Patent Application
20190360206
This application relates generally to the field of structural panel systems, and more particularly to structural wall, roof, and floor panel systems with improved ductility due to improved shear strength at the sidelaps created between adjacent structural panels and improved connection configurations that create buckling spans within the structural panel systems.
Structural wall, roof, or floor 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 in order to form a structural panel system when installed (e.g., wall system, roof system, floor system, or combination thereof). The structural panels are also connected to the other load resisting structural support members of a building, such as studs, joists, support beams, or the like to create the structural 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 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 structural panels, or longitudinal movement between the edges of the panels at the sidelap. To this end, the sidelap between adjacent structural panels is joined in such a way as to create resistance in-plane along the length of the sidelap (e.g., parallel with the decking) to thereby carry loads (e.g., resist forces) and prevent displacement between the structural panels along the sidelap. In addition, the connection of the structural panels at the sidelap also creates resistance out-of-plane along the sidelap (e.g., perpendicular to the decking) to thereby carry loads and prevent one panel lifting off an adjacent panel. As such, the connections along the sidelap and connections of the panel to underlying supports maintains the structural integrity of the diaphragm strength of the panel system.
Structural panels utilized within a structural panel system of a building typically include longitudinal flutes (e.g., upper flange, lower flange, and 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 panel run perpendicular (or transverse) 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 preset invention relates to structural panel systems, and in particular ductile fluted panel systems, which incorporate various embodiments of the present invention to improve the ductility of typical structural wall, floor, or roof panel systems. The ductile fluted panel systems of the present invention incorporate improved strength along the sidelaps between adjacent panels, as well as various connection configurations between the panels and the underlying supports in order to create buckling spans. The buckling spans allow for buckling of the panel upon reaching the ultimate load of the system before the connections fail. After reaching the ultimate load of the system, during subsequent loading, the capacity of the ductile fluted panel system is reduced; however, the ductile fluted panel system may continue to buckle over time under loading below the reduced capacity to prolong the diaphragm system strength of the ductile fluted panel system.
In stiff structural panel systems, upon reaching the ultimate load of the system, the connections within the system, which utilize couplings (e.g., fasteners, welds, sheared tabs, or the like) to operatively couple the panels to each other and/or to the support members, fail first. For example, the couplings between the panels and the support members (e.g., studs, or the like) will pull out of the support members, the panels will tear around the couplings, and/or the couplings will shear (e.g., fasteners will shear, welds will fail, or the like). After the failure of the connections, the diaphragm system strength rapidly degrades under subsequent loading.
The ductile fluted panel systems of the present invention improve upon the ductility of structural panels systems in order to provide prolonged diaphragm strength after ultimate loading, and thus, prolonged life of the structural panel system. The ductile fluted panel systems are of particular use within cyclic loading (e.g., in the case of seismic loading, or the like) because after being loaded past the ultimate load, additional loading of the ductile fluted panel systems result in the ductile fluted panels expanding and contracting to maintain the diaphragm system strength of the building system at the reduced capacity.
In order to achieve the ductile fluted panels systems of the present invention, the shear strength along the sidelaps of the adjacent ductile panels is improved, and the connection configurations of the panels to the underlying supports is made in order to allow the panels to buckle before the connections at the panel edges and/or at the support structures fail.
As such, in some embodiments of the invention a reinforcing member may be utilized within a sidelap between panels, a four-layer sidelap seam may be created at the sidelap between panels, a three or four-layer nested sidelap may be created at the sidelap between panels, or other like sidelaps may be created in order to improve the strength of the sidelaps between adjacent panels. When couplings are created in these types of sidelaps, the shear strength of the sidelap is improved over typical wall or roof sidelaps having overlapping edges (e.g., two-layer overlapping edges) and/or three-layer interconnected edges. The connections created by the couplings in these sidelaps creates improved shear strength along the sidelaps.
In some embodiments of the invention, a reinforcing member (otherwise described herein as a “reinforcement member”) may be utilized to increase the strength of the sidelap. The reinforcing member may include a first channel and a second channel. The channels in some embodiments may be U-shaped channels (or any other shaped channel), and may have openings on opposite sides, thus forming a generally S-shaped reinforcing member. As such, the reinforcing member may include a first leg, a second leg, and a third leg. The first leg and the second leg may be operatively coupled together to form the first channel, while the second leg and the third leg may be operatively coupled together to form the second channel. The reinforcing member is utilized between the edges of two lateral adjacent structural panels (e.g., wall panels, roof panels, or the like) such that the first edge of a first panel is inserted into the first channel, and the second edge of the second panel is inserted into the second channel (or otherwise the first channel and/or second channel are inserted over the edges of the first panel and the second panel). In some embodiments, when assembled a five-layer sidelap is created between the first panel, the second panel, and the reinforcing member. Connections are made using couplings at the sidelap (e.g., the sidelap created by the first edge of the first panel, the second edge of the second panel, and the reinforcing member), and thus, a panel system is created that has improved shear strength and stiffness along the sidelap. The improved strength and stiffness at the sidelap may allow for utilization of other connection configurations in the structural panel system that improve the flexibility (e.g., reduce stiffness) of the overall structural panel system.
In some embodiments of the invention, a sidelap seam configuration (e.g., standing interlocking out-of-plane edges) that has three layers may be used with the connection configurations described herein. Alternatively, a sidelap seam configuration that has four or more layers may be utilized to increase the strength and stiffness of the sidelap seam. When couplings (e.g., the connection configurations) are utilized to secure the four or more layers of the sidelap seam, the sidelap seam has improved strength and/or stiffness over other sidelap seams that utilize a two or three layer configuration. The improved strength and stiffness at the sidelap seam may allow for utilization of other configurations that improve the flexibility (e.g., reduce stiffness) of the overall structural panel system, such as the connection configurations discussed herein.
In still other embodiments of the invention, a nested sidelap (e.g., in-plane overlapping nested edges) that has two layers may be used with the connection configurations described herein. Alternatively, a nested sidelap that has three or more layers (e.g., three, four, five, or the like layers), may be utilized to increase the strength and stiffness of the nested sidelap. When couplings are utilized to secure the nested sidelap, the nested sidelap has improved strength and/or stiffness over other steams that utilize two overlapping layers. The improved strength and stiffness at the sidelap may allow for utilization of other configurations that improve the flexibility (e.g., reduce stiffness) of the overall structural panel system, such as the connection configurations discussed herein.
In addition to strengthening the sidelap of the ductile fluted panel systems, in order to achieve the ductile fluted panel systems of the present invention, buckling spans are created in the panels, such that the panels will buckle before the connections formed from the couplings within the panel systems fail. The buckling spans are created by reducing or eliminating the connections made using the couplings at the locations where the panels cross one or more of the intermediate support members. In some cases this may include where the sidelap crosses one or more of the intermediate support members.
As such, some embodiments of the invention include connection configurations in which the ends of the structural panels are operatively coupled (e.g., directly coupled or coupled through other components) to supports members (e.g., outer support members, such as outer studs) and/or the ends of adjacent panels through couplings, and the edges of the structural panels are operatively coupled to the edges of adjacent panels and/or support members through couplings. However, the structural panels are not coupled (e.g., within the body of the structural panels) to support members at locations at which the structural panels cross intermediate support members (e.g., at locations between the ends or edges of the structural panels). In other embodiments, it may be beneficial to reduce the buckling span of longer panels, as will be described in further detail later, and as such, the structural panels may be operatively coupled to one intermediate support member and/or alternating intermediate support members at locations between the ends or edges of the structural panels (e.g., between the outer support members). In some embodiments, when the sidelap of two adjacent panels cross a support member, the sidelap may or may not be coupled to the support members, such as one or more of the intermediate support members. Various connection configurations for the structural panel systems will be described in further detail herein. The couplings used to create the connections in the panel systems are typically screws, however other couplings may include welds, rivets, bolts, cut or sheared couplings, clinch couplings and/or other suitable fasteners. It should be understood that different couplings may be used in different areas in order to achieve the desired diagram strength and flexibility of the ductile fluted panel system and create the desired bucking spans for the cyclic loading.
