Patent Application
20210115665
This application relates generally to the field of structural panel systems, in particular structural wall and roof panel systems, and more particularly to structural wall panel systems, with improved strength and/or ductility.
Structural wall or roof panels (collectively “structural panels”) are used in commercial or industrial construction (and in some cases residential construction), for example, in commercial buildings, industrial buildings, institutional buildings, or the like. Structural panels, may be typically manufactured from steel sheets, which may or may not be coiled. In order to increase the structural strength and the stiffness of the individual steel sheets, structural panels with longitudinal flutes are formed from the steel sheets via roll forming, break forming, bending, stamping, or other like processes. The structural panels are secured to each other and to other load resisting structural support members in order to form a structural panel system when installed (e.g., wall system, roof system, combination thereof, or other like panel system).
In geographic regions that are prone to seismic activity (e.g., earthquakes) and/or high winds, the structural panels are solidly connected to each other and to the other load resisting structural members of the building so that the building is better able to withstand shear/lateral forces (e.g., in-plane and out-of-plane shear forces) created by the seismic activity and/or high winds. The structural panels are connected to reduce, or eliminate excessive, out-of-plane separation of the structural panels, or longitudinal movement between the edges of the structural panels (e.g., at the sidelap). To this end, the edges between adjacent structural panels are joined in such a way as to create resistance in-plane along the length of the edges (e.g., parallel with the edges) to thereby carry loads (e.g., resist forces) and prevent displacement between the structural panels along the edges. In addition, the connection of the structural panels at the edges also creates resistance out-of-plane along the edges (e.g., perpendicular to the edges) to thereby carry loads and prevent one panel lifting off an adjacent panel.
Structural panels utilized within a structural panel system of a building typically include longitudinal flutes (e.g., upper panel flange, lower panel flange, and panel webs that form a single flute as discussed in further detail later) that run longitudinally along the length of the panel in order to provide structural strength to the panels, and thus, to the structural panel system and building system. The structural panels typically comprise two edges and two ends. The edges of structural panels run parallel with the longitudinal flutes, while the ends of the structural panels run transverse (or perpendicular) to the longitudinal flutes. As such, one edge of the structural panels may be described as a “first edge” (or a “top edge” or “left edge”) while the second edge of the structural panels may be described as a “second edge” (or a “bottom edge” or “right edge”). The ends of the structural panels may be described as a “first end” (or a “top end” or “left end”) and a “second end” (or a “bottom end” or “right end”).
The structural in-frame fluted panel system configurations described herein provides similar, the same, or improved strength and/or ductility over fluted panel systems in which the panels, and thus the flutes of the panels, are located outside of support members of the frame (e.g., outside the openings of the support members, or otherwise outside of the width of the support structures). In addition to achieving the desired strengths, the in-frame fluted panel system allows for easier construction and lower costs when compared to fluted panel systems in which the panels are coupled to support members outside of the support members. Moreover, the in-frame configurations provide smooth surfaces for easier finishing of the wall panels (e.g., no flutes extending beyond the support members). For example, the shear wall structural fluted panel systems having panels within the width of the support members (e.g., studs, rolled or bent studs, or the like) results in panel systems that have the same width as adjacent members within the building, such as but not limited to window framing, door framing, non-structural walls, or the like. By including the panels within the width of standard support member sizes, the in-frame configurations described herein allow for easily covering the structural panels (as well as the door framing, window framing, etc.) with drywall, plaster, or other building material. The covering of the in-frame structural panels and other building elements with other construction materials without having to account for fluted panels being located outside of the support members vastly improves the cost, time, and difficulty with in constructing the building. It should be understood that the structural panel systems described herein may be prefabricated before shipping to constructions sites or formed on location.
Embodiments of the invention comprise a structural panel system. The structural panel system comprises a support structure having support members having a support structure width, and one or more panels operatively coupled to the support structure. Each of the one or more panels comprise flutes, opposing ends, and opposing edges, and the flutes of the one or more panels are generally parallel with the opposing edges. The flutes of the one or more panels are oriented generally perpendicular with the support members of the support structure. Moreover, the flutes of the one or more panels are located within the width of the support structure.
In further accord with embodiments of the invention, the structural panel system further comprises end support couplings. Moreover, the support structure comprises a first support member and a second support member, wherein the first support member and the second support member each have a web and a first flange and a second flange operatively coupled to the web and an opening formed by the web, the first flange, and the second flange. The opposing ends of the one or more panels are located within the openings of the first support member and the second support member. The end support couplings operatively couple the opposing ends of the one or more panels to the first flanges within the openings of the first support member and the second support member.
