws, self-drilling screws, rivets, or the like). Moreover, the support hanger flange 260 may also be operatively coupled to the support member using bracket connectors 290.
In some embodiments, two adjacent cold-formed beams 100 may be operatively coupled to a support member and/or each other, as illustrated in FIG. 6B. For example, a first cold-formed beam 106 may be operatively coupled to the support member through the use of first ends stiffeners 212 and a first hanger bracket 262, while a second cold-formed beam 108 may be operatively coupled the support member adjacent the first cold formed beam 106 through the use of second end stiffeners 214 and a second hanger bracket 264. Moreover, the first cold formed beam 106 and the second cold-formed beam 108 may be operatively coupled together through the use of a tie bracket 270. For example, the upper member 120 (e.g., the first upper member) of the first cold formed beam 106 may be operatively coupled to the upper member 120 (e.g., second upper member) of the second cold formed beam 108 through the use of the tie bracket 270. The tic bracket 270 may have any type of shape that has channel having a web 272 and one or more flanges 274. The tie bracket 270 may have any type of shape, such a U-shape, C-shape, hat-shape, or other like shape. The channel of the tie bracket 270 may extend around the first upper member 120 of the first cold formed beam 106 and the second upper member 120 of the second cold formed beam 108. The tic bracket 270 may be operatively coupled to the first upper member 120 and the second upper member 120 through the use of bracket connectors 290 (e.g., tie bracket connectors).
FIG. 6C illustrates an alternate embodiment of the stiffener 200 and/or the bracket 250. As illustrated in FIG. 6C, in some embodiments the stiffener 200 may be a stiffener bracket 220, such as L-shaped stiffener bracket 222. The stiffener bracket 200 may be utilized to provide additional strength to cold-formed beam 100, as well as to allow for operatively coupling with another support member. It should be understood that any type of traditional or non-traditional connection may be used between the cold-formed beam 100 and an adjacent support member, such as, but not limited to any framed or seated connection, such as any shear stiffener attachment, bearing, or the like, as will be described in further detail herein.
It should be understood that the one or more stiffeners 200, the one or more stiffener brackets 220, the one or more hanger brackets 250, and/or the one or more tie brackets 270 may have one or more stiffener and/or bracket embossments that are the same as or similar to the one or more chord embossments previously discussed herein. As such, these components may be configured to nest, or otherwise be operatively coupled to, the embossments within the adjacent upper members 120.
In some embodiments, the cold-formed beam 100 may be operatively coupled to other support members through the use of one more mounting apertures, such as one or more web mounting apertures 162 located in the web 160 adjacent the first end 102 and/or second end 104 of the cold-formed beam 100, as illustrated in FIGS. 3A, 4A, and/or 4C. It should be understood that the one or more web mounting apertures 162 may have any type of pattern, such as, one or more columns and/or rows of apertures having 1, 2, 3, 4, 5, 6, 7, 8, or the like apertures in a column and/or row depending on the size of the cold-formed beam 100. In the illustrated embodiment, the web mounting apertures 162 include two columns of apertures located in the same plane (i.e., not offset), each column including three web mounting apertures 162. In other embodiments (not illustrated), each of the two columns may include four, five, or six web mounting apertures 162 in each column.
In other embodiments, the cold formed beam 100 may have a first end 102 and/or a second 104 in which the upper member 120 and/or the lower member 140 extends past the web 160 of the cold-formed beam 100. As such, the first end 102 and/or the second end 104 may have an upper member 120 and/or a lower member 120 that has an overhanging portion and/or web 160 having a recessed portion. As illustrated in FIGS. 7A through 7F, the overhanging portion of the upper member 120 may be described and illustrated as one or more upper extension members 130, such as a first upper extension member 132 and a second upper extension member 134. The upper extension members 130 may have the same or different shape as the rest of the upper member 120 (or lower member 140 with respect to a lower extension member). However, in the illustrated embodiments the upper extension members 130 may have the same shape as the upper member 120. In some embodiments, the upper extension member 130 may further comprise an extension web 164 comprising a web flange 166, a web transition 168 from the web 160 to the web flange 166, and/or an upper extension member flange 138 (e.g., that may be the same as or different than the upper web flange 128). The web transition 168 may comprise a radius web transition (otherwise described as coped web transition) that extends into the extension web 164. The radiused web transition 168 between the web 160 on the first end 102 and second end 104 of the cold-formed beam 100 and into the extension web 164 may improve the structural support between the upper member 120 and the web 160 and/or reduce the chance for defects located between the upper extension members 130, the web extensions 164, the upper member 120 and/or the web 160.