The increased strength of the sidelaps between adjacent panels and/or the connection configurations, alone or in combination, provide the ability to create the buckling spans within the ductile fluted panel system, such that ductile fluted panel systems may prolong the life of the structural panel system. As discussed, the configurations of the present invention provide for improved structural panel systems, and in particular, for ductile fluted panel systems used in buildings that are more prone to seismic activity.
The ductile fluted panel systems described above may be achieved through other types of configurations of the present invention. For example, in some embodiments of the invention instead of the longitudinal flutes running perpendicularly with respect to the support members, the longitudinal flutes may run parallel the with support members to achieve the improvements described above in another way. When the longitudinal flutes run parallel with the support members, upon cycle loading the panels will buckle before the connections fail. This configuration may be utilized apart from, or together with, the embodiments of the present invention that improves the sidelap strength and/or increases the buckling span (e.g., improved strength at the sidelap between panels, and/or the connection configurations described herein). Having longitudinal flutes that run parallel with the support members may achieve the same general results as the other configurations described herein, however this embodiment of the invention may or may not provide the desired system strength before and/or after buckling, or may or may not provide the desired strength for other types of loading, when compared to the other configurations described herein. As such, the ductile fluted panel systems that use the improved strength at the sidelap between panels and the connection configurations described herein provides another, and potentially improved, way of achieving the ductile fluted panel system in which the longitudinal flutes run parallel the with support members.
Embodiments of the invention comprise structural panel system comprising a first support member, a second support member, and one or more intermediate support members. The system further comprises a first panel comprising first flutes, opposing ends, and opposing edges comprising at least a first edge, and a second panel comprising second flutes, opposing ends, and opposing edges comprising at least a second edge. The first panel and the second panel are oriented generally perpendicular with the first support member, the second support member, and the one or more intermediate support members. The system further comprises a sidelap formed between the first edge of the first panel and the second edge of the second panel. Panel edge couplings operatively coupling the first edge of the first panel to the second edge of the second panel, and end support couplings operatively coupling the opposing ends of the first panel and the second panel to the first support member and the second support member. The system is formed such that the first panel and second panel are void of couplings where the first panel and second panel cross at least one of the one or more intermediate support members.
In further accord with embodiments of the invention, the structural panel system further comprising edge support couplings further operatively coupling the first edge of the first panel to the second edge of the second panel and to the one or more intermediate support members where the sidelap crosses the one or more intermediate support members. However, the first panel and second panel are void of couplings where the first panel and the second panel cross at least one of the one or more intermediate support members, except for the edge support couplings.
In other embodiments of the invention, the structural panel system further comprises a reinforcing member comprising a first channel and a second channel. When assembled in the sidelap, the first edge of the first panel is located within the first channel, and the second edge of the second panel is located within the second channel to form the sidelap. Moreover, the panel edge couplings operatively couple the first edge of the first panel, the second edge of the second panel, and the reinforcing member together.
In yet other embodiments of the invention, the sidelap comprises a sidelap seam that is out-of-plane and formed from the first edge of the first panel being a male lip and the second edge of the second panel being a female lip, wherein the male lip and the female lip form the sidelap seam comprising four or more layers.
In still other embodiments of the invention, the sidelap comprises a nested sidelap that is in-plane and formed from the first edge of the first panel being an in-plane edge and the second edge of the second panel being an in-plane edge, wherein the first edge and the second edge form the nested sidelap comprising three or more layers.
In further accord with embodiments of the invention, the one or more intermediate supports comprise at least three or more intermediate supports, and wherein the structural panel system further comprises panel support couplings in the middle intermediate support of the three or more intermediate supports to reduce the buckling span of the first panel and the second panel.
In other embodiments of the invention, the structural panel system comprises a ductile fluted roof panel system.
In still other embodiments of the invention, the structural panel system comprises a ductile fluted wall panel system.
Other embodiments of the invention comprise structural panel system comprising a first support member, a second support member, and one or more intermediate support members. The structural panel system further comprises a first panel comprising first flutes, opposing ends, and opposing edges comprising at least a first edge, and a second panel comprising second flutes, opposing ends, and opposing edges comprising at least a second edge. The first panel and the second panel are oriented generally perpendicular with the first support member, the second support member, and the one or more intermediate support members. The system further comprises a sidelap formed between the first edge of the first panel and the second edge of the second panel. The system further comprises panel edge couplings operatively coupling the first edge of the first panel to the second edge of the second panel, and end support couplings operatively coupling the opposing ends of the first panel and the second panel to the first support member and the second support member. The first panel and second panel are void of couplings where the first panel, the second panel, and the sidelap of the first panel and second panel cross at least one of the one or more intermediate support members.
In further accord with embodiments of the invention, the structural panel system further comprises edge support couplings further operatively coupling the first edge of the first panel to the second edge of the second panel and to the one or more intermediate support members where the sidelap crosses the one or more intermediate support members. Moreover, the first panel and second panel are void of couplings where the first panel and the second panel cross at least one of the one or more intermediate support members, except for the edge support couplings.
In other embodiments of the invention, the structural panel system further comprises a reinforcing member comprising a first channel and a second channel. When assembled in the sidelap, the first edge of the first panel is located within the first channel, and the second edge of the second panel is located within the second channel to form the sidelap. Moreover, the panel edge couplings operatively couple the first edge of the first panel, the second edge of the second panel, and the reinforcing member together.
In yet other embodiments of the invention, the sidelap comprises a sidelap seam that is out-of-plane and formed from the first edge of the first panel being a male lip and the second edge of the second panel being a female lip, wherein the male lip and the female lip form the sidelap seam comprising four or more layers.
In still other embodiments of the invention, the sidelap comprises a nested sidelap that is in-plane and formed from the first edge of the first panel being an in-plane edge and the second edge of the second panel being an in-plane edge, wherein the first edge and the second edge form the nested sidelap comprising three or more layers.
In further accord with embodiments of the invention, the one or more intermediate supports comprise at least three or more intermediate supports, and wherein the structural panel system further comprises panel support couplings in the middle intermediate support of the three or more intermediate supports to reduce the buckling span of the first panel and the second panel
In other embodiments of the invention, the one or more intermediate supports comprise at least three or more intermediate supports, and wherein the structural panel system further comprises panel support couplings in the middle intermediate support of the three or more intermediate supports to reduce the buckling span of the first panel and the second panel.
In yet other embodiments of the invention, the structural panel system comprises a ductile fluted roof panel system.
In still other embodiments of the invention, the structural panel system comprises a ductile fluted wall panel system.
Other embodiments of the invention comprise a structural panel system comprising two or more support members, a first panel comprising first flutes, opposing ends, and opposing edges comprising at least a first edge, and a second panel comprising second flutes, opposing ends, and opposing edges comprising at least a second edge. The first panel and the second panel are oriented generally perpendicular with the two or more support members. The system further comprises a reinforcing member comprising a first channel and a second channel, wherein when assembled the first edge of the first panel is located within the first channel, and the second edge of the second panel is located within the second channel to form a sidelap. Moreover, couplings operatively couple the first panel and second panel to the two or more support members.
In further accord with embodiments of the invention, the reinforcing member comprises a first leg and a second leg forming the first channel, and a third leg and the second leg forming the second channel. The first channel and the second channel are open in opposite directions, and wherein the reinforcing member comprises three layers and when assembled with the first edge of the first panel and the second edge of the second panel forms the sidelap with least five layers.
