Static structures (e.g. – buildings) – Facer held by stiffener-type frame – Back-to-back facers spaced by concealed framing
Reexamination Certificate
2000-04-28
2001-12-11
Canfield, Robert (Department: 3635)
Static structures (e.g., buildings)
Facer held by stiffener-type frame
Back-to-back facers spaced by concealed framing
C052S478000, C052S506060, C052S508000
Reexamination Certificate
active
06327828
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a structural member that has a cross-sectional shape which accommodates insulation and/or acoustical panels. The overall height of the structural member can be selected as a function of different thicknesses of one or more panels. Two or more structural members can be attached to bearing plates or sub-purlins, to provide an economical roofing system which can be easily constructed and/or retrofitted.
2. Description of Related Art
Conventional support members used in roofing structures, for example sub-purlins, can have an I-beam shaped cross-section. After support members are fastened to a purlin, insulation panels or other structural panels are positioned between adjacent support members. A top flange of a support member having an I-beam shaped cross-section can interfere with a structural panel during an installation process. As a result, for example if one of the panels is damaged or cracked, or if the roof is leaking, it is difficult to remove an installed structural panel. Replacing the damaged panel or repairing the roof structure can thus be expensive and time consuming.
It is apparent that there is a need for a structural member that can support roof structures or decks and that facilitates easy and inexpensive replacement of damaged panels and/or retrofit of existing roof structures.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a structural member having sufficient strength to support roof panels and structures.
It is another object of this invention to provide a structural member that has an upper flange shape which provides increased dimensional clearance capabilities.
It is another object of this invention to provide a structural member that facilitates retrofitting, for example with additional insulating or acoustical panels.
The above and other objects of this invention are accomplished with a structural member, for example one which is marketed as a TRI COM® Zee structural member, having a top flange, a web and a bottom support. The bottom support has a first bottom flange that transitions into a second bottom flange which overlaps and contacts or is adjacent the first bottom flange. The overall height and width of the structural member, and/or the width of the top flange may be selected or designed as needed for different applications or structures.
The structural member can be of a galvanized steel, a similar material, aluminum, graphite and/or other metal or non-metal composites strong enough to support roof structures or decking. During the fabrication process of a structural member according to this invention, a continuous sheet, piece or plate of material is bent at a first end portion to form the top flange and is bent at a second end portion to form the bottom support. The bottom support is bent about 180° so that at least a portion of the second bottom flange overlaps and contacts or is adjacent the first bottom flange. The second bottom flange preferably extends from the bend up to and beyond the web.
The fabricated structural member is particularly suitable for use as a sub-purlin. A structural panel, such as a gypsum board, an insulating panel or an acoustical panel, is placed between two adjacent structural members. The structural panel is supported by a portion of each of two of the bottom supports, those facing each other, of adjacent structural members. The structural panel can be easily positioned between the adjacent structural members because the top flange extends only from one side of the web. During installation, a first end portion of the structural panel is inserted between the top flange and the bottom support of one structural member. The bottom flange supports a bottom surface of the first end portion of the inserted panel. After the first end portion of the panel is positioned, an opposite second end portion of the structural panel is then lowered into position against the bottom support of another adjacent structural member. During installation, the second end portion of the structural panel does not interfere with the top flange of the other adjacent structural member. Because the second end portion of the panel can be inserted between adjacent structural members with no interference, a damaged panel is easily removed and replaced.
In one preferred embodiment of this invention, an apparatus including a plurality of structural members used in conjunction with independent bearing plates forms a fire-retardant roofing system particularly beneficial for re-roofing procedures.
To begin the re-roofing procedure, the existing roofing and structural panels are removed, leaving the roof deck in place. Bearing plates can be positioned on the existing roof deck and fastened through the existing roof deck, for example into a roof joist. Preferably, the bottom support of the structural member is fastened to the bearing surface of the bearing plate. Alternatively, the structural member is fastened directly to the existing roof joist Insulation, acoustical and/or other structural panels are placed between two adjacent structural members and a roofing deck is then fastened to the top flanges.
The structural member and apparatus of this invention provide distinct advantages over conventional steel roof decks, including the ability to construct a new roof without removing the old roof; easy repair of leaks and replacement of damaged structural panels; and the ability to install insulation, acoustical and/or other structural panels after initial construction.
REFERENCES:
patent: 2767440 (1956-10-01), Nelsson
patent: 3055466 (1962-09-01), Brown
patent: 3276179 (1966-10-01), Rallis
patent: 3303624 (1967-02-01), Swain
patent: 3462901 (1969-08-01), Jamgochian
patent: 3740912 (1973-06-01), Sauer et al.
patent: 3934387 (1976-01-01), Moeller
patent: 4040758 (1977-08-01), Sauer
patent: 4044521 (1977-08-01), Fischer et al.
patent: 4384437 (1983-05-01), Coles
patent: 4875320 (1989-10-01), Sparkes
patent: 1227191 (1960-08-01), None
patent: 2093886 (1960-08-01), None
Canfield Robert
Decks, Inc.
Pauley Petersen Kinne & Fejer
LandOfFree
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