The upper extension members 130 may be configured for operative coupling with a support seat 400 (otherwise described as a bearing seat, beam seat, or the like). The support seat 400 may comprise a seat bracket 410 (otherwise described as a bearing seat bracket, or the like) having any type of shape and/or configuration. In some embodiments, as illustrated in FIGS. 7A and 7B, the cold-formed beam 100 comprises a first seat bracket 412 on a first end 102 and a second seat bracket 414 on a second end 104. In the illustrated embodiments, the seat bracket 410 is formed from one or more seat members 420, such as a first seat member 422 and a second seat member 424. The seat members 420 may be L-shaped members (otherwise described as angle members), which may be operatively coupled to the web 160 and/or upper members 120, such as through the upper extension member 130 and/or the extension web 164 thereof. For example, the seat bracket 410 (e.g., the members 420, such as L-shaped members, or the like) may comprise one or more seat apertures 428 through which seat connectors 430 (e.g., welds, clips, clamps, fasteners, such as bolts 432, nuts 434, screws, self-drilling fasteners, rivets, pins, or other like fasteners, or other like connectors) are used to operatively couple the seat bracket 410 to the upper member 120 (e.g., through the web 160 and/or upper web flange 128) and/or the upper member extension 130 thereof (e.g., through the extension web 164, such as the web flange 166 and/or upper extension member flange 138). As such, in the illustrated embodiments, the upper portions of the two L-shaped members 412, 414 (e.g., vertical portions) are operatively coupled to the extension web 164, and the lower portions of the two L-shaped members 412, 414 (e.g., horizontal portions) are configured for operative coupling with another support member (e.g., upper portion of an I-beam, or the like). It should be understood that in some embodiments the end of the seat bracket 410 and the end of the upper extension member 130 may be in-line with each other (e.g., in the same plane). However, in some embodiments, end of the seat bracket 410 may extend past the end of the upper extension member 130. In still other embodiments, as illustrated in FIGS. 7C and 7D, the end of the upper extension member 130 may extend past the end of the seat bracket 410. The end of the upper extension members 130 may be utilized to support the caves of the roof (e.g., which may run perpendicular to the cold-formed beams 100).
Regardless of the alignment and/or connection of the seat bracket 410 and the extension member 130 and/or cold-formed beam 100 thereof, it should be understood that the support seat 400, such as the seat bracket 410, may be any type of shape made up of one or more seat members 420. For example, the seat support 400 (e.g., the seat bracket 410) and/or the seat members 412, 414 thereof, may be V-shaped, C-shaped, u-shaped, n-shaped, w-shaped, x-shaped, y-shaped, z-shaped, hat-shaped, or the like shaped.
FIGS. 8A and 8B illustrate the cold formed beam 100 with the beam connectors 190. As previously discussed herein, the beam connectors 190 operatively couple the upper web flange 128 to the web 160 and/or the lower web flange 148 to the web 160 of the cold formed beam 100. In some embodiments, the beam connectors 190 may comprise welds, fasteners, interference connections (e.g., deformed metal connectors as previously described herein), or the like connections. The beam connectors 190 may be located any distance apart; however, in some embodiments the beam connectors 190 may be spaced apart 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 15, 20, 24 inches, or the like. Alternatively, the beam connectors 190 may be spaced apart at a range of 2 to 10 inches, and in particular 4 to 8 inches. However, it should be understood that the beam connectors 190 may be spaced apart a range between, overlapping, or outside of any of the values discussed above.