In yet other embodiments of the invention, the couplings comprise panel edge couplings operatively coupling the first edge of the first panel to the second edge of the second panel, edge support couplings operatively coupling the first edge of the first panel, the second edge of the second panel, and the one or more intermediate support members when the sidelap crosses the one or more intermediate support members, and end support couplings operatively coupling the opposing ends of the first panel and the second panel to the first support member and the second support member. The first panel and second panel are void of couplings where the first panel and second panel cross at least one of the one or more intermediate support members, except for the edge support couplings.
In still other embodiments of the invention, the two or more support members comprise a first support member, a second support member, and one or more intermediate support members. The one or more intermediate supports comprise at least three or more intermediate supports, and wherein the structural panel system further comprises panel support couplings in the middle intermediate support of the three or more intermediate supports to reduce the buckling span of the first panel and the second panel.
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.
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 may now 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.
A key to developing safe, economical, and high performance shear systems using structural panels is the ductility of the system. The ductile fluted panel system described herein is able to go through large in-plane shear displacement cycles prior to and after the peak shear load is reached. As previously discussed, some embodiments of the invention include configurations in which the ends of the structural panels are coupled to support members and/or ends of adjacent panels through couplings, and the edges of the structural panels are coupled to the edges of adjacent panels and/or to support members through couplings. However, the structural panels are not coupled within the body of the structural panels where the panels cross support members at locations between the ends or edges of the structural panels. Alternatively, the structural panels are only connected to one support member and/or alternating support members at locations between the ends or edges of the structural panels where the structural panels cross the support members. In this way, buckling spans are created in the panels that improve the ductility of the structural panel system while having the same or similar structural strength. Various connection configurations for structural panel systems are described in further detail herein, which result in an improved ductile fluted panel system.
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 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 wide by 1 foot to 50 feet long. These dimensions include some sizes of structural panels 2, but it should be understood that any size of structural wall 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 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 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 fifth stud 46), and cross one or more intermediate support members 31 (e.g., the studs 32, such as the second stud 40, the third stud 42, the fourth stud 44, or the like) along the panel length 4. As illustrated in
The depiction in
The ductile fluted wall panel systems 1 depicted in
The present invention is an improvement over traditional systems which connect the panels 2 to each of the one or more intermediate supports members 31, which creates a very stiff structural wall panel system 1. This stiffness is a result of the stiffness of the fluted structural panel 2 and the stiffness of the connections to the support members 31. This configuration will carry load well, but is not very ductile when the system is loaded past its ultimate capacity in cyclic shear loading. The poor ductility is due to the construction of the walls to which the panels 2 are connected and the connection of the panels 2 to each of the support members 31. This combination of close support framing, the fluted panel stiffness, and connection stiffness leads to a stiff structural wall panel system 1 that carries load up to the ultimate capacity at which point the couplings 50 at the connections fail and the wall panel system 1 loses shear strength with very little additional displacement during additional cyclic in-plane shear loading. It should be understood that the traditional systems are described with respect to wall systems, but it should be understood that roof systems in which the roof panels are coupled to each of the intermediate support members also creates a very stiff structural roof panel system 1, and has the same problems as the traditional wall panel systems described above.
The present invention provides a ductile fluted panel system (e.g., ductile fluted wall panel system and/or a ductile fluted roof panel system) that provides increased load capacity after reaching the ultimate failure load by allowing panel buckling between support members 31. When the ductile fluted panel system (e.g., wall or roof system) of the present invention is subjected to cyclic in-plane shear loading, the panel 2 will buckle between support members 31 (e.g., between the studs 32 at which the connections are made), then when the load is reversed, the panel 2 pulls straight before buckling in the other direction. In the present invention, panels 2 can buckle back and forth through multiple in-plane loading cycles without a rapid failure caused by the failure of the couplings 50 or panel at the connection locations. Structural wall panel systems and roof panel systems that behave in this way are not generally practical because the spacing between supports must be very wide to achieve panel buckling when the couplings 50 are used at connection locations between the panel 2 and each support member 31 in the system. This large spacing between support members 31 is too wide for other building considerations, which require the close spacing between support members 31 in order to support structural loads other than in-plane shear loading (e.g., seismic loading), such as the loads from the weight of the building and furnishing therein.
As such, the use of the combination of the sidelaps described herein that increase the strength of the sidelaps, along with the connection configurations described herein, allows the panels 2 to buckle with close support member 31 spacing that maintains the diaphragm strength of the panel system. For example, the ductile wall panel system 1 has buckling spans (e.g., distance between support members 31 with end support couplings 52, panel support couplings 58, and/or both) that may range from 4 ft to 16 ft, and typically range from 5 ft to 10 ft. It should be understood that the bucking spans may be within, outside, or overlapping these ranges. Alternatively, the ductile roof panel system 1 has buckling spans that may range from 6 ft to 20 ft, and typically range from 8 ft to 16 ft. It should be understood that the buckling spans may be within, outside, or overlapping these ranges.
As previously discussed, in addition to the structural wall panel system 1 discussed with respect to
The present invention provides a ductile fluted roof panel system 100 with improved ductility through buckling that occurs before connection failure. Like the ductile fluted wall panel system 1 previously discussed, the improved ductility is created by the increased strength at the sidelap between adjacent panels 2, and the increased buckling span formed by the absence of couplings 50 between the panels 2 and the one or more of the intermediate support members 31 located between the end support members 31 having end support couplings 52, as illustrated by
The performance of the ductile fluted wall panel systems 1 and ductile fluted roof panel systems 100 described herein has been demonstrated in various tests. The connection patterns in which none of the intermediate supports are coupled to the panel 2, versus coupling the panels 2 to all of the intermediate support members 32 was tested. The load displacement graphs illustrating the displacement of the systems verses shear loading are shown in
It should be understood that in some embodiments of the invention the first leg 252, the second leg 254, and the third leg 256 are the same height, such that the overall height of the reinforcing member 250 is the same as the heights of the legs. In some embodiments of the invention the connectors 258 may extend the height of one or more of the first leg 252, the second leg 254, and/or the third leg 256. In still other embodiments the first leg 252, the second leg 254, and/or the third leg 256 may be different heights. As such, it should be understood that different configurations of the reinforcing member 250 may be provided, in which the individual legs have heights that may extend beyond, short of, or are in line with the other legs and/or connectors of the reinforcing member 250. The legs may be straight, or may have portions that are straight with other portions that are shaped (e.g., bent, curved, or the like) in order to add additional support to the reinforcing member 250.
As such, in some embodiments of the invention the couplings 50, such as fasteners, may extend through all of the legs of the reinforcing member 250. In some embodiments, the couplings 50, such as the fasteners, may extend through the straight portions and/or the shaped portions of the legs of the reinforcing members 250 and the edges of the panels 2. In other embodiments of the invention, the first leg 252 and/or the third leg 256 may be of a length, such that the couplings 50 (e.g., fasteners) do not extend through the first leg 252 and/or third leg 256; however, in this embodiment these legs may still provide channels 260, 262 in which the panel edges 12 are located for assembly purposes.
It should be further understood that while the legs of the generally S-shaped reinforcement member 250 are illustrated herein as being generally parallel, the first leg 252 and the third leg 256 may diverge from the second leg 254 such that the channels 260, 262 become wider at the opening of the channels 260, 262, which may facilitate assembly of the edges 12 of the panels 2 into the reinforcing members 250.
As illustrated in
It should be further understood that in some embodiments, two or more reinforcing members 250 may be utilized along the length of a single panel 2. For example, one reinforcing member 250 may be located between a first span between a first support member 31 and an intermediate support member 31 (e.g., it may or may not cross one or more of the support members), and a second reinforcing member 250 may be located between a second span between a second support member 31 and an intermediate support member (e.g., it may or may not cross one or more of the support members). As such, in some embodiments the reinforcing member may not be located in the sidelap 13 where the sidelap 13 crosses a support member 31. Alternatively, the reinforcing member 250 may be notched (or a portion thereof may be notched, such as one or more of the legs) at a location where the reinforcing member 250 crosses one or more of the support members 31, such that the couplings 50 at the support member location may be easier to make (e.g., coupling doesn't have to be made through one or more of the additional layers of the reinforcing member 250).
