US3732656A

US3732656A - Roll-up corrugated steel roofing sheet material

Info

Publication number: US3732656A
Application number: US00204875A
Authority: US
Inventors: E Robinsky
Original assignee: Individual
Current assignee: Individual
Priority date: 1971-07-12
Filing date: 1971-12-06
Publication date: 1973-05-15
Anticipated expiration: 1990-05-15
Also published as: CA950631A

Abstract

A resilient corrugated building sheet having three or more plys of corrugated thin sheets secured together so that crests of one ply rests on the reverse crest of the contiguous ply, the crests of contiguous plys being the mirror image of each other thereby forming a plurality of open ended cells in parallel relationship. Each end of the cell is closed by an end plate, the end plates of each cell being interconnected by a tie to prevent displacement. The top ply is provided along one edge with an overhanging corrugation while the opposite edge is formed with a longitudinal socket. A plurality of sheets can be fitted together for roofing a building, a floor, decks for bridges, etc. For increased strength, the sheets can be formed in secondary corrugations and/or by filling the cells with a plastic material, formed in the cells or alternatively, with insulating material such as lightweight concrete.

Description

llnite States Patent Robinsky [54] ROLL-UP CORRUGATED STEEL ROOFING SHEET MATERIAL [76] Inventor: Eli I. Robinsky, 66 Lytton Boulevard, Toronto, Ontario, Canada [22] Filed: Dec. 6, 1971 [21] Appl. No.: 204,875

[30] Foreign Application Priority Data July 12, 1971 Canada ..1 17,912

[52] U.S. Cl. ..52/108, 52/223, 52/618, 52/537, 52/625, 52/627, 206/59 G [51] Int. Cl. ..E04d 5/10 [58] Field of Search ..52/l08, 222, 223, 52/521, 526, 537, 618, 624, 625, 627, 630,

11 3,732,656 1 May 15, 1973 Primary ExaminerJohn E. Murtagh Assistant Examiner-John R. Masterman Attorney- George H. Riches [57] ABSTRACT A resilient corrugated building sheet having three or more plys of corrugated thin sheets secured together so that crests of one ply rests on the reverse crest of the contiguous ply, the crests of contiguous plys being the mirror image of each other thereby forming a plurality of open ended cells in parallel relationship. Each end of the cell is closed by an end plate, the end plates of each cell being interconnected by a tie to prevent displacement. The top ply is provided along one edge with an overhanging corrugation while the opposite edge is formed with a longitudinal socket. A plurality of sheets can be fitted together for roofing a building, a floor, decks for bridges, etc. For increased strength, the sheets can be formed in secondary corrugations and/or by filling the cells with a plastic material, formed in the cells or alternatively, with insulating material such as lightweight concrete.

9 Claims, 10 Drawing Figures PATENTED MAY! Fl 732.656

SHEET 1 BF 3 ROLL-UP CORRUGATED STEEL ROOFING SHEET MATERIAL BACKGROUND OF THE INVENTION This invention relates to a resilient corrugated building sheet having three or more plys corrugated thin sheets secured together and which can be delivered to the construction site in a rolled-up condition for easy transport.

In my prior patents, U.S. Pat. No. 3,466,685 dated Sept. 16, 1969 and its Canadian counterpart, Pat. No. 813,558 dated May 27, 1969 and also in my US. Pat. No. 3,528,543 dated Sept. 15, 1970 and its Canadian counterpart, Pat. No. 810,367 dated Apr. 15, 1969, I have described roll-up structures which are particularly useful for constructing bridges, decks and other structures. The present invention constitutes an improvement on the prior patents and is particularly useful as a roofing material, for decks, floors and many other similar purposes which will be obvious to a person skilled in the building and construction trades.

The sheet structure of the present invention when used as roofing material, etc. and the like, is very light compared to heavy conventional roof structures.

Once the sheet is unrolled and placed in position, it can then be pumped full of insulating or structural materials and may be formed into slabs, decks, floors, arches, etc. When additional strength is required, additional secondary corrugations can be created by cables, as hereinafter described.