As previously discussed, the beam connectors 190 may be formed through interference connectors by deforming the metal layer of the web flanges 128, 148 and/or the upper extension member flange 138, and the web 160. FIGS. 9A through 9E illustrate one embodiment, wherein one or more dies 310 are used to deform the metal layers to create an example interference connection. In particular, FIGS. 9A through 9E illustrate a cross-sectional view of the dies 310 and metal layers that are being deformed in order to form the beam connectors 190. The dies illustrated in FIGS. 9A through 9E, are used to form a circular clinched interference connection; however, it should be understood that the interference connection may be any size and shape (e.g., generally square, rectangular, triangular, any polygonal, or other like shape).
In some embodiments, the clinching system 300 illustrated in FIGS. 9A through 9E may utilize one or more dies 310, such as a first die set 320 and a second die set 330. In some embodiments the first die set 320 may include a first actuating die 322 and a first stationary die 322. Moreover, the second die set 330 may include a second stationary die 332 and one or more second moving dies 334 (e.g., one or more rotating dies). As illustrated in FIG. 9A, the two or more metal layers, such as the upper web flange 128 or lower web flange 148 and the web 160 may be located between the first die set 320 and the second die set 330. As illustrated in FIG. 9B, the first die set 320 and/or the second die set 330 may move closer to each other, and the first actuating die 322 of the first die set 320 may extend to deform at least a portion of the upper web flange 128 layer or the lower web flange 148 layer (or the upper extension member flange 138) and the web 160 layer into a second die cavity formed in the second die set 330 (e.g., formed by the second stationary die 332 and the one or more second moving dies 334). As illustrated in FIG. 9C as the first actuating die 322 deforms the upper web flange 128 layer or the lower web flange 148 (or the upper extension member flange 138) and the web 160 layer, the one or more second moving dies 334 (e.g., one or more rotating dies) move outwardly (e.g., rotate, or the like) such that the upper web flange 128 layer and the lower web flange 148 (or the upper extension member flange 138) are pushed outwardly to form the circular clinching connection. Thereafter, as illustrated in FIG. 9D, the first actuating die 322 is retracted. Moreover, the first die set 320 and/or the second die set 330 are moved away from each other and/or the formed interference connector 192 (e.g., the clinch connection). Furthermore, as illustrated in FIG. 9E, the second moving die 334 is moved back into place, and the opposing die sets 320, 330 and/or the metal layers are moved into another position in order to form another clinching connection 192.
As previously discussed, the interference connector 192 (e.g., the clinched connection) may be illustrated as a circular clinched connection; however, the clinched connection may be another type of shape, such as rectangular, square, triangular, any polygonal shape, or any other shape. Moreover, while the interference connector 192 is illustrated as being deformed, it should be further understood that a connection aperture (e.g., punch, cut, sheared, or the like aperture) may be formed in the interference connector 192. Furthermore, as previously discussed herein, instead of using an interference connector 192, other types of beam connectors 190 may be used to operatively couple the layers of the beam (e.g., fasteners, or the like)
FIGS. 10A through 10M illustrate different types of cross-bracing systems 350 having different types of cross-bracing 360 that may be used between adjacent cold-form beams 100 in a roof and/or floor system. As illustrated in FIGS. 10A and 10B, the cross-bracing system 350 may comprise one or more lower horizontal cross-braces 362 that operatively couple a first lower member 140 of a first cold-formed beam 100 and a second lower member 140 of a second cold-formed beam 100. It should be understood that in some embodiments, the one or more lower horizontal cross-braces 362 may operatively couple more than two cold-formed beams 100 (e.g., 3, 4, 5, 6, or the like cold-formed beams 100). In the illustrated embodiment, the one or more lower horizontal cross-braces 362 may be operatively coupled to lower members 140 at the third lower flange 144 (e.g., outer flanges of the lower members 140). It should be understood that the cross-bracing 360 of the cross-bracing system 350 may be operatively coupled to the lower and/or upper members 120, 140 through the use of bracing connectors 370 (e.g., fasteners, such as bolts, nuts, screws, self-drilling fasteners, powder driven fasteners, pins, rivets, or the like, welds, interference connections, or the like). In some embodiments, the bracing connectors 370 may be operatively coupled through the use of bracing apertures 380, located in the upper and lower members 120, 140 and/or the bracing members 360.
