US3872636A

US3872636A - Light weight load bearing metal structural panel

Info

Publication number: US3872636A
Application number: US358071A
Authority: US
Inventors: Joseph A Nicosia
Original assignee: Individual
Current assignee: Individual
Priority date: 1973-05-07
Filing date: 1973-05-07
Publication date: 1975-03-25
Anticipated expiration: 1992-03-25
Also published as: AU6867374A; DE2462243A1; BR7403712D0; DE2422091A1; DE2462244A1; CA1004021A; ZA742903B; GB1468709A; DE2462245A1

Abstract

A light weight load bearing metal structural panel is provided which is adapted to replace other forms of wall and partition studding or framing and to which suitable wall coverings are adapted to be secured such as wall board or other desirable sheathing materials, and the like. Prefabricated built-up panel units may utilize the metal structural panel units as body reinforcement for efficient load bearing utility such as in prefabricated walls, partitions, roof decking, floor decking, etc.

Description

llnited States Patent [191 Nicosia Mar. 25, 1975 LIGHT WEIGHT LOAD BEARING METAL STRUCTURAL PANEL [75] Inventor: Joseph A. Nicosia, River Forest, 111.

[73] Assignee: Robert A. Pacenti, Berwyn, 111.

[22] Filed: May 7, 1973 [21] Appl. No.2 358,071

52/600, 52/615, 52/672 [51] int. Cl. E04c 5/04 [58] Field of Search 52/672, 671, 670, 241,

[56] References Cited UNITED STATES PATENTS 1,128,659 2/1915 Clark 52/672 1,299,425 4/1919 Carpenter.....

1,852,002 4/1932 Clark 52/352 X 2,076,472 4/1937 London 52/241 2,263,814 1 H1941 Nicholson 52/672 X 2,448,109 8/1948 Michael a 52/364 2,582,144 1/1952 Miles 52/404 2,663,181 12/1953 Collman 52/241 2,934,934 5/1960 Berliner 52/601 3,108,406 10/1963 Ellis 52/670 X 3,562,985 2/1971 Nicosia 52/241 FOREIGN PATENTS OR APPLICATIONS 16,187 1898 United Kingdom 52/670 Primary E.\'uminerAlfred C. Perham Attorney, Agent, or Firm-Hill, Gross, Simpson, Van Santen, Steadman, Chiara & Simpson [57] ABSTRACT A light weight load bearing metal structural panel is provided which is adapted to replace other forms of wall and partition studding or framing and to which suitable wall coverings are adapted to be secured such as wall board or other desirable sheathing materials, and the like. Prefabricated built-up panel units may utilize the metal structural panel units as body reinforcement for efficient load bearing utility such as in prefabricated walls, partitions, roof decking, floor decking, etc.

12 Claims, 6 Drawing Figures LIGHT WEIGHT LOAD BEARING METAL STRUCTURAL PANEL The present invention relates to improvements in structural panel unit structures, and is more particularly concerned with light weight units of this type formed from sheet metal.

Numerous and varied forms and arrangements of reinforcement have been provided for prefabricated structural panels and other structural units. Such reinforcements have been useful only as reinforcement and have not been useable as studding or framing as such. In other words, it has been necessary to incorporate the reinforcement in a built-up panel or other structural shape with other materials. Insofar as I am presently informed, no one has heretofore provided a light weight load bearing metal structural panel which is adapted either to serve as building framing or studding to receive any desired wall covering or sheathing thereon, or to serve as a body reinforcement'for a built-up or prefabricated panel. It is to the attainment of such a structure that the present invention is directed.

An important object of the invention is to provide a new and improved light weight structural panel unit formed from sheet metal and possessed of great compression strength and resistance to applied forces in its plane as well as across its plane and which may serve by itself as building wall framing or studding or may be embedded in a built-up prefabricated panel constructron.

Another object of the invention is to provide a low cost light weight structural panel unit formed in part of expanded metal sections. 7

A further object of the invention is to provide a new and improved load bearing sheet metal panel unit.

Still another object of the invention is to provide a new and improved prefabricated panel unit having unique load sustaining body reinforcement.

Other objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof, taken in conjunction with the accompanying drawing although variations and modifications may be effected without departing from the spirit and scope of the novel concepts embodied in the disclosure, and in which:

FIG. 1 is an isometric fragmentary, exploded detail view showing a representative form of a light weight high compression strength load bearing metal structural panel unit embodying features of the invention;

FIG. 2 is a fragmental isometric view showing one use of the panel unit of FIG. 1.

FIG. 3 is an enlarged fragmentary sectional detail view taken substantially along the line III-III of FIG. 2.