DESCRIPTION OF THE INVENTION The invention relates to a resilient, corrugated, laminated building sheet comprising:

a. a top ply, a bottom ply and at least one intermediate ply therebetween, said plys being formed of corrugated flexible resilient thin sheets, the crests of contiguous plys being the mirror image of each other whereby respective crests are in contact to thereby form open ended cells therebetween;

b. end plates covering opposite open ends of said cells;

c. a tie interconnecting the end plates and securing said plates in position against displacement;

d. an overlapping corrugation along one edge of the top ply adapted to overlie an oppositely disposed marginal corrugation of an abutted sheet, and

e. a longitudinal socket in the opposite edge, said socket being formed by the overlying edges of the bottom ply and the adjacent intermediate ply.

The features of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 illustrates the laminated building sheet of the invention in a partly rolled state;

FIG. 2 illustrates a pair of sheets in abutting overlapping relationship;

FIG. 3 is a cross-section on the line 3-3 of FIG. 2;

FIG. 4 is a fragmentary view to show the connection between the overhang of one sheet to the underlying part of an abutting sheet;

FIG. 5 is a'view showing the sheet being used as a deck;

FIG. 6 illustrates the manner in which a number of sheets, in abutting overlapping relationship, can be formed into an arch;

FIG. 7 illustrates the manner in which a number of sheets in abutting overlapping relationship can be given secondary corrugations;

FIG. 8 is an enlarged fragmentary view of the cables and clamping means shown in FIG. 7;

FIG. 9 shows a prefabricated sheet being rolled up with the corrugations parallel to the axis of rotation; and

FIG. 10 shows the prefabricated sheet illustrated in FIG. 9 in a flat condition with two individual sheets joined permanently together.

FIG. 1 shows the building sheet with the corrugations running tangentially to the cylindrical roll. FIGS. 2 to 8 show a roof made up of several sheets in abutting edge-to-edge relationship and secured together as illustrated.

A complete roof can be fabricated in a factory and shipped to the construction site in a rolled up condition. The prefabricated roof can be of indefinite length, the length, of course, being limited by the load carrying capacity and bridge clearance on the road which the transport is to traverse, and the width of the sheet is limited only by the transportation restrictions in load length (presently about 72 feet). This can be accomplished by rolling the prefabricated, integrally joined sheet with the corrugation running parallel to the axis of the roll. This is illustrated in FIGS. 9 and 10.

In FIG. 9 and 10, the parts which correspond to the same parts of FIGS. 1 through 8 are given corresponding numbers. The pin and slot arrangement which is shown in FIGS. 2 and 10 is omitted. In lieu therefor

corrugation overhangs

17,17a are shortened as shown in FIG. 10 at 17b. The overlapping abutting edges 17b,17c and l4a,14c of a pair of individual sheets (see FIG. 10) are permanently joined, in the factory, either spot welding or riveting. In FIG. 10 they are shown as being spot welded as indicated by the number 30.

FIG. 9 diagrammatically shows a prefabricated sheet, composed of a plurality of individual sheets joined together all their abutting edges, as hereindescribed, rolled-up onto a power driven roll 31 with the corrugations parallel to the axis of rotation. A supplemental roller 32 rotatably mounted on an axis parallel to the axis of the roll 31 and frictionally engaging with prefabricated sheet being wound-up. The roller 32 is mounted soas to initially press the corrugations flat at the commencement of the roll-up and also move radially in a direction away from roll 31 as the diameter of the rolled-up sheet increases.

It is pointed out that the roller 32 is not essential because the corrugations will flatten automatically as they are wound. However, the roller 32 does assist the rollup operation.

When rolled as shown in FIGS. 1 and 9 the rolled-up sheet can be transported to the building site. If being used for roofing as shown in FIGS. 5 through 8, the sheet can be crane lifted in the rolled-up state to the roof and when in position released to assume its flat position.

The building sheet is generally indicated by the letter A and is shown as partly rolled-up into a roll indicated by the letter B. It is delivered to a building site in a rolled-up condition as illustrated in FIG. 1 and is then unrolled to assume a flat state as shown in FIG. 2.

FIG. 2 illustrates two sheets A and Al butted together to show details of construction and the manner of using the sheet to form a structure such as a roof,

floor, bridge, deck and the like. Each sheet is constructed in the same manner and therefore it is necessary to describe in detail, only sheet A, but for the purpose of distinction, the corresponding parts of sheet AI will be given a distinguishing reference character. The sheets A, A1 each comprise at least three plys, top plys 10,10a, bottom plys 11, 11a, and at least one intermediate ply each 12, 12a, respectively.