As illustrated in FIGS. 10C and 10D, the cross-bracing system 350 may comprise one or more lower horizontal cross-braces 362 and one or more upper horizontal cross-braces 364. The one or more lower horizontal cross-braces 362 may operatively couple a first lower member 140 of a first cold-formed beam 100 and a second lower member 140 of a second cold-formed beam 100. Alternatively, or additionally, the one or more upper horizontal cross-braces 364 may operatively couple a first upper member 120 of the first cold-formed beam 100 and a second upper member 120 of the second cold-formed beam 100. In the illustrated embodiments, the one or more lower horizontal cross-braces 362 are operatively coupled between the first lower member 140 and the second lower member 140 using a second lower flange 143 (e.g., side flange) and a fourth lower flange 145 (e.g., side flange) of the lower members 140, respectively (e.g., side flanges). Moreover, in the illustrated embodiments, the one or more upper horizontal cross-braces 364 are operatively coupled between the first upper member 120 and the second upper member 120 using a second upper flange 123 (e.g., side flange) and a fourth upper flange 125 (e.g., side flange) of the upper members 120, respectively. It should be understood that the cross-bracing 360 of the cross-bracing system 350 may be operatively coupled to the lower and/or upper members 120, 130 in the same or similar way as described above with respect to FIGS. 10A and 10B (e.g., bracing connectors 370 and/or bracing apertures 380).
FIGS. 10E and 10F illustrate that the cross-bracing system 350 may comprise one or more diagonal cross-braces 366. The one or more diagonal cross-braces 366 may operatively couple a first lower member 140 of a first cold-formed beam 100 to a second upper member 120 of a second cold-formed beam 100. Additionally, or alternatively, the one or more diagonal cross-braces 366 operatively couples a first upper member 120 of the first cold-formed beam 100 and a second lower member 140 of the second cold-formed beam 100. Furthermore, as illustrated in FIG. 10F, the two-diagonal cross-braces 366 may be operatively coupled to each other at a location at which the two-diagonal cross-braces 366 cross (e.g., back-to-back L-shaped members, or the like). In the illustrated embodiments, the two-diagonal cross-braces 366 are operatively coupled between the side flanges of the upper and lower members 120, 140, as previously discussed herein. Furthermore, as illustrated in FIGS. 10E and 10F, one or more lower cross-braces 362 may also be used between two or more adjacent lower cross-braces 362, as previously discussed with respect to FIGS. 10A and 10B.
Moreover, FIGS. 10G and 10H, further illustrate that the cross-bracing system 350 may utilize both upper and lower cross-bracing 362, 364 and diagonal cross-bracing 366, as previously discussed with respect to FIGS. 10C and 10D, and FIGS. 10E and 10F. In this configuration, the upper members 120 and the lower members 140 may each have three bracing apertures 380, to allow for the connection of the upper and lower cross-bracing 362, 364 and diagonal cross-bracing 366 between the upper and lower members 120, 140, as illustrated in FIG. 10H (e.g., to allow any cold-form beam 100 to be connected using any of the cross-bracing systems 350).
FIG. 10I illustrates cross-bracing similar to FIG. 10A. As such, the cross-bracing system 350 may comprise one or more lower horizontal cross-braces 362 that operatively couple a first lower member 140 of a first cold-formed beam 100 and a second lower member 140 of a second cold-formed beam 100. In the illustrated embodiment, the one or more lower horizontal cross-braces 362 may be operatively coupled to lower members 140 at the first lower flange 142 and/or fifth lower flange 146 (e.g., one or more lower inner flanges of the lower members 140).