FIG, 4 is a fragmentary isometric view showing a modification in the structural panel unit.

FIG. 5 is a transverse sectional detail view showing another use for the panel unit.

FIG. 6 is a fragmentary transverse sectional view showing still another use for the structural panel unit.

In a representative form of light weight high compression strength load bearing metal structural panel unit 10 embodying features of the invention, as shown in FIG. 1, principal elements comprised spaced coextensive generally U-shaped load bearing side channel bars 11 provided with Web portions 12 defining side edges of the panel unit and having solid marginal substantial width bearing and nailing flanges 13 extending inwardly of the unit at opposite face planes of the unit. An open mesh body connects certain of the flanges 13 of the side bars 11 in the unit 10 and maintains the side bars in substantially fixed spaced relation.

In the illustrated instance the unit 10 is of a width wherein a load bearing intermediate bar 15 is desirably located midway between and coextensive with the side bars 11. In one preferred construction, the intermediate bar 15 is of rugged channel beam structure comprising a pair of spaced apart oppositely extending coplanar solid bearing and nailing flanges 17 to which respective sections 18 of the body 14 are connected. The flanges 17 are substantially the same width as and lie in a face plane with those flanges 13 of the side bars 11 to which the sections 18 are also connected. Extending angularly from the flanges 17 in spaced apart relation are side wall flanges 19 ofthe bar 15 which join a connecting solid bearing and nailing web flange 20 desirably of the same width as and lying in a plane with the side bar flanges 13 at the opposite face ofthe panel unit 10 from the flanges 17. It will thus be apparent that the panel unit 10 comprises the rigid side bars 11 and the rigid intermediate bar 15, all cooperating to provide an efficient load bearing structure in the plane thereof considered longitudinally with respect to the bars 11 and 15 and wherein great resistance is provided against not only compression but also tension loads transverse to the axes of the several bars of the unit.

Low cost, efficient construction of the panel unit 10 is enhanced by making the entire unit from a single sheet of suitable gauge metal and with the body sections 18 of open mesh structure, preferably provided by the expanded metal technique wherein staggered longitudinal slits are made in the sheet metal in an area which is narrower than intended for the completed panel, and the metal than stretched laterally to expand the slits whereby a uniform pattern of mesh openings 21 and integral mutually interconnecting portions 22 are integrally connected to the bar flanges 13 and 17. By preference, also, the side wall flanges 19 of the intermediate bar 15 are provided with respective expanded sections 23 preferably extending throughout the length of these flanges 19. It will be observed that substantial width portions of the side walls 19 angularly joining the flanges 17 and the web 20 are solid and unexpanded, whereby longitudinal load bearing integrity of the bar 15 is preserved. If preferred, although not shown, the web portions 12 of the side bars 11 may also be formed with expanded metal sections similarly as the expanded metal sections 23.

In one desirable embodiment, the panel unit 10 may be adapted for building wall or partition use, being generally conformed to conventional dimensions for that purpose thus, for example, the panel unit may be of an over-all width of four feet, with the flanges 13 of the side bars 11 of about 1 /2 inch width and 2 inch depth, with the intermediate bar 15 also of 2 inches depth and preferably about 4 /2 inches in width, i.e. substantially three times the width of one of the flanges 13, as shown in FIGS. 1 and 5, between the edges of the flanges 17 to which the expanded metal sections 18 are connected. Length of the unit may be as preferred for any particular requirement such as 8 or 10 feet. Through this arrangement, a plurality of the units 10 can be mounted in upright coplanar relation edge to edge and provide framing for a partition of a wall and conforming generally to a similar partition of a wall framed out with wooden 2" X 4"s. For doorways or other openings, suitable gaps can be provided between panel units, and with shorter panel units providing head closure framing above doorways and windows, and shorter panel portions also providing wall closure framing below the windows.

By way of example of use of the panel unit in a partition or wall, as represented in FIGS. 2 and 3, the length of the unit is such as to fit closely between a floor 24 and a roof or ceiling 25. Attachment of the panel to the floor is desirably effected through a horizontal base plate 27 which is preferably in the form of a channel or L-shaped cross-section sheet metal bar having a web flange secured in any suitable manner as by means of lag bolts, nails, or other fastening means to the floor and providing one or more upwardly extending longitudinally running flanges to which the lower end portions of the side bars 11 and the intermediate bar are secured by any suitable means such as spot welding, suitable clips, power driven fasteners, or the like. At the ceiling, the unit 10 is secured as by means of a sheet metal head runner strip 28 having a horizontal flat flange 29 secured in any suitable manner such as by nails, lag screws, and the like to the ceiling and with a downwardly projecting flange 30 to which the upper end portions of the panel unit bars are secured as by means of spot welding 31, power driven fasteners, or the like. If preferred, of course, the channel runner member 27 may be applied to the ceiling to secure the upper end of the panel unit and the I.- shaped member 28 may be secured to the floor. Through this arrangement, after the U-shaped runner member has been secured in place, the panel unit 10 can be inserted endwise therein and the unit then swung to position its other end within the member 28 against the flange 30.