As shown in FIGS. 1 and 2, each sheet is oblong in shape with the corrugations running in the direction of the long axis. The dimensions of each sheet will depend on the specific type of construction and the specifications as prepared by the engineers of the construction. The length of each sheet can be 50 feet or more and possibly 6 feet in width.

The three plys 10,11,12 are laid on each other with the corrugations of one ply being reversed with respect to the contiguous sheet so that their respective troughs and crests are in contact thus permitting the three plys to be permanently secured together by rivets 13 (13a in the case of sheet Al). The Bottom ply l1 and the contiguous intermediate ply 12 have corrugations 14,15 respectively along one longitudinal edge to form a socket 16. The other longitudinal edge of each sheet has an overhanging corrugation 17 (and sheet A1 overhangs 17a) which will overlap the longitudinal marginal edge of an abutted sheet. It will thus be seen from FIG. 2, that when sheet A1 is butted against sheet A, corrugation overhang 17a overlies the longitudinal marginal corrugation of sheet A, with the underlying leading edge 18a fitted into socket 16. In this manner, there is obtained a leak-proof joint between abutting sheets.

Between the respective crests and troughs, are cells 19 which may be filled, after the sheet has been fixed in its prescribed position, with insulating material expanded in situ, or other material for adding strength to the structure. In order to permit the material to completely fill all the cells, all intermediate plys are provided with perforations, such as perforations 20a (sheet A has similar perforations but they cannot be seen) to allow the cell filling, if any, to penetrate all cells.

To provide a means for connecting the overhang 17 to the underlying part of an abutted sheet, the overhang 17 is provided, along the marginal edge, with a plurality of keyholes 21 which receive complemental pins 22, see FIG. 4.

The open ends of the cells are closed by

end plates

23,24 which are interconnected by cables 25 (only one is shown). Each cable may be held, under tension, in position by

wedges

26,27 driven into the end plates.

FIG. shows the assembled sheets used as a floor. In this case, the sheets are supported on

walls

40,44 and are covered by flooring material, such as plywood 42 which can be conveniently secured to the sheet. The sheet A is given a slight camber by tightening the tie rod 25, previously described in conjunction with FIGS. 1-3, until the desired camber is obtained.

FIGS. 6,7 and 8 illustrate the sheets being formed into arches and secondary corrugations. As diagrammatically illustrated in FIG. 6, this is accomplished by fastening a cable 28 to two spaced apart pins 29,30 located on the bottom plys of assembled sheets. Similarly, the crests of adjoining secondary corrugations are connected by cables. For example, in FIG. 6, only one secondary corrugation is shown with two cables 8,9 running respectively to the right and left. Cable 8 has its right end fastened to the left crest of the illustrated corrugation and its opposite end will be joined to the right crest of the adjoining crest (not shown). Similarly, cable 9 is connected to the right crest of the secondary corrugation shown and the left crest of the adjoining secondary corrugation (not shown to the right. The

cables

8,9 and 28 thus cooperate to maintain the secondary corrugations in their fixed position. The spacing is determined by the size of the arch or secondary corrugation desired and then tightening the cable until the sheets are bowed to the desired amount. As will be seen in FIG. 7, the arched sheets can be retained in this position by links 31 which are connected to

pins

32,33 which are secured to the crests of the arch. These may be replaced by a cable 34 which spans the sheet and is connected to the crests of the arches by a plurality of clamps, at least one on each, such as

clamps

35,36,37,38,39. The cells are then pumped full of insulating material such as polyurethane which is foamed in situ, or other lightweight plastics, lightweight concrete etc.

What I claim is:

1. A resilient corrugated laminated building sheet comprising:

a. a top ply, a bottom ply and at least one intermediate ply therebetween, said plys being formed of corrugated flexible resilient material, the crests of contiguous plys being the mirror image of each other whereby respective crests are in contact forming open ended cells therebetween;

b. end plates covering opposite open ends of said cells;

2. The resilient sheet according to claim 1 including complemental connecting means on said overlapping corrugation and the underlying marginal corrugation of the abutted sheet whereby said sheets are connected together.