FIGS. 10J and 10K illustrate cross-bracing similar to FIGS. 10C and 10D. As illustrated in FIGS. 10J and 10K, the cross-bracing system 350 may comprise one or more lower horizontal cross-braces 362 and one or more upper horizontal cross-braces 364. The one or more lower horizontal cross-braces 362 may operatively couple a first lower member 140 of a first cold-formed beam 100 and a second lower member 140 of a second cold-formed beam 100, as previously described with respect to FIG. 10I. The one or more upper horizontal cross-braces 364 may operatively couple a first upper member 120 of the first cold-formed beam 100 and a second upper member 120 of the second cold-formed beam 100. In the illustrated embodiments, the one or more upper horizontal cross-braces 364 are operatively coupled between the first upper flange 122 and/or the fifth upper flange 126 (e.g., one or more upper inner flanges of the upper members 120).
FIG. 10L illustrates cross-bracing between three or more beams 100. As illustrated in FIG. 10L, the cross-bracing 360 may comprise one or more lower horizontal cross-braces 362, one or more upper horizontal cross-braces 364, and one or more diagonal cross-braces 366. The one or more upper horizontal cross-braces 364 and the one or more lower horizontal cross-braces 362 may be operatively coupled to the upper and lower members 120, 140 as previously described with respect to FIGS. 10J and 10K. Additionally, the one or more diagonal cross-braces 366 may operatively couple a first lower member 140 of a first cold-formed beam 100 to a second upper member 120 of a second cold-formed beam 100, as previously described herein. However, as illustrated in FIG. 10L, the diagonal cross-braces 366 may be operatively coupled to the upper horizontal cross-braces 364 and/or lower horizontal cross-braces 362 through the use of one or more bracing connectors 370 and/or one or more bracing apertures 380 (e.g., in the cross-bracing 360).
FIG. 10M illustrates cross-bracing 360 between three or more beams 100. As illustrated in FIG. 10M, the cross-bracing 360 may comprise one or more lower horizontal cross-braces 362, one or more upper horizontal cross-braces 364, one or more diagonal cross-braces 366, and/or one or more vertical cross-braces 368. The one or more upper horizontal cross-braces 362, the one or more lower horizontal cross-braces 364, and/or the one or more diagonal cross-braces 366 may be operatively coupled to the upper and lower members 120, 140, and/or each other as previously discussed with respect to FIG. 10L. It should be understood that the one or more vertical cross-braces 368 may be operatively coupled to the upper member 120, lower member 140, and/or the upper horizontal cross-braces 364 and/or the lower horizontal cross-braces 362 through the use of one or be more bracing connectors 370 and/or one or more bracing apertures 380 (e.g., in the cross-bracing 360 or the upper and/or lower members 120, 140). As illustrated in FIG. 10M, the vertical cross-braces 368 may be operatively coupled to a first upper flange 122 and/or a fifth upper flange 126 and/or a first lower flange 142 and/or a fifth lower flange 146. However, it should be understood that the vertical cross-braces 368 may be operatively coupled to any of the flanges of the upper and/or lower members 120, 140 and/or other cross-bracing 360.
In the illustrated embodiments, the cross-bracing 360 utilizes L-shaped cross-bracing members (otherwise described as angle cross-bracing members). However, it should be understood that the cross-bracing 360 may be any shape (e.g., u-shaped, c-shaped, x-shaped, y-shaped, n-shaped, w-shaped, m-shaped, circular, oval, uniform, non-uniform, or the like shaped). Moreover, it should be understood that while specific cross-bracing systems 350 are illustrated, other types of cross-bracing systems 350 may be utilized. Depending on the configuration, the cross-bracing systems 350 may be categorized as different types of cross-bracing such as horizontal, vertical, diagonal, uplift, termination, or the like cross-bracing systems 350.