Returning to
Block 204 in
Block 208 in
Block 210 in
As previously discussed, in one embodiment of the invention the five-layer, six-layer, or other like sidelap may be operatively coupled using couplings 50 that are fasteners 70. In one embodiment of the invention, as illustrated in
As such, in other embodiments of the invention, the couplings 50 in the five or more layer sidelap (or three-layer, four-layer, five-layer, six-layer, or the like) may be welds that are welded from the inside or outside of the building. When welding from the inside of the building, the additional layers at the sidelap 13 provide additional material for creating the weld and preventing burn-through. The weld may fuse portions of the first edge 14, second edge 16, and/or the reinforcing member 250 together. When welding two-layer sidelaps, for example, burn through may occur when filler material burns through the single edges of the panels, which causes a defective weld. A defective weld may result in additional time for a welder to repair the weld, and even after repairing the weld may not have the desired strength. The extra layers of material provided by the reinforcing member 250 creates a sidelap that is less likely to be burned through during the welding process.
In other embodiments of the invention, instead of the couplings 50 being fasteners 70 or welds, the five-layer (or other layer) sidelap may be deformed and/or cut (e.g., sheared) to couple the structural panels 2 together. In some embodiments of the invention a tool that punches through the sidelap may be utilized to create the couplings 50.
Block 212 of
During assembly of longitudinal adjacent wall panels 2, the panels may either be butted up against each other, or may be overlaid on top of each other at the ends 18 of the structural panels 2. When the ends 18 of longitudinal adjacent panels 2 are overlaid on top of each other, fasteners 70 or other means for coupling the ends 18 of the longitudinal adjacent structural panels 2 may be utilized. However, in some embodiments, overlaying the ends of the longitudinal adjacent structural panels 2 may create a double sidelap location at the corners of the panels 2, such as a ten-layer sidelap or eleven-layer sidelap (e.g., when five-layer sidelaps are used on top of each other, and potentially when located at a support member 31 that adds an additional layer). In some embodiments of the invention, a coupling 50 may be created at the overlapping location. As previously discussed with respect to the couplings 50 in the five-layer sidelap, the couplings 50 used in the double sidelap locations, such as the ten-layer sidelap location (or other number of layers) may be the same. However, in some embodiments of the invention a special fastener (e.g., self-drilling screw, pin, rivet, or the like) may be utilized to create a coupling 50 at the double sidelap location (e.g., in the ten-layer or eleven-layer sidelap location, or other number of layers). In other embodiments, a weld may be used as a coupling at the double sidelap locations, while the same or different types of couplings may be used at other locations on the sidelaps 13. However, it may be difficult to create a proper weld at a sidelap 13 that has ten-layers or eleven-layers. Creating a coupling 50 at the double sidelap location may further improve the shear strength of the sidelap 13 and structural wall panel system 1, thus allowing for a reduced thickness of the wall panels 2, a reduction of the number of couplings used along a sidelap 13 or within the ductile fluted wall panel system 1 and/or improved flexibly. However, in some embodiments the ductile fluted wall panel system 1 may be formed without a coupling 50 at the double sidelap location, and the improvements of the shear strength and/or flexibility described herein may be still be achieved. In still other embodiments of the invention, the panels 2 may have a cut-away (e.g., notch) at the corner of one or more of the ends 18 to prevent the double seem locations at the corners of the wall panels 2. In still other embodiments of the invention the reinforcing member 250 may be shorter than the length of the panel 2 or have a cutout (e.g., notch), such that the one or more ends 18 of the panels 2 when assembled would not include the additional layers created by the reinforcing member 250. For example, the reinforcing member 250 may not exist at the overlap of longitudinally adjacent ends 18, or only a single reinforcing member may exist at the overlap of the longitudinally adjacent ends 18.
The sidelap 13 created in the present invention is much easier to assemble than an interlocking sidelap and/or overlapping sidelaps, because the wall panels 2 can be slid right into the channels 260, 262 of the reinforcing member 250, or the reinforcing member 250 may be slid over the edges 12. The reinforcing member 250, in addition to ultimately increasing the strength and/or stiffness of the sidelap 13 and/or system 1 when the couplings 50 are installed, also holds the panels 2 in place while being assembled together. It should further be understood that the improved strength at the sidelap 13, allows for the use of other features of the present invention that improve the flexibility of the structural panel systems. For example, increasing the strength of the sidelap 13, and utilizing the connection configurations previously described above, create the buckling spans in the panels 2 without degrading the strength of the overall ductile fluted panel system (e.g., without reducing the ultimate loading strength). Without increasing the strength of the sidelaps 13 between the panels 2, the ability to create the buckling spans in the panels 2 without degrading the strength of the overall system may not be possible.
It should be understood that while the edges 12 of the panels 2 are represented as single layer edges 12. It should be understood that the edges 12 may be multiple layer edges 12, and may be formed by folding the edge 12 of the panel 2 back upon itself. In this embodiment, one or more of the panels 2 may be inserted into the reinforcing member 250 and provide additional layers at the edges 12 of the panels 2. Alternatively, the reinforcing member 250 may include legs that are folded back upon themselves in order to create legs that have additional layers.
Like the structural panels 2 previously described, the reinforcing member 250 described herein, may be manufactured from a variety of rigid materials including steel, aluminum, titanium, plastic, a composite, or another type of rigid material. The reinforcing member 250 may typically be made of steel and may have a length that ranges from 1 foot to 50 feet long. As such, the reinforcing member 250 may be the same length as a panel 2, may be longer than a panel 2, or may be shorter than a panel 2, in which case one or more reinforcing members 250 may be utilized within a sidelap 13 between two adjacent lateral panels 2. It should be understood that any size of reinforcing member 250 may be utilized that is within these ranges, overlapping these ranges, or outside of these ranges. The material thickness of the reinforcing member 250, like the structural panels 2, may be any thickness; however, the reinforcing member 250 thicknesses, may be the thickness of 29 gage to 16 gage steel, inclusive. Other material thicknesses of the present invention may be within this range, overlap this range, or be located outside of this range.
As previously discussed the reinforcing member 250 may improve the strength of the sidelap 13 and/or the panel system with or without the use of the connection configurations discussed above. It should be understood that utilizing the reinforcing member 250 of the present invention described herein (e.g., five-layer sidelap, or other layer sidelap) may improve the shear strength of the sidelap and/or structural panel system 1 over an overlapping sidelap and/or interlocking sidelap by 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 150, 200, 250, 300 or more percent. In other embodiments, the improvement may be outside of, within, or overlapping any range of these numbers. This improvement in the strength of the sidelap 13 and/or structural panel systems 1, 100 may allow for the other configurations described herein that improve the flexibility of the overall structural panel systems 1, 100, while still maintaining the desired strength of the structural panel systems 1, 100.