In other embodiments, the structural panel system further comprises an intermediate support member and panel support couplings. The intermediate support member has a width smaller than the width of the first support member and the second support member of the support structure. The one or more panels are operatively coupled to the first intermediate flange of the intermediate support member using the panel support couplings.
In yet other embodiments of the invention, the intermediate support member comprises an intermediate web, a first intermediate flange and a second intermediate flange operatively coupled to the intermediate web, and an intermediate opening formed from the intermediate web, the first intermediate flange, and the second intermediate flange, and wherein the one or more panels are operatively coupled to the first intermediate flange of the intermediate support member outside of the intermediate opening.
In still other embodiments of the invention, the first support member and the second support member are c-shaped.
In further accord with embodiments of the invention, the first intermediate flange has a first intermediate lip and the second intermediate flange has a second intermediate lip.
In other embodiments, the invention further comprises an intermediate support member comprising a first intermediate opening and a second intermediate opening each having a first intermediate flange, second intermediate flange, and a web. Moreover, the one or more panels at least comprise a first panel comprising first flutes, first opposing ends, and first opposing edges, a second panel comprising second flutes, second opposing ends, and second opposing edges. The end support couplings operatively couple the first opposing ends of the first panel to the first flange in the opening of the first support member and to the first intermediate flange in the first opening of the intermediate support member. The end support couplings further operatively couple the second opposing ends of the second panel to the first flange in the opening of the second support member and to the first intermediate flange in the second opening of the intermediate support member.
In yet other embodiments of the invention, the intermediate support member is an I-shape or an H-shaped single intermediate member.
In still other embodiments of the invention, the intermediate support member comprises a first intermediate support member and a second intermediate support member operatively coupled together. The web of the intermediate support member is formed from a first intermediate web of the first intermediate support member and a second intermediate web of the second intermediate support member.
In yet other embodiments of the invention, the first intermediate support member and the second intermediate support members are c-shaped.
In further accord with embodiments of the invention, each of the second intermediate flanges have a lip.
In other embodiments of the invention, the first support member and the second support member are c-shaped.
In still other embodiments of the invention, the first support member and the second support member each have a lip on the second flange.
Embodiments of the invention further comprises a structural panel system. The structural panel system comprising a first support member and a second support member. The first support member and the second support member each have a web, and a first flange and a second flange operatively coupled to the web. The web, the first flange, and the second flange form openings within the first support member and the second support member. The structural panel system further comprises an intermediate support member having a first intermediate opening and a second intermediate opening each having an intermediate web operatively coupled to a first intermediate flange and a second intermediate flange. The structural panel system also comprises two or more panels, each panel having flutes, opposing ends, and opposing edges. The flutes of the panel are generally parallel with the opposing edges. End support couplings operatively coupling the two or more panels to the first support member, the intermediate support member, and the second support member. The two or more panels comprise at least a first panel and a second panel, wherein the flutes of the first panel and second panel are oriented generally perpendicular with the first support member, the intermediate support member, and the second support member. The opposing ends of the first panel are located within the opening of the first support member and the first intermediate opening of the intermediate support member, and the end support couplings operatively couple the opposing ends of the first panel to the first flange of the first support member and the first intermediate flange of the intermediate support member. The opposing ends of the second panel are located within the opening of the second support member and the second intermediate opening of the intermediate support member, and the end support couplings operatively couple the opposing ends of the second panel to the first flange of the second support member and the first intermediate flange of the intermediate support member.
In further accord with the invention, each of the second flange of the first support member and the second support member, and the second intermediate flanges of the intermediate support member have lips.
In other embodiments of the invention, the intermediate support member comprises a single intermediate member or comprises a first intermediate support member and a second intermediate support member operatively coupled together, wherein the intermediate web of the intermediate support member is formed from a first intermediate web of the first intermediate support member and a second intermediate web of the second intermediate support member.
Embodiments of the invention further comprise a structural panel system. The structural panel system comprises a first support member and a second support member. The first support member and the second support member each have a web, and a first flange and a second flange operatively coupled to the web. The web, the first flange, and the second flange form openings within the first support member and the second support member. The structural panel system further comprises an intermediate support member. The structural panel system also comprises one or more panels, each panel having flutes, opposing ends, and opposing edges. The flutes of the panel are generally parallel with the opposing edges. Couplings operatively couple the one or more panels to the first support member, the intermediate support member, and the second support member. The flutes of the one or more panels are oriented generally perpendicular with the first support member, the intermediate support member, and the second support member. The opposing ends of the one or more panels are located within the opening of the first support member and the opening of the second support member. The intermediate support member has a width smaller than widths of the first support member and the second support member.