FIGS. 11A through 11E illustrate other embodiments of the cold formed beam 100, which have apertures 170 of different shapes and/or multiple embossments 172. FIG. 10A illustrates one embodiment in which the apertures 170 are circular and have multiple embossments 172 in the web 160 of the cold-formed beam 100. FIG. 11B illustrates one embodiment in which the apertures 170 are polygonal (e.g., having eight sides) and have multiple embossments 172 in the web 160 of the cold-formed beam 100. FIG. 11C illustrates one embodiment in which the apertures 170 are square or diamond shaped and have multiple embossments 172 in the web 160 of the cold-formed beam 100. FIGS. 11D and 11E illustrate embodiments in which the apertures 170 are triangular (e.g., two back-to-back triangular apertures as illustrated in FIG. 11D, and four triangular apertures with the points directed towards each other as illustrated in FIG. 11E) and have multiple embossments 172 in the web 160 of the cold formed beam 100.
FIG. 12 illustrates a process flow for forming the cold formed beams 100 discussed herein. As illustrated in block 510 of FIG. 12, a steel sheet is procured (e.g., manufactured, purchased, or the like). Depending on the beam connectors 190 that will be used to form the cold formed beam 100, it should be understood that the steel sheet may already be coated (e.g., galvanized, painted, or coated with another material), or it may be coated before being formed into the cold formed beam 100. As such, the interference connectors 192 may be formed in the coated steel sheets, whereas welded connectors may not be able to be formed and/or would require additional coating after welding.
Block 520 of FIG. 12 illustrates that the steel sheet is formed into the cold formed beam 100 through rolling, pressing, bending, or other like forming operation. In particular embodiments, the cold formed beam 100 may be created by rolling the steel sheet through one or more sets of opposing dies (e.g., rolling dies) to form the portions of the steel sheet adjacent the edges of the steel sheet into the multiple flanges in order to create the upper member 120, lower member 140, and/or extension member(s) 130 of the cold formed beam 100 described herein.
FIG. 12 further illustrates in block 530 that that the apertures 170 are formed in the web 160 of the cold formed beam 100. It should be understood that the apertures 170 may be formed in the web 160 before, during, or after the upper and lower members 120, 140 are formed as described in block 520. Regardless of when the apertures 170 are formed, in some embodiments the apertures 170 are formed through a stamping process. The stamping process may include using one or more sets of dies to punch out the material in the web 160 in the desired shape and/or create the one or more embossments 172 around at least a portion of the web 160 surrounding the apertures 170. While the apertures 170 may be formed through a stamping process, it should be understood that in other embodiments, the apertures 170 may be formed by other processes (e.g., laser cutting, water cutting, plasma cutting, or the like).
Block 540 of FIG. 12 further illustrates that a plurality of beam connectors 190 are formed in the in the cold formed beam 100. For example, the beam connectors 190 may be formed between the web flanges (e.g., first web flange 128, second web flange 148, an upper extension member flange 138) and the web 160 (e.g., the metal web layer). As previously described herein, the beam connectors 190 may include welds, fasteners, and/or metal deformation connector, such as the interference connectors 192 (e.g., clinching connections, or the like) as previously described herein. It should be understood that when welding is described herein, the welding may be any type of welding, such as but not limited to MIG, stick, TIG, plasma arc, electron beam, laser, gas, or the like welding.
FIG. 12 further illustrates in block 550 that one or more stiffeners 200 and/or one or more support member brackets 250 may be operatively coupled to the cold-formed beam 100. For example, the one or more stiffeners 200 may be assembled to the cold formed beam 100. For example, end stiffeners 210 may be assembled on each end 102, 104 of the cold formed beam 100 using one or more stiffener connectors (e.g., as described with respect to other connectors). The stiffeners 200 may be operatively coupled to the upper member 120, the lower member 140, and/or the web 160 of the cold formed beam 160 using the stiffener connectors.
Moreover, one or more support member brackets 250 may be assembled to the ends of the cold-formed beam 100, such as to the stiffeners 200. In some embodiments, the support member brackets 250 and/or the stiffeners 200 may be pre-assembled before assembly to the cold-formed beam 100. Alternatively, or additionally, the support member brackets 250 and/or the stiffeners 200 may be an integral component, such as a combined stiffener bracket 220.