After framing of a partition or a wall has been completed by securing the necessary number of the panel units 10 in place, suitable wall covering can be applied to one or both faces of the panel units. For example on an inside wall, wall-board panels 32 can be applied to the faces of the panel units 10 and secured thereto by means such as nails 33 driven directly into the side bar flanges 13 as shown in FIG. 3, and also secured by such nails 13 to the flanges 17 as indicated in FIG. 2, and also at the opposite face to the web flange 20 of the intermediate bar 15. Similarly, the wall covering panels 32 can be secured along with their upper and lower margins to the vertical flanges of the runner plates or

strips

27 and 28, if desired. For sound-proofing, fire resistance and insulation, batts 34 (FIGS. 2 and 3) of suitable material such as fiberglass, rockwool, or the like, may be filled into the hollow spaces provided between the side bars 11 and the intermediate bar 15, and into the hollow space within the intermediate bar 15. At ei- ,ther or both faces of the batt 34 a vapor barrier sheet 35 may be provided.

Where the panel units 10 provide'outside wall framing, it will be readily apparent that instead of wallboard such as employed for inside wall and partition covering, exterior wall sheathing may be applied, and then any preferred outside wall covering applied thereover as preferred. Where the panel units 10 serve as direct load bearing wall framing, they can be erected on a base slab or floor and suitably propped similarly as with conventional framing, and either the member 28 or the member 27 applied as a cap plate on the upper end of one or more of the panel units, and a superstructure such as a floor or roof then erected on top of the thus provided framing, with the cap plates providing the means to which the super-structure is secured.

Instead of having the intermediate load carrying bar of a generally channel beam form as is true of the bar 15 shown in FIG. 1, a generally Z-shaped cross-section intermediate bar 37 (FIGS. 4 and 6) may be provided in a panel unit 10 which in other respects may be substantially the same as the panel unit 10. In this instance, the intermediate bar 27 has a web flange 38 extending between and maintaining a pair of oppositely projecting coextensive solid flat flanges 39 in spaced relation and at the opposite face planes of the unit 10. Ex-

panded metal sections 18' are integral with and extend diagonally from the distal edges of the flanges 39 to and are integral with the distal edges of the respective flanges 13 of the side bars 11' of the unit which lie in the other face plane of the unit 10 from that in which the respective flanges 39 lie. By preference, the web flange 38 is provided with an open mesh, expanded metal section 40. As shown, the solid bearing and nailing flanges 13' and 39 are all of substantially identical width. This Z-shaped formation of the intermediate bar 37 is, as will be apparent, a simpler formation than the intermediate bar 15, and for some purposes will be adequate from a load supporting consideration, and for some reasons may be preferred.

In addition to its use as in wall and partition structures, the

panel unit

10 or 10 may be used as planking or deck covering such as in floors, roofs, walkways in bridge structures and overpasses, balconies, and the like. By reason of load supporting capabilities of the various bars in the units, they are capable of thoroughly withstanding not only compression but also tension loads applied there across from the faces of the unit. Hence, a roof or floor may be constructed by mounting the

units

10, 10 in generally horizontal fashion on suitable supporting structure and then applying any suitable covering, i.e. roof covering, tread surface material, etc, to the upper face of the panels in the deck assembly. Where the structure is a roof, ceiling panels or sus pended ceiling may be applied to the undersurface of the erected panel units l0, 10'. On the other hand, the

panel

10 or 10 if preferred, may be completely embedded as structural reinforcement within a concrete slab 41 (FIG. 5). In such an arrangement, the expanded metal body sections 18 and the expanded metal sections 23 of the intermediate bar 15 as well as expanded sections in the webs of the side bars 1] enable thorough interlocking of the panel section 10 within the concrete slab 41. This arrangement is especially suitable for use of light weight types of concrete, thereby gaining not only the advantages of the light weight reinforcement provided by the panel unit 10, but also the light weight characteristics of the concrete. Of course, if preferred, the panel unit 10 may be utilized to provide the internal body reinforcement for the concrete slab 41 and for some purposes may be preferred. One or both faces of the concrete slab 41 may be provided with a suitable sheathing or facing 42.