In further accord with embodiments of the invention, the couplings are end support couplings and panel support couplings, wherein the end support couplings operatively couple the opposing ends of one or more panels to the first flanges of the first support member and the second support member, and wherein the panel support couplings operatively couple a portion of the panel to the intermediate support member where the panel crosses the intermediate support member.
In other embodiments of the invention, the intermediate support member comprises an intermediate web, and a first intermediate flange and a second intermediate flange operatively coupled to the intermediate web. The intermediate web, the first intermediate flange, and the second intermediate flange form an intermediate opening within the intermediate support member. The panel support couplings operatively couple the portion of the panel to the first intermediate flange of the intermediate support member outside of the intermediate opening.
In yet other embodiments of the invention, each of the second flange of the first support member and the second support member, and the second intermediate flange of the intermediate support member have lips.
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 or aspects of the invention. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments or aspects of the invention may be employed, and this description is intended to include all such embodiments or aspects, and their equivalents.
The foregoing and other advantages and features of the invention, and the manner in which the same are accomplished, will become more readily apparent upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings, which illustrate embodiments of the invention and which are not necessarily drawn to scale, wherein:
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 structural in-frame fluted panel system configurations described herein provides similar, the same, or improved strength over fluted panel systems in which the panels, and thus the flutes of the panels, are located outside of the support members of the frame (e.g., outside the openings of the support members, or otherwise outside of the width of the support structures). In addition to achieving the desired strengths, the in-frame fluted panel system allows for easier construction and lower costs than the fluted panel systems in which the panels are coupled to support members outside of the support members. Moreover, the in-frame configurations provide smooth surfaces for easier finishing of the wall panels 2 (e.g., no flutes extending beyond the width of the support members). As such, the in-frame configurations provide continuity of the wall components in that the width of all the framing is the same for the structural shear wall fluted panels, the doors, the windows, the non-structural framing, or the like throughout the building.
As illustrated throughout the various figures, the panels 2 are operatively coupled to a support structure 30 (e.g., frame, or the like) using couplings 50 at coupling locations (otherwise described herein as a joint, attachment, or the like locations). The fluted panel system 1 includes structural panels 2 (e.g., wall panels, or the like), such as a first wall panel 4, a second wall panel 6, a third wall panel 8, and an nth wall panel located laterally adjacent to one another, and configured to form at least a portion of the fluted panel system 1. In other aspects of the invention, the structural panel used between two support members 30 (e.g., a first support member and a second support member) may be a single panel 2. As such, it should be understood that the panels 2 used in the fluted panel system 1 may include multiple panels 2 (more than two located longitudinally adjacent to each other) operatively coupled together, or may include a single panel 2 between the span of each support member (e.g., between first and second support members, and/or between first, second, and intermediate support members).
Each panel 2 may include edges 12, such as a first edge 14 and a second edge 16, as well as ends 18, such as a first end 20 and a second end 22. The edges 12 of structural panels run parallel (e.g., 0 degrees, or the like), substantially parallel (e.g., −10 to 10 degrees, or the like), or generally parallel (e.g., −45 degrees to 45 degrees, or the like) with the longitudinal flutes 3, while the ends of the structural panels run perpendicular (e.g., 90 degrees, or the like), substantially perpendicular (e.g., 80 to 100 degrees, or the like), or generally perpendicular (e.g., 45 degrees to 135 degrees, or the like) to the longitudinal flutes 3.
Sidelaps 13 (e.g., sidelap seams, nested sidelaps, and/or other sidelaps where the edges of panels meet), if applicable, are formed between adjacent edges 12 of the panels 2. Couplings 50 may be made in the sidelaps 13, and operatively couple, the first edge 14 and the second edge 16 of each lateral adjacent panel 2 within the fluted wall panel system 1. Additionally, the ends 18 of each panel 2 may be operatively coupled to longitudinally adjacent structural panels 2, for example, the first end 20 of a first panel 4 may be operatively coupled to a second end 22 of a longitudinally adjacent panel (not illustrated in the Figures). As described herein, laterally adjacent panels 2 are panels 2 located parallel to each other and to the longitudinally extending flutes 3 of each panel 2, while the longitudinally adjacent panels are panels 2 located in series with each other and to the longitudinally extending flutes 3 of the panels 2. When installed to a support structure with end support members and/or intermediate support members, the flutes 3 of the panels 2 may be oriented perpendicular (e.g., 90 degrees, or the like), substantially perpendicular (e.g., 80 to 100 degrees, or the like), or generally perpendicular (e.g., 45 degrees to 135 degrees, or the like) to the end support members and/or intermediate support members.