FIG. 12 further illustrates in block 560 that one or more support member seats 400 may be operatively coupled at the ends of the cold formed beam 100, such as to the stiffeners 200 discussed with respect to block 550 and/or to one or more of the extension members 130 previously discussed herein. For example, a seat bracket 410 may be operatively coupled to the ends of the cold-formed beam 100, such as a seat bracket 410 that is formed of two L-shaped seat members that are operatively coupled back-to-back around a portion of an extension member 130.
The cold-formed beam 100 may support at least the following loading or more, a dead load of 4 sf+self-weight of the beam 100; a live load of 20 psf, a snow load of 30 psf; an uplift wind load of 60 psf; a downward wind load of 20 psf; live load deflection limit of L/180; and/or a dead plus live load deflection limit of L/150. The structural support performance of the cold-formed beam 100 may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, 30, 40, 45, 50, 60, 70, 80, 90, 100 or the like percent higher or lower than these values.
The cold formed beam 100 of the present disclosure may be a unitary cold formed beam 100 formed form a single steel sheet, and in particular, the cold form beam 100 is a long-span cold-formed beam 100 (e.g., greater than 30 feet in length) that has a reduced weight due to the thickness of the steel sheet and/or the plurality of apertures 170 in the web 160. The beam is generally described herein as being a cold-formed beam 100, such that the beam is formed without having to heat the beam above its recrystallization temperature. It should be understood that the steel sheet used to form the cold-formed beam 100 may be any type of steel made from any process.
The configuration of the cold-formed beam 100 may allow for the reduction and/or elimination of bridging between parallel cold-formed beams 100, which reduces costs and time associated with installing the amount of traditional bridging that is required in traditional long-span beams. However, as previously described herein, the cold-formed beam 100 may be used with any type of bridging system 350.
Furthermore, due to the configuration (e.g., shape, thickness, or the like) of the upper member 120 (e.g., the upper flange thereof) the upper member 120 allows for the case of installation of the standing seem clips 30, bridging members 40, decking panels 70, wooden nailer and/or wooden panels (not illustrated) and/or other components of structural framing systems into the upper member 120 of the cold formed beams 100. Moreover, the plurality of apertures 170 allow for components to be easily passed through and installed across multiple cold formed beams 100.
Furthermore, the cold formed beams 100 of the present invention, depending on the type of connectors, reduce (e.g. lower or eliminate) the need for welding the cold formed beam 100, which reduces safety issues around welding (e.g., wire pokes, or the like), allows for the use of pre-coated steel sheets that have the desired finishes, and/or reduces the carbon footprint and other use of gases associated with welding. Moreover, in some embodiments a footprint of the manufacturing equipment used to form the cold formed beam 100 can be reduced since the cold formed beam 100 can be rolled, stamped, and mended to form the interference connectors in a single location and does not require sending to beam to a different location for welding.
Finally, it should be understood that the cold formed beam 100 may be formed within 5, 4, 3, 2, or the like minutes, which may be about half the time it takes for traditional long-span beams to be formed (e.g., open web joists, castellated beams, or the like).
It should be understood that “operatively coupled,” when used herein, means that the components may be formed integrally with each other, or may be formed separately and coupled together. Furthermore, “operatively coupled” means that the components may be formed directly to each other, or to each other with one or more components located between the components that are operatively coupled together. Furthermore, “operatively coupled” may mean that the components are detachable from each other, or that they are permanently coupled together.
Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and/or operational aspects of any of the embodiments of the present invention described and/or contemplated herein may be included in any of the other embodiments of the present invention described and/or contemplated herein, and/or vice versa. In addition, where possible, any terms expressed in the singular form herein are meant to also include the plural form and/or vice versa, unless explicitly stated otherwise. Accordingly, the terms “a” and/or “an” shall mean “one or more.”
Certain terminology is used herein for convenience only and is not to be taken as a limiting, unless such terminology is specifically described herein for specific embodiments. For example, words such as “top”, “bottom”, “upper”, “lower”, or the like may merely describe the configurations shown in the figures and described herein for some embodiments of the invention. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. The terminology includes the words specifically mentioned above, derivatives thereof and words of similar import.
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations, modifications, and combinations of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
Patent Application
20250043573