Efficient use may be made, as shown in FIG. 6, of the panel units of the present invention in prefabricated slabs such as may be filled with expanded polyurethane 43 or other light weight body material for which the panel unit may serve as the principal load sustaining structure. As shown the unit has been incorporated in the slab although the unit 10 may be similarly employed. In such a slab, the core material 43 fills the panel unit between the end bars 11 of the panel unit, and flush with the opposite face flanges l3 and 39. If preferred any suitable facing sheets 44 may be applied to either or both faces of the slab. Numerous and varied uses for such a slab will be readily envisioned, such as prefabricated wall or partition panels, roofpanels, floor panels, and the like. Where used as wall or partition panels, the prefabricated slab of FIG. 6 may be substituted for the drywall construction as described in connection with FIGS. 2 and 3.

It should be apparent that the present invention provides a versatile light weight high compression and tensile strength load bearing metal structural panel unit which is adapted to be made from light weight steel, aluminum, or other light sheet metal of suitable gauge to meet particular load requirements Maximum utility of material is provided for in the one piece thoroughly reinforced expanded metal body construction with the efficient load carrying flanged bar structures providing excellent compression load resistance not only longitudinally thereof but also transversely thereof, and in addition excellent tension load resistance transversely thereof. Manufacture of the panel units can be economically effected by utilizing coiled sheet metal stock slit according to expanded metal techniques in those areas to be expanded and shaped in those areas which provide the bars, utilizing metal expanding techniques and shaping rolls in continuous stream production. The finished metal panel units are provided with integral load bearing column or beam bars integrally connected in the preferred dimensional relationships for unit handling and erection such as in walls, partitions, roofs, floors, walkways, patios and the like.

It will be understood that variations and modifications may be effected without departing from the spirit and scope of the novel concepts of this invention.

I claim as my invention:

1. A light weight high strength compression and tension load sustaining structural panel unit formed from sheet metal and especially suitable to be fabricated in 4 feet width by 8 to 10 feet length and 2 inches thickness, comprising:

spaced coextensive generally U-shaped load supporting side channel bars provided with web portions defining side edges of the panel unit and each bar having two solid marginal flanges extending inwardly of the unit and lying in respective parallel opposite face planes of the unit and providing bearing and nailing surfaces of substantial and about equal width;

a single intermediate load carrying bar of rugged channel beam multi-flange cross section coextensive with and substantially spaced from and midway between said side bars and being of no greater than about three times the width of said side bar marginal flanges;

said intermediate bar having:

a pair of spaced apart oppositely extending coplanar solid bearing and nailing surface flanges, the distances between the remote edges of said pair of flanges being about three times the width of one of said marginal flanges, and said pair of flanges lying in one of said face planes of the unit and coplanar with the marginal flanges in said one face plane;

a solid bearing and nailing surface web flange at least as wide as one of said marginal flanges lying in the other of said face planes and coplanar with the marginal flanges in said other face plane; and

respective angularly extending side wall flanges rigidly connecting and spacing the adjacent edges of said web flange and the proximal edges of the pair of flanges; and open mesh body portions of the unit connecting the marginal flanges of said side bars in said one face plane with the respective distal edges of the adjacent ones of said pair of flanges of said intermediate bar and thereby maintaining the side bars and the intermediate bar in substantially fixed spaced relation.

2. A panel unit according to claim 1, wherein said sidewall flanges are of open mesh structure.

3. A panel unit according to claim 2, wherein said bars and said body portions are all formed from one piece of sheet metal and said open mesh body portions and said open mesh sidewall flanges comprising expanded metal sections.

4. A panel unit according to claim 1 wherein the web portion of said side bars are expanded metal sections between said marginal flanges.

5. A panel unit according to claim 1, wherein the webs of said side bars are expanded metal sections between said marginal flanges, and said intermediate bar has an expanded metal section in each side wall flange.

6. A structural panel according to claim 1, mounted vertically in and as part of a wall, wall board applied to at least a selected one of said face planes, and nails secured through the wall board and through the flanges of the side bars and the intermediate bar flange or flanges in said selected face plane and thereby securing the wall board panel to the unit at said selected face plane.

7. A panel unit according to claim 1, wherein the side wall flanges of said intermediate bar have expanded metal sections, and a body of light weight material molded in said unit between said side bars and having said side wall flanges embedded therein.

8. A panel unit according to claim 7, including vapor barrier sheet means interposed between said body and said marginal flanges and said intermediate bar flanges lying in said one face plane of the unit and said open mesh body portions.