As illustrated in the various figures, the fluted panel system 1 further includes a support structure 30. The support structure 30 may include support members 31. In some embodiments the support members 31 may be studs 32 (e.g., a first stud 38 such as a first end stud, a second stud 42 such as a second end stud, and one or more an intermediate studs 40 such as a third stud and/or nth studs). The support structure 30 may further include a lower cap and an upper cap (not illustrated and otherwise described as a lower track and upper track). The support structure 30 may further include other support members 31, such as joists, trusses, purlins, beams, or any other type of support members 31 that may be included in a building structure. As such, in some embodiments, as illustrated in
The structural panels 2 may have profiles that include longitudinal flutes 3. The longitudinal flutes 3, as illustrated in the various figures (e.g., as illustrated in one example in
The structural panels 2, described herein, may be manufactured from a variety of rigid materials including steel, aluminum, titanium, plastic, a composite, or another type of rigid material. Typical structural panels 2 are made of steel and are sized in ranges from 12 inches to 42 inches (inclusive) wide by 1 foot to 50 feet (inclusive) long. These dimensions include some sizes of structural panels 2, but it should be understood that any size of structural panels 2 within these ranges, overlapping these ranges, or outside of these ranges might be utilized within the present invention. The material thickness of the structural panels 2 may be any thickness; however, the panel thicknesses may correspond to 29 gage panels to 16 gage panels, inclusive. Other gage material, or the associated thicknesses therefor, may be within this range, overlap this range, or be located outside of this range.
The distance from the top of the top flange 84 and the bottom of the bottom flange 86 may generally range from ½ inch to 3 inches (inclusive) in depth; however, other ranges of depths within this range, overlapping this range, or outside of this range may be used in the profiles. For example, in some embodiments the distance may range from ½ inch to 12 inches (inclusive) in depth, or the like. The panels 2 may or may not include longitudinal ribs, bends, or cutouts that affect the moment of inertia and section modulus of the panels 2 (e.g., profile dimensions, ribs, cutouts, or the like are used to target different performance characteristics, such as but not limited to strength, stiffness, moment of inertia, and section modulus). Depending on the material thickness, the length and width of the panels 2, and the height of the top flanges 84 and bottom flanges 86, the panels 2 may weigh between 30 and 420 lbs. In other embodiments, the weight of the panels may be within, overlap, or be located outside of this range.
In some embodiments, the panel 2 has a panel length 48, ends 18 that are connected to end support members 31, and a body that crosses at least one or more intermediate support members 31. For example, the panel 2 may be operatively coupled to end support members 31 (e.g., first stud 38 and second stud 42), and cross one or more intermediate support members 31 (e.g., the third studs 40, or nth stud, or the like) along the panel length 48. The panel 2 may be operatively coupled to the end support members 31 with couplings 50 at the panel ends 18 (e.g., the first stud 38 and the second stud 42). The panel 2 is further operatively coupled to the one or more intermediate support members 31 with couplings 50 at varying locations. Additionally, two laterally adjacent panels 2 are operatively coupled together with couplings 50 along a sidelap 13. As such, as illustrated in the various figures, the couplings 50 may include end support couplings 52 (e.g., at the panel ends and end support members), panel edge couplings 54 (e.g., at the sidelap between two laterally adjacent panels), edge support couplings 56 (e.g., at the sidelap between two laterally adjacent panels where the sidelap crosses an intermediate support member), and panel support couplings 58 (e.g., between a panel body and where the panel body crosses an intermediate support member).
Each of the panel systems described in
A number of samples of each of the panel systems described and illustrated with respect to
Tests were run for the configurations illustrated in
As illustrated by Table 1 and the curves in
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.”
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.
The present application for a patent claims priority to U.S. Non-Provisional patent application Ser. No. 15/466,983 entitled “In-Frame Shear Wall” filed on Mar. 23, 2017, which issued into U.S. Pat. No. 10,822,793 on Nov. 3, 2020, and which claims priority to U.S. Provisional Patent Application Ser. No. 62/312,872 entitled “In-Frame Shear Wall” filed on Mar. 24, 2016, both of which are assigned to the assignees hereof and hereby expressly incorporated by reference herein.
This invention was made with government support under PFI:AIR-TT Grant #1445065 entitled “Innovative High-Performance Cold-Formed Steel Walls for Light Framed Construction” awarded by the National Science Foundation. The government has certain rights in the invention.
| Number | Date | Country | |
|---|---|---|---|
| 62312872 | Mar 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15466983 | Mar 2017 | US |
| Child | 17084189 | US |
