Structural panel systems with a nested sidelap and method of securing

Patent metadata

Field	Value
Publication number	US-9863146-B2
Application number	US-201615153460-A
Country	US
Kind code	B2
Filing date	May 12, 2016
Priority date	May 14, 2015
Publication date	Jan 9, 2018
Grant date	Jan 9, 2018

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 decking panel system, comprising:
a first structural panel comprising first top flanges, first bottom flanges, first webs, and at least one edge of the first structural panel comprising an upper lip, wherein the first top flanges are operatively coupled to the first bottom flanges through the first webs;
a second structural panel comprising second top flanges, second bottom flanges, second webs, and at least one edge of the second structural panel comprising a lower lip, wherein the second top flanges, are operatively coupled to the second bottom flanges through the second webs;
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, and wherein the sidelap is in a generally in-plane orientation with respect to the first structural panel and the second structural panel; and
one or more couplings formed in the three or more layers of the sidelap 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 the 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 sidelap is a nested sidelap, and wherein the lower lip of the nested sidelap comprises:
a nested portion formed at a distal portion of the lower lip of the second structural panel that extends from the in-plane orientation of a proximate portion of the lower lip;
wherein the nested portion extends around a web of the first webs adjacent the upper lip such that a lower flange corner of the first structural panel rests within the nested portion of the lower lip; and
wherein the nested portion of the lower lip of the second structural panel inhibits movement between the first structural panel and the second structural panel of the nested sidelap before the one or more couplings are formed in the nested sidelap.

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 the 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; and wherein the one or more couplings are formed in the four or more layers of the sidelap.

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 of the first webs and is bent at a lower flange corner in the 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 the 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 decking panel system, comprising:
a first structural panel comprising first top flanges, first bottom flanges, first webs, and at least one edge comprising an upper lip, wherein the first top flanges are operatively coupled to the first bottom flanges through the first webs;
a second structural panel comprising second top flanges, second bottom flanges, second webs, and at least one edge comprising a lower lip having a nested portion formed at a distal portion of the lower lip that extends from a generally in-plane orientation of a proximate portion of the lower lip, wherein the second top flanges are operatively coupled to the second bottom flanges through the second webs;
wherein the upper lip of the first structural panel is placed over the lower lip of the second structural panel to create a nested sidelap with three or more layers, wherein the nested sidelap comprises the nested portion of the lower lip that extends around a web adjacent the upper lip such that a lower flange corner of the first structural panel rests within the nested portion of the lower lip, and wherein the lower lip and the upper lip are in the in-plane orientation with respect to the first structural panel and the second structural panel; and
one or more couplings formed in the three or more layers of the nested sidelap to couple the first structural panel to the second structural panel.

16. The system of claim 15 , wherein the nested sidelap comprises four or more layers and 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 the in-plane orientation with respect to the second structural panel; and
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 the in-plane orientation with respect to the first structural panel.

17. The system of claim 15 , wherein the nested portion of the lower lip of the nested sidelap inhibits movement between the first structural panel and the second structural panel of the nested sidelap before the one or more couplings are formed in the nested sidelap.

Assignees

• Nucor Corp

Inventors

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

Classifications

• E04D3/365

  by simple overlapping of the marginal portions with use of separate connecting elements, e.g. hooks or bolts for corrugated sheets · CPC title

• E04B5/40

  with metal form-slabs · CPC title

• E04C2/08

  of metal, e.g. sheet metal (E04C2/26 takes precedence) · CPC title

• E04C2/32 Primary

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

• E04D3/362 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