9. A light weight high strength compression and tension load sustaining structural panel unit formed from sheet metal and especially suitable to be fabricated in 4 feet width by 8 to l0 feet length and 2 inches thickness, comprising:

a single intermediate load carrying bar of rugged generally Z shape multi-flange cross section coextensive with and substantially spaced from and midway between said side bars and being of about two times the width of said marginal flanges and having:

a solid bearing and nailing surface flange in one of said face planes lying coplanar with and of substantially the same width as one of the marginal flanges in said one face plane;

another bearing and nailing surface flange in the other of said face planes lying coplanar with and of substantially the same width as one of the marginal flanges which are in said other face plane; and

an angular connecting and spacer web flange rigidly integrally connected to and between proximal edges of said bearing and nailing surface flanges of the intermediate bar;

an open mesh body portion of the unit extending diagonally between and integral with the distal edge of the marginal flange at said one face plane and the distal edge of the intermediate bar flange of the other face plane; and

an open mesh body portion of the unit extending diagonally between and integral with the distal edge of the intermediate bar flange at said one face plane and the distal edge of the marginal flange at said other face plane.

10. A panel unit according to claim 9, wherein said Z bar has the web flange of open mesh structure.

11. A panel unit according to claim 9, wherein said bars and said body portions are all formed from one piece of sheet metal and said body portions comprise expanded metal sections 12. A panel unit according to claim 9, wherein the web flange is of open mesh structure, and a slab body of light weight material molded within the panel unit between and within said side bars and having said web

Claims

1. A light weight high strength compression and tension load sustaining structural panel unit formed from sheet metal and especially suitable to be fabricated in 4 feet width by 8 to 10 feet length and 2 inches thickness, comprising: spaced coextensive generally U-shaped load supporting side channel bars provided with web portions defining side edges of the panel unit and each bar having two solid marginal flanges extending inwardly of the unit and lying in respective parallel opposite face planes of the unit and providing bearing and nailing surfaces of substantial and about equal width; a single intermediate load carrying bar of rugged channel beam multi-flange cross section coextensive with and substantially spaced from and midway between said side bars and being of no greater than about three times the width of said side bar marginal flanges; said intermediate bar having: a pair of spaced apart oppositely extending coplanar solid bearing and nailing surface flanges, the distances between the remote edges of said pair of flanges being about three times the width of one of said marginal flanges, and said pair of flanges lying in one of said face planes of the unit and coplanar with the marginal flanges in said one face plane; a solid bearing and nailing surface web flange at least as wide as one of said marginal flanges lying in the other of said face planes and coplanar with the marginal flanges in said other face plane; and respective angularly extending side wall flanges rigidly connecting and spacing the adjacent edges of said web flange and the proximal edges of the pair of flanges; and open mesh body portions of the unit connecting the marginal flanges of said side bars in said one face plane with the respective distal edges of the adjacent ones of said pair of flanges of said intermediate bar and thereby maintaining the side bars and the intermediate bar in substantially fixed spaced relation.

9. A light weight high strength compression and tension load sustaining structural panel unit formed from sheet metal and especially suitable to be fabricated in 4 feet width by 8 to 10 feet length and 2 inches thickness, comprising: spaced coextensive generally U-shaped load supporting side channel bars provided with web portions defining side edges of the panel unit and each bar having two solid marginal flanges extending inwardly of the unit and lying in respective parallel opposite face planes of the unit and providing bearing and nailing surfaces of substantial and about equal width; a single intermediate load carrying bar of rugged generally Z shape multi-flange cross section coextensive with and substantially spaced from and midway between said side bars and being of about two times the width of said marginal flanges and having: a solid bearing and nailing surface flange in one of said face planes lying coplanar with and of substantially the same width as one of the marginal flanges in said one face plane; another bearing and nailing surface flange in the other of said face planes lying coplanar with and of substantially the same width as one of the marginal flanges which are in said other face plane; and an angular connecting and spacer web flange rigidly integrally connected to and between proximal edges of said bearing and nailing surface flanges of the intermediate bar; an open mesh body portion of the unit extending diagonally between and integral with the distal edge of the marginal flange at said one face plane and the distal edge of the intermediate bar flange of the other face plane; and an open mesh body portion of the unit extending diagonally between and integral with the distal edge of the intermediate bar flange at said one face plane and the distal edge of the marginal flange at said other face plane.

11. A panel unit according to claim 9, wherein said bars and said body portions are all formed from one piece of sheet metal and said body portions comprise expanded metal sections.

12. A panel unit according to claim 9, wherein the web flange is of open mesh structure, and a slab body of light weight material molded within the panel unit between and within said side bars and having said web flange embedded therein.