Patent Application
20120060443
1. Field of the Invention
The present invention relates generally to using cold rolled steel formed beams for sub-deck fabrication.
2. Description of Related Art
Sub-deck constructed from wooden beams is a standard way of building frames for surface flooring and decks. Though wooden beams are relatively easy to work with, decomposition due to weather and time generally only permit between 10 and 20 years of life span before falling apart. This has been, somewhat, improved with the introduction of pressure treated wood lumber, which is a formaldehyde-based impregnated wood. It is to innovations related to the longevity of sub-decks that the claimed invention is generally directed.
The present invention relates generally to a novel deck frame configuration for building construction of sub-decks, which overcomes the disadvantages and limitations of the present state of the art through advantageous arrangements of ceramic-based coated channel beams. The present invention also relates to methods of fabrication and utilization of such ceramic-based coated channel beams as well as to building and employing such ceramic-based coated channel beams.
One embodiment of the present invention can therefore comprise a channel beam comprising: steel sheet metal that is bent in a C-shaped cross-section possessing a web with bends forming an upper flange and a lower flange, the channel beam extending in length along the C-shaped cross-section; a ceramic coating essentially encapsulating the channel beam wherein the sheet metal is essentially encapsulated by the ceramic coating prior to being bent in the C-shaped cross-section; the sheet metal is between 14 gage and 18 gage steel.
Yet another embodiment of the present invention can therefore comprise a channel beam constructed by a method comprising: providing steel sheet metal possessing a length, a width, and a thickness, wherein the length is dimensionally greater than the width, the width is dimensionally greater than the thickness, the width and the thickness define a plane wherein a cross-section of the sheet metal resides, the thickness is between 14 gage and 18 gage steel; applying a ceramic coating on the sheet metal to essentially encapsulate the steel sheet metal; bending the sheet metal after the applying step into a first flange, a second flange, and a web, to form a C-shaped cross-section in the plane, the first flange and the second flange terminate at the edges of the C-shaped cross-section, after the bending step, the sheet metal remains essentially encapsulated by the ceramic coating.
Referring to the drawings in general, and more specifically to
In certain embodiments, the deck frame assembly 100 is generally comprised of a deck ledger 104 adapted to be fixedly attached to an external building wall, such as the house wall 102. The deck ledger 104 can be fixedly attached to the house wall 102 via a plurality of screws, pins, nails, etc., just to name several illustrative elements used for attaching known to those skilled in the art. As illustratively shown, extending from the deck ledger 104 is a plurality of deck joists 106, which in some embodiments are steel channel beams, that are essentially evenly spaced apart, such as in increments of 18 inches, for example. Other types of metal used to compose the beams are contemplated. In another embodiment, the deck joists 106 can be spaced at non-constant intervals, i.e., random spacing or, optionally, spacing alternating spacing, such as 12 inches, 20 inches, 12 inches, etc. In the illustrative embodiment, the deck joists 106 terminate into a rim plate 108 that is essentially perpendicular to the deck joists 106 and parallel to the deck ledger 104. The deck joists 106 can e attached to the rim plate 104 or the deck ledger 106 via hanging brackets, for example. In optional embodiments, the deck ledger 104 and rim plate 108 are not parallel to one another and the deck joists 106 are not perpendicular to either the deck ledger 104 or the rim plate 108 or both the deck ledger 104 and rim plate 108. As illustratively shown in the present embodiment, essentially parallel and in plane to the deck joists 106 are two rim joists 110. The deck joists 106 are interposed between the rim joists 110 in order to provide both an aesthetically finished look and enhanced structural integrity to the deck frame assembly 100. The deck ledger 104 is arranged to support the deck joists 106 and rim joists 110 at one end of the deck frame assembly 100 and one drop beam 112 supports the deck joists 106 and rim joists 110 at a location along the length of the deck joists 106 and rim joists 110. In this example, the drop beam 112 is supporting the deck frame assembly 100 near the distal end of the deck joists 106 and rim joists 110. The drop beam 112 is supported by two caissons 114 in the present illustrative embodiment, however, conceivably multiple caissons 114 can be used. Optionally, the drop beam 112 can be supported by a number of different structures, including, but not limited to a wall structure or structures, block structures, a platform, etc. In optional embodiments, multiple drop beams 112 can be used along the length of the deck joists 106 and rim joists 110. In the embodiment of
In certain embodiments, the deck ledger 104 is cold formed from 14 gage pre-galvanized painted steel sheets and the deck joists 106 and rim joists 110 are cold formed from 18 gage pre-galvanized painted steel sheets, however, certain optional embodiments contemplate any combination between 12 and 18 gage steel sheet metal that is not necessarily galvanized. In more detail, prior to forming the deck ledger 104, deck joists 106 and rim joists 110, a flat roll of galvanized steel (essentially a steel sheet roll) is primed on both sides with a primer followed by being coated on both sides with a ceramic-based coating that is heat cured. In certain embodiments, the radius of the inner bends 207 is preferably between 0.125 inches to 0.25 inches, preferably the radius of the outer bends is between 0.25 and 0.5 inches. In certain embodiments, the flat, unrolled, sheet width for the deck ledger 104 is different from the sheet width for the deck joist 106, for example, the metal rolls can be 42-68 inches wide depending on whether the metal sheet is for a deck joist 106 or a deck ledger 104, for example. In an optional embodiment, the widths can be essentially the same. The coated, or painted, steel sheets are then cut to size and cold rolled to form the “C” and “U” profiles of the deck ledger 104, deck joists 106 and rim joists 110.