In other embodiments of the invention, other types of improved sidelaps 13 may be utilized in order to improve the strength of the sidelap 13 and/or the overall ductile fluted panel systems 1, 100. As such, as previously described, the improved strength at the sidelap 13 may allow for the use of other aspects of the invention that improve the flexibility of the panel system, such as the use of the connection configurations previously described. Two examples, of improved sidelaps may be a sidelap seam (e.g., an out-of-plane sidelap seam) with four or more layers as described in further detail with respect to
The male lip 30 may be created at one of the decking panel edges 12 by roll forming (or other like operation) the decking panel edge 12 into a generally inverted U-shape, V-shape, or other like shape. The male lip 310 may have a first male lip layer 320 that is extended generally out of plane from an in-plane orientation of the decking panel 2, as illustrated in
As further illustrated in
In some embodiments, the male lip 310 may have a second male lip layer 22 that is folded in an open configuration to the inside or the outside of the decking panel edge 12 (e.g., inwardly or outwardly), as depicted in
When folded, the male lip 310 typically includes a thickness of two layers of the panel 2 as illustrated in
The panel edge 12 on the opposite side of the panel 2 as the male lip 310 may include an inverted “U” shaped female lip 312 as shown in
The female lip 312, in some embodiments, is configured to substantially cover the male lip 310 (e.g., configured to receive the male lip 310), such that the female lip 312 is typically larger than the male lip 310. The female lip 312 may be formed by folding the panel edge 12 into an “inverted U” or “inverted V” shape, or other like shape, with a channel that fits over the male lip 310. The female lip 312 may have a first female lip layer 330 that is extended generally out-of-plane from the in-plane orientation of the panel 12.
The female lip 312 may have a second female lip layer 332 that is folded outwardly towards the outside of the decking panel edge 12, as depicted in
It should be understood that the layers may be straight, or may have portions that are straight with other portions that are shaped (e.g., bent, curved, or the like), in order to add additional support to the male lip 310, the female lip 312, and/or the sidelap 13. The couplings 50 formed at the connection locations may occur in the straight portions and/or the shaped portions of the male lip 310, the female lip 312, and/or the sidelap 13
In order to operatively couple two adjacent panels 2 together, the male lip 310 of a first panel 4 may be received by a female lip 312 of a second panel 6. The female lip 312 may be placed over the male lip 310 as depicted in
In one embodiment of the invention the four-layer sidelap seam (or five-layer, six-layer, or the like) may be top-seam welded or side-seam welded in order to create the coupling (also described as a joint, connection, attachment, or the like) between adjacent decking panels 2. As illustrated by
In other embodiments, a side-seam weld may be utilized to create the couplings 50 in the sidelap seam 314. As was described with respect to the top seam weld, the side seam weld may fuse the one or more layers of the four-layer sidelap seam 314 and/or utilize filler material to create the welded coupling 50. Also, like with top-seam weld, when only three layers are present burn through may occur through the three layers, and as such, the coupling may not be formed properly and the shear strength of the coupling 50 may be reduced. As such, the presence of the fourth layer (or additional layers) provides additional material that helps to prevent burn through. However, the presence of the fourth layer may also make it more difficult to create a weld through all four layers. Moreover, the space limitations on either side of the sidelap seam 314 between the top flanges 84 of adjacent decking panels 2 may make it difficult to access the side of the sidelap seam 314 in order to create the side-seam weld. As such, in some embodiments a top seam weld may be more effective and/or easier to form than a side-seam weld.
In other embodiments of the invention, instead of a welded sidelap seam 314, as previously discussed, the four-layer sidelap seam 314 may be deformed and/or cut (e.g., sheared) to couple the decking panels 2 together. In some embodiments of the invention a tool having jaws is used to form the couplings 50 in the sidelap seam 314. The jaws (e.g., two or more opposed jaws) of the tool may span the out of plane side lap seam 314. The jaws may perform the deformation and cutting operations, or the jaws may include blades, cavities, punches, dies, and/or any other feature that deforms and/or cuts at least a portion of the sidelap seam 314. When actuated, the jaws, and/or other feature on the jaws, deform and/or cut the sidelap seam (e.g., in any order) in order to form the coupling 50. The jaws may be manually actuated or actuated through a power source, such as but not limited to pneumatically actuated, hydraulically actuated, electromechanically actuated, or actuated using any other type of power source in order to create the coupling 50. Depending on the material thickness of the four layers of the sidelap seam 314, pneumatic or hydraulic actuation may be required in order to cut through the four layers (or more) of the sidelap seam 314.
In one embodiment cutting the sidelap seam 314 comprises shearing and deforming a portion of the sidelap seam 314 to create a tab that provides interference at the ends of the tab to resist lateral movement of the adjacent panels.
As illustrated generally in
The number of cut locations at a particular coupling location in the sidelap seam 314 may vary depending on the desired shear strength, thicknesses of the layers, shape of the jaws (or shape of an attachment feature to the jaws). In some embodiments, only one tab 350 (e.g., one rectangular tab) may be sheared into a coupling location in the sidelap seam 314. However, in other embodiments multiple tabs may be sheared into the sidelap seam 314 at a particular coupling location. Namely, the coupling may contain two or more tabs 350 (e.g., two or more sheared rectangular tabs). More tabs 350 may theoretically mean better shear strength and resistance to lateral forces. As illustrated in
In still other embodiments of the invention, fasteners 70 may be utilized instead of welds or the cut or sheared couplings 50 described with respect to
As illustrated in Table 1, as the thicknesses of the decking panels increase (e.g., as the gage decreases from 22 to 20 to 18 to 16, or the like) the shear strength along the sidelap seam between two decking panels generally increases. However, when compared to a three-layer sidelap seam having a single male lip layer, a four-layer sidelap seam having two male lip layers shows improvements in shear strength. For example, for panels 2 that were 0.0299 inches thick (e.g., 22 gage) the two examples tested using the four-layer sidelap seams illustrated a 46% improvement in the shear strength (for both the open and closed configurations) over using the same type of coupling in a three-layer sidelap seam. With respect to the decking panels that were 0.0359 inches thick (e.g., 20 gage) the two examples tested using the four-layer sidelap seam illustrated an improvement in the shear strength of 53% (for the open male lip configuration) and 41% (for the closed male lip configuration), respectively, over the shear strength of the three-layer sidelap seam using the same type of coupling. With respect to the decking panels that were 0.478 inches thick (e.g., 18 gage) the two examples tested using the four-layer sidelap seam illustrated an improvement in the shear strength of 66% (for the open male lip configuration) and 62% (for the closed male lip configuration), respectively, over the shear strength of the three-layer sidelap seam using the same type of coupling. With respect to the decking panels that were 0.0598 inches thick (e.g., 16 gage) only the three layer sidelap seam was tested. It should be understood that four or more layers may be created in the seam of the 16 gage material, however, tests were not performed on the 16 gage material with a four-layer sidelap seam. As illustrated, the shear strength of the 16 gage material using a three-layer sidelap seam was 6628 lbs., while the shear strength of the four-layer sidelap seam using the 18 gage material (e.g., thinner than the 16 gage material) was 7717 lbs. As such, the four-layer sidelap seam using the thinner material provided improved shear strength of 16% over the three-layer sidelap seam using the thicker material.
The values displayed in Table 1 relate to single results of testing of the four-layer sidelap seams of the present invention versus three-layer sidelap seams in one example. The actual repeatable product testing may provide different results, but generally it should be understood that with other variables being equal the four-layer sidelap seam provides improved shear strength when compared to three-layer sidelap seams. As such, based in part on Table 1, the use of a four-layer sidelap seam over a three-layer sidelap seam generally increases the shear strength of the sidelap seam. The increased shear strength, with all other factors being equal, shows at least a 40% improvement in the shear strength. However, in other embodiments of the invention, with reduced material thickness the shear strength of the four-layer sidelap seam may also illustrate an improvement over three-layer sidelap seams with greater material thicknesses. As such, in the present invention, the shear strength of the four-layer sidelap seam, may have a 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 150, or more percent improvement over the shear strength of a three-layer sidelap seam (e.g., with the other factors of panel thickness and number of couplings being equal). The improvement in shear strength may include a range that falls within, is outside of, or overlaps any of the percent values recited above. It should be noted that the shear strengths illustrated in Table 1 are for the isolated couplings within a sample of a panel system. Moreover, the shear strengths of the sidelap seam 314 may be less than, the same as, or greater than what is illustrated in Table 1 based on the type of couplings formed in the sidelap seam. For example, a different type of coupling formed by cutting may result in a shear strength that is less than, equal to, or greater than what is illustrated in Table 1. In another example, using a weld or a fastener (e.g., different types of fasteners) as couplings 50 may result in a shear strength that is less than, equal to, or greater than what is illustrated in Table 1. However, it should be understood that utilizing the four-layer sidelap seam (or more than four-layers) with various types of couplings 50 may result in improved shear strength over the use of the same or similar couplings 50 in a three-layer sidelap seam.
