Structural panel systems with a nested sidelap and method of securing

Patent metadata

Field	Value
Publication number	US-2016333584-A1
Application number	US-201615153460-A
Country	US
Kind code	A1
Filing date	May 12, 2016
Priority date	May 14, 2015
Publication date	Nov 17, 2016
Grant date	—

Abstract

The invention relates to structural panel systems with at least a four-layered generally in-plane sidelap, at least a three layer generally in-plane sidelap, or corner sidelaps of various layers, and methods for manufacturing and assembling structural panel systems with these types of sidelaps. The structural panels may be provided with an edge having a “lower lip” with two layers, and an opposite edge having an “upper lip” with two layers. Individual panels may be coupled together by placing the upper lip of a first panel over the lower lip of an adjacent panel, thus creating an un-joined sidelap. The lips may have nested portions for helping to place one lip over the other. The panels may be operatively coupled through various couplings configurations, such as fasteners, welding, cutting the sidelap, or the like. The present invention improves the shear strength of the structural panel system and reduces costs.

First claim

What is claimed is:

1 . A structural panel system, comprising:
a first structural panel comprising first top flanges, first bottom flanges, and at least one edge comprising an upper lip; a second structural panel comprising second top flanges, second bottom flanges, and at least one edge comprising a lower lip; wherein the upper lip of the first structural panel is placed over the lower lip of the second structural panel to create a sidelap with three or more layers, wherein the sidelap is generally in-plane with respect to the first structural panel and the second structural panel; and one or more couplings formed in the sidelap with three or more layers to couple the first structural panel to the second structural panel.

2 . The system of claim 1 , wherein the lower lip comprises:
a first lower layer; a second lower layer; and wherein the second lower layer is folded back upon the first lower layer to form a lower lip with two layers in an in-plane orientation with respect to the second structural panel.

3 . The system of claim 2 , wherein the second lower layer is folded on top of the first lower layer or folded under the first lower layer.

4 . The system of claim 1 , wherein the lower lip comprises:
a nested portion curved upwardly from an in-plane orientation of the lower lip with respect to the second structural panel; and wherein a lower flange corner of the first structural panel rests within the nested portion of the lower lip.

5 . The system of claim 1 , wherein the upper lip comprises:
a first upper layer; a second upper layer; and wherein the second upper layer is folded back upon the first upper layer to form an upper lip with two layers in an in-plane orientation with respect to the first structural panel.

6 . The system of claim 5 , wherein the second upper layer is folded on top of the first upper layer or folded under the first upper layer.

7 . The system of claim 1 , wherein the sidelap formed from the upper lip placed over the lower lip forms a sidelap with four or more layers.

8 . The system of claim 1 , wherein the one or more couplings are fasteners that operatively couple the upper lip to the lower lip.

9 . The system of claim 1 , wherein the one or more couplings are formed by welding the upper lip to the lower lip, or by cutting the upper lip and lower lip to operatively couple the upper lip to the lower lip.

10 . The system of claim 1 , wherein the upper lip is formed at least partially along a web and is bent at a lower flange corner in an in-plane orientation with respect to the first structural panel to form an in-plane edge of the first structural panel, and wherein the lower lip is formed at least partially along an edge of the second structural panel in an in-plane orientation with respect to the second structural panel and is bent upwardly in order to receive the upper lip formed along the web, the lower flange corner, and the in-plane edge of the first structural panel.

11 . The system of claim 1 , wherein the one or more couplings in the sidelap with the three or more layers improves the shear strength of the sidelap by greater than a factor of 1.05 over a sidelap with two layers.

12 . The system of claim 1 , wherein the one or more couplings in the sidelap with the three or more layers results in a shear strength that is the same as or similar to a sidelap with two layers with at least 5 percent fewer couplings in the sidelap with the three or more layers.

13 . The system of claim 1 , wherein the one or more couplings in the sidelap with the three or more layers results in a shear strength that is the same as or similar to a two layer sidelap with a material thickness of the first or second structural panels that is at least 5 percent thinner than the two layer sidelap structural panel thickness.

14 . The system of claim 1 , wherein the first panel and the second panel of the structural panel system has a first material thickness, a first number of couplings from the one or more couplings, and a first shear strength that is the same or similar to a second shear strength of a second structural panel system utilizing a two layer sidelap having a second material thickness greater than the first material thickness and a second number of couplings greater than the first number of couplings when a length and a width of the structural panel system is the same as the second structural panel system.

15 . A structural panel system for a building structure, comprising:
two or more support members; a first structural panel comprising first top flanges, first bottom flanges, and at least one edge comprising an upper lip, wherein the first structural panel is operatively coupled to at least one of the two or more support members; a second structural panel comprising second top flanges, second bottom flanges, and at least one edge comprising a lower lip, wherein the second structural panel is operatively coupled to at least one of the two or more support members; wherein the upper lip of the second structural panel is placed over the lower lip of the first structural panel to create a sidelap with four or more layers, wherein the sidelap is generally in-plane with respect to the first structural panel and second structural panel; and one or more couplings formed in the sidelap to couple the first structural panel to the second structural panel.

16 . The system of claim 15 ,
wherein the lower lip comprises:
a first lower layer;
a second lower layer; and
wherein the second lower layer is folded on top of or under the first lower layer to form a lower lip with two layers; and
wherein the upper lip comprises:
a first upper layer;
a second upper layer; and
wherein the second upper layer is folded on top of or under the first lower layer to form an upper lip with two layers.

17 . The system of claim 16 , wherein the lower lip comprises:
a nested portion curved upwardly from the in-plane orientation of the lower lip; and wherein a lower flange corner of the first structural panel rests within the nested portion of the lower lip.

18 . The system of claim 15 , wherein the first structural panel and the second structural panel of the structural panel system has a first material thickness, a first number of couplings from the one or more couplings, and a first shear strength that is the same or similar to a second shear strength of a second structural panel system utilizing a two layer in-plane sidelap having a second material thickness greater than the first material thickness and/or a second number of couplings greater than the first number of couplings, and wherein a length and a width of the structural panel system is the same as the second structural panel system.

19 . A method of assembling a structural panel system, the method comprising:
assembling a first structural panel to at least one of two or more support members, wherein the first structural panel comprises first top flanges, first bottom flanges, and at least one edge comprising an upper lip; assembling a second structural panel to at least one of the two or more support members, wherein the second structural panel comprises second top flanges, second bottom flanges, and at least one edge comprising a lower lip; assembling the upper lip of the second structural panel over the lower lip of the first structural panel to create a sidelap with four or more layers that is in a generally in-plane orientation with respect to the first structural panel and the second structural panel; and for

Assignees

• Nucor Corp

Inventors

• Bogh Brian Hansen
• Brown Christopher Lawrence
• Martin Jeffrey Reino

Classifications

• E04C2/322

  with parallel corrugations · CPC title

• E04B5/40

  with metal form-slabs · CPC title

• E04D3/362 Primary

  by locking the edge of one slab or sheet within the profiled marginal portion of the adjacent slab or sheet, e.g. using separate connecting elements · CPC title

• E04C2/32

  formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material · CPC title

• E04D3/30

  of metal · CPC title