More specifically, channel beam construction embodiments using ceramic based coatings are contemplated via a method described below. It should be recognized that the steps presented in the described embodiments of the present invention do not necessarily require any particular sequence unless otherwise stated. In certain embodiments, rolls of steel sheet metal having a thickness of between 12 gage to 18 gage is galvanized. One commercial example is a G60 galvanized steel roll that can be upwards of 3,000 linear feet of sheet metal between 42 inches and 68 inches in width, such as that produced by Wheeling Nissan Steel Mill of Follansbee, W.V.
With regards to coating the rolls of sheet metal, one commercial embodiment is performed by Centria Coating Service, Head Quartered in Pittsburg, Pa. Here, a roll of galvanized steel sheet metal is threaded in a machine that applies and cures both a primer and ceramic-based paint in a continuous process. After cleaning the sheet metal to remove undesirable contamination such as oils, for example, the sheet metal is primed using a polyester primer (that is compatible with the ceramic-based paint) in a continuous roller process whereby the primer is rolled onto the top and bottom surfaces of the sheet metal. The primed sheet metal is then cured in long ovens at between 435° F. and 450° F. during a continuous feed process. The cured primed sheet metal is then coated with a ceramic-based paint on both the top and bottom surfaces of the sheet metal with rollers and then cured in the same ovens at 435° F. and 450° F. in the same continuous feed process. One example of a ceramic-based paint is a class of polyester paints modified with ceramic, such as the Brown-Texture paint line manufactured by Duracoat Head Quartered in Riverside, Calif. Optionally, the sheet metal can be coated by brush, sponge, baths, spray, and other techniques know to those skilled in the art. In certain embodiments, a ceramic coating may have a ceramic concentration that is greater than 20% by weight, preferably greater than 50%, even more preferably greater than 60%, and even more preferably greater than 70%, but ceramic concentrations at 80% and in excess of 90% are contemplated. Ceramics in the ceramic coating include, but are not limited to, silica, titanium-dioxide, alumina, just to name a few examples. The sheets of metal are then cut into rolls between 10 inches and 15 inches wide.
With regards to forming the final channel shape, embodiments of the present invention contemplate forming the sheet metal through a cold-rolling process. Here, the metal sheets are bent in a cold-rolling process that, in one embodiment, employs rollers that bend the metal sheets progressively and gradually into their final channel shape with the specified bend radii, or bend angles. This process can be commercially practiced by Iron Deck Corporation of 4935 Newport St., Commerce City, Colo. 80022, whereby the rolls of ceramic-based coated sheet metal are loaded into an uncoiler machine and the coated metal sheets are fed through an 11-stand roll former where they are bent into shape and sheared to desired lengths, such as 20 foot beams, for example. The ceramic-based coating remains essentially completely adhered to the sheet metal after the channel beams are finished being formed.
It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with the details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, similar channel beams of different geometries can be manufactured without departing from the scope and spirit of the present invention. Another example can include using multiple ceramic-based coatings, or the formation of composite ceramic-based coatings, while still maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Finally, although the preferred embodiments described herein are directed to deck frame assemblies, it will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other sub-structural systems, without departing from the spirit and scope of the present invention.
It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes may be made which readily suggest themselves to those skilled in the art and which are encompassed in the spirit of the invention disclosed and as defined in the appended claims.
This application is a non-provisional application of provisional U.S. Ser. No. 61/382,025, entitled DECK FRAME, filed Sep. 12, 2010, as to which this application claims benefit of priority and the subject matter of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61382025 | Sep 2010 | US |