As previously discussed with respect to the improved shear strength resulting from the use of the reinforcing member 250, the improved shear strength of the four layer sidelap seam 314 allows for the use of aspects of the present invention that improve the ductility of the panel system. The improved sidelap seam 314 allows for the use of panels 2 with reduced thicknesses, a reduce number of connections along the length of the sidelap seam, the use of the connection configuration patterns previously discussed herein, and/or use of other aspects of the invention described herein that create bucking spans in the panels, which allow for buckling of the panels 2 before failure of the connections (e.g., failure of the couplings to the support members 31, failure of the couplings in the sidelap seam 314, and/or failure of the sidelap seam 314 or panels around the couplings). For example, by increasing the strength of the sidelap seam 314, and utilizing the connection configurations previously described herein, the buckling spans are created in the panels 2 without degrading the strength of the overall ductile fluted panel system (e.g., without reducing the ultimate loading strength of the ductile fluted panel system). Without increasing the strength of the sidelap seams 314 between the panels 2, the ability to create the buckling spans in the panels 2 without degrading the strength of the system may not be possible.
Moreover, as previously discussed, the increased shear strength utilizing the four-layer out-of-plane sidelap seam 314 may be an improvement over a three-layer sidelap seam because not as many couplings would be needed in the four-layer sidelap seam in order to achieve the same or similar shear strength in the three-layer sidelap seam. In one example, with respect to Table 1, when using 18 gage panels with a ten (10) foot long sidelap seam of mating decking panels 10 and couplings that are located one foot apart (e.g., at 0.5 ft, 1.5 ft, 2.5 ft . . . 9.5 ft) a decking system that utilizes the three-layer sidelap seam may have a shear strength of 46,560 (e.g., 10 couplings multiplied by the 4656 lbs. shear strength of a single coupling in the 18 gage panel). In the present invention, the same system (e.g., 18 gage panels with a ten (10) foot long sidelap seam, and the same type of couplings) can achieve the same or similar shear strength in the four-layer sidelap seam by utilizing only 6 couplings (e.g., 46,560/7717 equals 6.033 couplings). This illustrates a 40% reduction in the amount of couplings. As such in some embodiments of the invention, depending on the gage thickness, the length of the sidelap seam, the type of four-layer sidelap seam, the type of couplings, or other like parameters, the number of couplings used in the four layer sidelap seam of the present invention may be reduced by 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or more percent when compared to the number of couplings used in a three layer sidelap seam (e.g., with all the other factors of the systems being equal) while maintaining the same or similar shear strength. As such, the number of couplings 50 may be reduced by any percentage illustrated or by any range that falls within, is outside of, or overlaps any of the percentages listed above. The reduction in the number of couplings 50 used reduces the assembly time of the system, which results in lower costs and improved safety (e.g., the workers spend less time on roofs installing the systems).
As previously discussed the increased shear strength utilizing the four-layer sidelap seam may be an improvement over a three-layer sidelap seam because using the four-layer sidelap seam may allow a four-layer sidelap seam system to drop gage thicknesses (e.g., move from 18 gage to 20 gage) without sacrificing shear strength. As illustrated in Table 1, a system may be able to utilize 20 gage panels using the four-layer sidelap seam to achieve a shear strength (e.g., 5164 lbs. or 4750 lbs.) that is the same or similar to the shear strength (e.g., 4656 lbs.) using a three-layer sidelap seam with an 18 gage panel (e.g., thicker than the 20 gage panel) and the same number of couplings 50. In some embodiments of the invention, a reduction in the thickness of the panels (e.g., a drop down in the gage thickness from 18 to 20, or any other drop) may not be achieved without also increasing the number couplings used in the four-layer sidelap seam. This would only occur when a reduction in the thickness of the panels using a four-layer sidelap seam with the same number of couplings as the three-layer sidelap seam using the thicker panels would not result in the same shear strength. Adding additional couplings 50 in the four-layer sidelap seam may achieve the desired shear strength, while still reducing costs because the material is less expensive (e.g., thinner decking panels), even though creating the additional couplings 50 in the sidelap seam would increase the cost of assembly. As such, in some embodiments of the invention, depending on the gage thickness, the length of the sidelap seam, the type of four-layer sidelap seam, the type of couplings, or other like parameters, the thickness (or in other embodiments of the invention the weight) of the panels may be reduced by 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or more percent, while still achieving the same shear strength as a three layer sidelap seam that utilizes the same, more, or in some cases less couplings.
In other embodiments of the invention, a nested sidelap 414 may be utilized as the sidelap 13 in embodiments of the present invention in order to strengthen the sidelap 13 to be able to create the desired buckling spans in the panels 2. Embodiments of the nested sidelap 414 may be illustrated in
One structural panel edge 12 may include a generally in plane lower lip 410 (e.g., located between 45 degrees+/−from an in-plane orientation with the plane of the structural panel 2, or the like) as illustrated in
The lower lip 410 may be created at one of the structural panel edges 12 by roll forming (or other like operation) the structural panel edge 12 into a generally flat in plane shape (as illustrated in
The figures illustrate that the first lower lip layer 420 and the second lower lip layer 422 touch; however, it should be understood that in some embodiments there may be no gap between the surfaces of the first lower lip layer 420 and the second lower lip layer 422 (as illustrated in the figures), may be some gaps along at least a portion of the first lower lip layer 420 and the second lower lip layer 422, or a gap along the entire length of the lower lip 410 between the first lower lip layer 420 and the second lower lip layer 422. As such, in some embodiments of the invention the second lower lip layer 422 may converge towards the first lower lip layer 420, diverge away from the first lower lip layer 420, or both depending on the location along the length of the lower lip 410.
When folded, the lower lip 410 typically includes a thickness of two layers of the structural panel 2 as illustrated in
The opposite structural panel edge 12 may include a generally in-plane upper lip 412 (e.g., located between 45 degrees+/−from a parallel orientation with the plane of the structural panel 2, or the like) as illustrated in
The upper lip 412 may be created at one of the structural panel edges 12 by roll forming (or other like operation) the structural panel edge 12 into a generally flat in-plane shape (e.g., horizontal orientation in roof or floor systems) as illustrated in the figures, or another shape such as a bowed shaped (e.g., concave or convex), or the like. The upper lip 412 may have a first upper lip layer 430 that is extended in a generally in-plane orientation, as illustrated in
The figures illustrate that the first upper lip layer 430 and the second upper lip layer 432 touch. However it should be understood that in some embodiments there may be no gap between the surfaces of the first upper lip layer 430 and the second upper lip layer 432 (as illustrated in the figures), may be some gaps along at least a portion of the first upper lip layer 430 and the second upper lip layer 432, or a gap along the entire length of the upper lip 412 between the first upper lip layer 430 and the second upper lip layer 432. As such, in some embodiments of the invention the second upper lip layer 432 may converge towards the first upper lip layer 432, diverge away from the first upper lip layer 432, or both depending on the location along the length of the lower lip 410.
When folded, the upper lip 412 typically includes a thickness of two layers of the structural panel 2 as illustrated in
In some embodiments the upper lip 412 and/or the lower lip 410 may extend beyond the lower flange corners 85 of the adjacent structural panels 2. In still other embodiments the nested sidelap 414 with three or more layer may be located over a width within the center, on the left side, on the right side, or anywhere else within the bottom flange 86 created between two adjacent top flanges 84 of adjacent structural panels 2.