3. The resilient sheet according to claim 1 in which the tie comprises a cable adapted to pre-stress said sheet.

4. The resilient sheet according to claim 1 in which the intermediate sheet or sheets are perforated to provide communication between contiguous cells.

5. The resilient sheet according to claim 1 including means for creating macro-corrugations, said means comprising a plurality of second ties, the second ties having one end connected to the sheet at spaced apart intervals along the length of one of the first mentioned corrugations and their opposite ends connected to a second corrugation at corresponding spaced apart intervals, said second corrugation being separated from the first corrugation by at least one corrugation, and means for progressively shortening the second ties whereby the sheet is bent to form said macrocorrugations.

6. A roll-up resilient corrugated structural member comprising a plurality of sheets integrally joined along their marginal edges, each sheet consisting essentially of:

b. end plates covering opposite open ends of said cells;

d. an overlapping corrugation along one edge of the top and bottom plies adapted to overlie an oppositely disposed marginal corrugation of the top and bottom plies an abutted sheet; and

e. means permanently connecting the overlapping corrugations of the top and the underlying marginal corrugation of the abutted sheet whereby said sheets are connected together.

7. The resilient sheet according to claim 6 in which the tie comprises a cable adapted to pre-stress said sheet.

8. The resilient sheet according to claim 6 in which the intermediate sheet or sheets are perforated to provide communication between contiguous cells.

9. The resilient sheet according to claim 6 including means for creating macro-corrugations, said means comprising a plurality of second ties, the second ties having one end connected to the sheet at spaced apart intervals along the length of one of the first mentioned corrugations and their opposite ends connected to a second corrugation at corresponding spaced apart intervals, said second corrugation being separated from the first corrugation by at least one corrugation, and means for progressively shortening the second ties whereby the sheet is bent to form said macrocorrugations.

Claims

1. A resilient corrugated laminated building sheet comprising: a. a top ply, a bottom ply and at least one intermediate ply therebetween, said plys being formed of corrugated flexible resilient material, the crests of contiguous plys being the mirror image of each other whereby respective crests are in contact forming open ended cells therebetween; b. end plates covering opposite open ends of said cells; c. a tie interconnecting the end plates and securing said plates in position against displacement; d. an overlapping corrugation along one edge of the top ply adapted to overlie an oppositely disposed marginal corrugation of an abutted sheet, and e. a longitudinal socket in the opposite edge, said socket being formed by the overlying edges of the bottom ply and the adjacent intermediate ply.

5. The resilient sheet according to claim 1 including means for creating macro-corrugations, said means comprising a plurality of second ties, the second ties having one end connected to the sheet at spaced apart intervals along the length of one of the first mentioned corrugations and their opposite ends connected to a second corrugation at corresponding spaced apart intervals, said second corrugation being separated from the first corrugation by at least one corrugation, and means for progressively shortening the second ties whereby the sheet is bent to form said macro-corrugations.

6. A roll-up resilient corrugated structural member comprising a plurality of sheets integrally joined along their marginal edges, each sheet consisting essentially of: a. a top ply, a bottom ply and at least one intermediate ply therebetween, said plys being formed of corrugated flexible resilient material, the crests of contiguous plys being the mirror image of each other whereby respective crests are in contact forming open ended cells therebetween; b. end plates covering opposite open ends of said cells; c. a tie interconnecting the end plates and securing said plates in position against displacement; d. an overlapping corrugation along one edge of the top and bottom plies adapted to overlie an oppositely disposed marginal corrugation of the top and bottom plies an abutted sheet; and e. means permanently connecting the overlapping corrugations of the top and the underlying marginal corrugation of the abutted sheet whereby said sheets are connected together.

9. The resilient sheet according to claim 6 including means for creating macro-corrugations, said means comprising a plurality of second ties, the second ties Having one end connected to the sheet at spaced apart intervals along the length of one of the first mentioned corrugations and their opposite ends connected to a second corrugation at corresponding spaced apart intervals, said second corrugation being separated from the first corrugation by at least one corrugation, and means for progressively shortening the second ties whereby the sheet is bent to form said macro-corrugations.