In order to couple two adjacent panels 2 together, the lower lip 410 of a first structural panel 2 (with or without the nested portion 411) may receive an upper lip 412 of a second structural panel 2. The upper lip 412 may be placed over the lower lip 410 as depicted in
As illustrated in
As illustrated in
It should be understood that the layers in the upper lip 410 and/or lower lip 420 may be straight, or may have portions that are straight with other portions that are shaped (e.g., bent, curved, or the like), in order to add additional support to the upper lip 410, the lower lip 420, and/or the nested sidelap 414. The couplings 50 formed at the connection locations may occur in the straight portions and/or the shaped portions of the lower lip 410, the upper lip 412, and/or the sidelap 13.
As such, the nested sidelap 414 in some embodiments may be formed in multiple planes around a lower flange corner 85, such as in-plane with the lower flange 86 formed between adjacent structural panel edges 12, at an angle from the lower flange 86 and in-plane with a web 88, and around a lower flange corner 85. The connections formed by the couplings 50 in the nested sidelap 414 illustrated in
Table 2 illustrates percent improvements for the diaphragm shear strength values for a four-layer nested sidelap 414 over a two-layer nested sidelap 414 for structural decking systems with different panel thicknesses, and using self-drilling screws as the couplings 50 at the connection locations. The minimum shear strength improvements illustrated in Table 2 were found at the lower span lengths (e.g., shorter lengths of the decking panels), while the maximum shear strength improvements were found at the higher span lengths.
It should be understood that utilizing a nested sidelap of the present invention described herein (e.g., four-layer, three-layer, corner nested sidelap, or other layer nested sidelap greater than two-layers) may improve the shear strength of the nested sidelap and/or structural panel system over a two-layer nested sidelap and/or structural panel system by 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 150, 200, 250, 300 or more percent. In other embodiments the improvement may be outside of, within, or overlapping any numbers within this range.
As previously discussed, with respect to the improved strength resulting from the use of the reinforcing member 250 or the out-of-plane four-layer sidelap seam 314, the improved shear strength of the nested sidelaps 414 described herein allows for the use of aspects of the present invention that improve the ductility of the panel system. The improved nested sidelaps 414 allows for the use of panels 2 with reduce thicknesses, the use of a reduced number of couplings 50 at the connection locations, the use of the connection configuration patterns previously discussed herein, and/or use of other aspects of the invention described herein that create bucking spans in the panels 2, which allow for buckling of the panels 2 before failure of the connections (e.g., failure of the couplings 50 to the support members 31, failure of the couplings 50 in the nested sidelap 414, and/or failure of the nested sidelap 414 or panels 2 around the couplings 50). For example, by increasing the strength of the sidelap through the use of a nested sidelap 414, and utilizing the connection configurations previously described herein, the buckling spans are created in the panels 2 without degrading the strength of the overall ductile fluted panel system (e.g., without reducing the ultimate loading strength of the ductile fluted panel system). Without increasing the strength of the sidelap between the panels 2, the ability to create the buckling spans in the panels 2 without degrading the strength of the system may not be possible.
Alternatively, as discussed herein, using the four-layer nested sidelap 414 (or three-layer nested sidelap) of the present invention can increase the stiffness without affecting the costs because the number of couplings and/or the thickness of the decking panels remain unchanged. The improvement of the present invention is due in part to creating a connection through four-layers (or three-layers) using a coupling 50, which is stiffer than creating a connection through two-layers. The values for Table 2, and discussion thereof, are described as being related to roof systems 100, but it should be understood that the same principals would also apply to wall systems 1.
Moreover, as previously discussed, the increased shear strength utilizing the four-layer nested sidelap 414 may be an improvement over a two-layer in-plane nested sidelap because not as many couplings 50 would be needed in the four-layer nested sidelap 414 in order to achieve the same or similar shear strength in the two-layer sidelap. As such in some embodiments of the invention, depending on the gage thickness, the length of the nested sidelap, the type of four-layer nested sidelap 414, the type of couplings 50, or other like parameters, the number of couplings used in the four layer nested sidelap of the present invention may be reduced by 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or more percent when compared to the number of couplings used in a two-layer in-plane sidelap (e.g., with all the other factors of the systems being equal) while maintaining the same or similar shear strength. As such, the number of couplings 50 may be reduced by any percentage illustrated or by any range that falls within, is outside of, or overlaps any of the percentages listed above. The reduction in the number of couplings 50 used reduces the assembly time of the system, which results in lower costs and improved safety (e.g., the workers spend less time on roofs installing the systems).
As previously discussed the increased shear strength utilizing the four-layer nested sidelap, or other sidelap discussed herein, may be an improvement over a two-layer in-plane sidelap (or in other embodiments a three-layer sidelap seam) because using the four-layer nested sidelap may allow a four-layer nested sidelap system, or other sidelap discussed herein, to drop gage thicknesses (e.g., move from 18 gage to 20 gage, or the like) without sacrificing shear strength. In some embodiments of the invention, a reduction in the thickness of the panels (e.g., a drop down in the gage thickness from 18 to 20, or any other drop) may not be achieved without also increasing the number couplings used in the four-layer nested sidelap, or other sidelaps discussed herein. This would only occur when a reduction in the thickness of the panels using a four-layer nested sidelap, or other sidelaps discussed herein, with the same number of couplings as a two-layer sidelap (or a three-layer sidelap seam) using the thicker panels would not result in the same shear strength or the desired shear strength. Adding additional couplings in the four-layer nested sidelap, or other sidelaps discussed herein, may achieve the desired shear strength, while still reducing costs because the material is less expensive (e.g., thinner structural panels), even though creating the additional couplings in the seam may increase the cost of assembly (e.g., if the cost of inserting the fasteners of the present invention were less than the cost savings of the thinner structural panels). As such, in some embodiments of the invention, depending on the material thickness of the panels, the length of the nested sidelap, the type of four-layer nested sidelap, or other sidelaps herein, the type of couplings, or other like parameters, the thickness (or in other embodiments of the invention the weight) of the panels may be reduced by 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 150, or more percent, while still achieving the same shear strength as a two-layer sidelap (or a three layer sidelap seam) that utilizes the same, more, or in some cases less couplings.
Generally, because of the additional strength at the sidelaps 13 discussed herein (e.g., the sidelap with the reinforcing member 250, the four-layer sidelap seam 314, and/or the three or more layer nested sidelaps 414) the overall structural panel system may be less flexible when compared the same structural panel system with a two-layer in-plane sidelap or three layer sidelap seam, with all other features being the same. As such, in some applications of the structural panel system in some types of building structures, it may be desirable to improve the diaphragm system flexibility or ductility (e.g., reduce stiffness) at the expense of the shear strength. The sidelaps of the present invention may facilitate the ability to improve flexibility without degrading the shear strength. As discussed herein, improvements in the flexibility may be achieved through a number of different ways, such as reducing the thickness of the structural panels 2, reducing the number of couplings in the sidelaps 13, using the connection patterns described herein (e.g., no connections with the intermediate support members 31, or no connections at alternating intermediate support members 31), changing the orientation of the panels (e.g., as discussed in further detail below), or the like, all of which can be achieved while maintaining the desired shear strength of the sidelaps 13 or structural panel systems. As such, not only may the sidelaps 13 discussed herein be utilized to increase the shear strength of the sidelap, but may also be used to increase the diaphragm system flexibility of the ductile fluted panel systems 1, 100 while keeping the shear strength the same or similar to two layer sidelap configurations.
The sidelaps discussed herein have been discussed with respect to being either in wall panel systems 1 and/or roof panel systems 100; however, it should be understood that the sidelaps discussed herein may be utilized in either wall panel systems 1 or roof panel systems 100, or within different zones of wall panel systems 1 or roof panels systems 100. For example, different areas within a roof and/or wall panel system may require different strengths and/or flexibility. As such, the present invention may be utilized to provide systems that have the desired flexibility, strength, and/or cost.
Instead of using the combination of the increased strength along the sidelaps 13 between adjacent panels 2, and the connection configurations described herein, in order to achieve the buckling spans of the ductile fluted panel systems 1, 100 described herein, the orientation of the decking panels 2 may be changed. Changing the orientation of the panels 2 may also provide for improved flexibility of the roof and/or wall panel systems.
It should be understood that the ability of fluted panels 2 to resist out-of-plane loading 580, such as wind loads, is typically not critical when in-plane loading 590, such as seismic loading, is more of a concern. The key characteristic for ductile fluted wall panel systems 1000 to resist in-plane loading 590, such as seismic loads, is the ductility of the wall panel systems 1000. The ductility of the ductile fluted wall panel system 1000 is directly related to how much in-plane displacement a wall can absorb both leading up to and after the peak shear load is applied.
The process 600 may also include block 604 of assembling a panel 2 (e.g., a first panel) to the two or more studs, wherein the panel 2 comprises a plurality of flutes 3 running longitudinally along the panel 2 in the first direction along with the two or more support members 31.
The process 600 further includes block 606, in which additional panels 2 are operatively coupled to the support members 31, the panel 2 from block 604, and/or each other. The flutes 3 of the additional panels 2 are assembled in the first direction along with the two or more support members 31 and the panel 2 from block 604 in order to form the ductile fluted panel system 1000.
In some embodiments, multiple panels 2 may be assembled together such that they form at least a portion of a roof or wall panel system. In such embodiments, the panels 2 may overlap each other at the ends 18 of longitudinally adjacent panels (e.g., adjacent panels in which the flutes 3 align longitudinally in series) such that longitudinally adjacent panels 2 may be assembled together by using couplings 50 that operatively couple the overlapping portions of the ends 18 together and/or to support members 31. In other embodiments, the panels 2 do not overlap, and the couplings 50 operatively couple the ends 18 of the panels 2 to the support members 31 (e.g., studs 32 or other supports). Laterally adjacent panels 2 (e.g., adjacent panels in which the flutes 3 are not aligned but are positioned parallel to each other) are further configured for coupling along the edges 12 of the panels 2. In such embodiments, the panel edges 12 create a sidelap 13 that may be assembled together by using couplings 50 that operatively couple the edges 12 of adjacent panels 2. These sidelaps may or may not utilize the seams described herein, such as but not limited to sidelaps with the reinforcing member 250, sidelap seams 314, and/or nested sidelaps 414.
In some embodiments of the process 600, the panels 2 and the two or more support members 31 (e.g., studs 32) are assembled such that when the ductile fluted wall panel system 1000 is under its peak load, the displacement of the ductile wall panel system 1 is at least 1.5 (e.g., approximately 2.25) times greater than wall panel systems 500 having flutes 3 oriented transverse to the support members 31 (e.g., studs 32) without the increased shear strength at the sidelaps and without the connection configurations described herein.
In some embodiments of the process 600, the panel 2 and the two or more support members 31 (e.g., studs 32) are assembled such that when the ductile fluted wall panel system 1000 is under eighty percent (80%) of its peak load, the displacement of the ductile wall panel system 1000 is at least 1.5 (e.g., approximately 2.25) times greater than wall panel systems 500 having flutes oriented transverse to the support members 31 (e.g., studs 32) without the increased shear strength at the sidelaps and without the connection configurations described herein.
The displacement of the ductile fluted wall panel system 1000 is due to the parallel configuration of the panels 2 with the support members 31, as this configuration provides less rigidity in a wall panel system. The reduced rigidity gives the ductile fluted wall panel system 1000 greater resiliency with respect to in-plane cyclic loading, such as seismic activity, whereby the panels 2 are allowed to bend and buckle due to the loading instead of transferring substantial forces to couplings 50 between the panels 2 and the support members 31 (e.g., studs 32). The reduced transferred forces on the couplings 50 between the panels 2 and the support members 31 (e.g., studs 32) reduces the likelihood that the connections (e.g., the couplings 50 or panels around the couplings 50) will fail, allowing the panels 2 of a ductile fluted wall panel system 1000 to buckle and continue to remain attached to the support structures 31 (e.g., studs 32) after enduring external forces that would have removed a fluted panel in a transverse configuration (without the increased shear strength at the sidelap and connection configurations discussed herein). However, it should be understood that these ductile fluted panel systems 1000 having flutes 3 running parallel to the support members 31 are not very resilient to other types of loading. As such, the ductile fluted panel systems 1, 100 that combines both the increased shear strength along the sidelaps 13, 314, 414, and the connection configurations described herein, provide and improved system that allows for increased displacement during cyclic in-plane loading, while still providing the desired strength in other types of loading (e.g., wind loading or other building loading). Alternatively, while ductile fluted panel systems 1000 having flutes 3 running parallel to the support members provides improvements for cyclic loading, these configurations have reduced strength during other types of loading.
It should be understood the orientating the panels 2 in parallel with the support members 31 (e.g., studs 32) has been described with respect to a ductile fluted wall panel system 1000. However, it should be understood that this same principal may be utilized in a roof panel system, and the same results may be achieved.
It should be understood that the combinations of different embodiments described herein allows for improved ductile fluted panel systems, which lead to a safer and more cost effective panel system when protection from in-plane loading 590 is more important than out-of-plane loading 580, such as when protection from seismic loading is more important than resisting wind loading.
It should be further understood that combinations of different embodiments described herein may be used within the ductile fluted wall panel systems 1, the ductile fluted roof panel systems 100, and/or building systems utilizing both the ductile fluted wall panels systems 1 and the ductile fluted roof panel systems 100. For example, in some embodiments different types of sidelaps (e.g., sidelap with reinforcing member 250, four-layer sidelap seam 314, three or four layer nested sidelap 414, or the like) may be utilized within different sections of the same ductile fluted wall panel system 1 and/or the same ductile fluted roof panel system 100. Moreover, in other examples, a ductile fluted wall panel systems 1 with one or more types of sidelaps will be used in the same building system with a ductile fluted roof panel systems 100 with one or more types of sidelaps. In one example, a ductile fluted wall panel system 1 with the reinforcing member 250 at the sidelap may be utilized as a wall within a building system, while a ductile fluted roof panel system with the sidelap seam 314 and/or the nested sidelap 414 may be utilized as a floor and/or roof within the building system. It these particular embodiments it may be easier to assemble the wall system with the reinforcing member 250, while it may be easier to assemble the floor and/or roof structure with the sidelap seam 314 and/or the nested sidelap 414.
It should be further understood when describing that a component is perpendicular with another component, perpendicular may be 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) (e.g., the flutes 3 of a panel are perpendicular, substantially perpendicular, or generally perpendicular to the support members 31, or the like). Moreover, it should be further understood when describing that a component is parallel with another component, parallel may be 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) (e.g., the flutes 3 of a panel are parallel, substantially parallel, or generally parallel to the support members 31, 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.
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.
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.”
The present application for a patent claims priority to U.S. Pat. No. 10,370,851 entitled “Structural System with Improved Sidelap and Buckling Spans” filed on Mar. 20, 2017 and issued on Aug. 6, 2019, which claims priority to U.S. Provisional Patent Application Ser. No. 62/311,257 entitled “Structural Wall and Roof Panel Systems Having Panel Seams With Improved Strength and Connection Configurations that Improve Ductility” filed on Mar. 21, 2016, both of which are assigned to the assignees hereof and hereby expressly incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 62311257 | Mar 2016 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15463937 | Mar 2017 | US |
| Child | 16532145 | US |
