Interlocking panel for light weight insulating concrete
An interlocking panel configured for lightweight insulating concrete has channels which form a profile that includes transversely protruding anchoring cavities. When the lightweight insulating concrete is poured into the channels and hardens, the concrete interlocks and forms an underside interlocking which resists vertical separation of the concrete from the deck panel.
This application claims the priority of U.S. Provisional Patent Application No. 61/127,077 filed May 9, 2008, the disclosure of which is incorporated by reference herein.
FIELDThe present disclosure relates to light weight insulating concrete (LWIC), and is more particularly concerned with a deck panel for receiving LWIC.
The disclosure is directed to an improved deck panel that will result in superior performance and enhanced lifetime of an LWIC structure, in particular, a deck or roof installation subjected to windy and adverse environmental conditions.
SUMMARYBriefly stated, a deck panel for receiving a lightweight insulating concrete (LWIC) has an upper aerial surface which receives LWIC. The aerial surface longitudinally extends between opposed first and second edges. A multitude of transversely spaced parallel channels traverse the panel and longitudinally extends between the edges. The panel has a transverse profile defined by the geometry of the channels wherein each channel has at least one transversely protruding anchoring cavity with an upper and a lower wall. The elongated channels may be configured in various shapes. One channel has two opposite elongated anchoring cavities, each with an upper and a lower wall. In one embodiment of the deck panel, channels are symmetric about a central longitudinal plane through the channel. A channel may have a transverse profile segment having a generally inverted T-shape, a general L-shape, a bulbous shape or various other shapes configured to provide an interlock between the deck panel and the LWIC.
A roofing assembly comprises a deck panel having an upper aerial surface longitudinally extending between first and second edges. A multitude of transversely spaced parallel channels traverse the panel. Each channel has at least one transversely protruding elongated anchoring cavity. Lightweight insulating concrete overlies the aerial surface and extends into the channels and forms an integral rigid structure which interlocks with the deck panel.
In one embodiment, each channel has two opposite elongated anchoring cavities, each with an upper and a lower wall, and the hardened LWIC extends into the anchoring cavities. In another embodiment, each channel may be symmetric about a central longitudinal plane through the channel. At least some of the channels have a transverse profile segment which are configured to provide an interlocking function for the LWIC. In all of the latter embodiments, the LWIC extends into the anchoring cavities and is joined with the integral LWIC substrate.
A process for constructing a decking structure comprises providing a panel having an aerial surface for receiving LWIC and which panel longitudinally extends between opposed first and second edges. A multitude of transversely spaced parallel channels traverse the panel. The panel defines a transverse profile wherein the geometry of each channel has at least one longitudinally extending transversely protruding anchoring cavity with an upper wall and a lower wall. LWIC is poured over the panel so that the flowing LWIC substantially fills each channel and anchoring cavity and the LWIC forms a relatively flat surface above the aerial surface of the panel. The LWIC hardens to form a structure which integrally includes the hardened LWIC which is retained in the anchoring cavities.
As shown in
As can be seen, the truncated U or V-shaped channels do not vertically hold the dried, hardened LWIC in place (i.e., do not provide “mechanical” attachment or a vertical restraint). Thus, the hardened LWIC layer is susceptible to separation from the panel along interface 160, to vertical movement or lifting, and to possible damage in the presence of high winds. Representative vertical movement and separation vectors are symbolized by arrows F in
With reference to
As indicated in the embodiment depicted in
A deck, roof or similar structure can be constructed or installed with the disclosed panel 10 in a manner similar to the prior art. The panel 10 can be rigidly fastened to a frame or similar structure. LWIC is poured over the panel 10, filling in the channels 12. The LWIC typically assumes and/or is distributed to form a flat upper surface, as indicated by reference numeral 16 in
While the
As further illustrated in
Although it is generally preferred that the channels be symmetric, for some panel embodiments, the interlocking anchoring cavities 114A, 114B may be asymmetric with respect to a central vertical axis or longitudinal plane as best illustrated in
As best illustrated in
For ease of fabrication of the deck panels, which are typically formed from steel, the formed channels with the anchoring cavities typically extend from one longitudinal edge to the opposing edge. However, for some embodiments, the channels need not extend the entire longitudinal length of the panel. For most applications, channels with the symmetric profiles are also preferable since the channels of multiple panels may interlock at adjoining edges across the roof substructure. Such a symmetrical relationship facilitates ease of placement and installation. Naturally, a wide variety of channels and spacings both including anchoring cavities as described and conventional channel form may be provided across the deck panel.
While preferred embodiments have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.
Claims
1. A deck panel for receiving light weight insulating concrete (LWIC) to create a generally flat upper roofing structure, comprising:
- a panel having an upper aerial surface for receiving LWIC and extending between opposed first and second edges; and
- a multitude of transversely spaced parallel channels traversing said panel and longitudinally extending between said edges, said panel defining a transverse profile defined by the geometry of said channels wherein each channel has at least one transversely protruding anchoring cavity with an upper and a lower wall.
2. The deck panel of claim 1, wherein each channel has two opposite anchoring cavities, each with an upper wall and a lower wall.
3. The deck panel of claim 2, wherein each channel is symmetric about a central longitudinal plane through said channel.
4. The deck panel of claim 1, wherein a said channel has a transverse profile segment having a generally inverted T-shape.
5. The deck panel of claim 1, wherein a said channel has a said transverse profile segment having a general L-shape.
6. The deck panel of claim 1, wherein a said anchoring cavity has a transverse profile segment having a bulbous shape.
7. A roofing assembly comprising:
- a deck panel having an upper aerial surface and longitudinally extending between first and second edges, a multitude of transversely spaced parallel channels traversing said panel and longitudinally extending between said edges, said panel having a transverse profile defined by the geometry of said channels wherein each channel has at least one transversely protruding anchoring cavity with an upper wall and a lower wall; and
- lightweight insulating concrete (LWIC) overlying said aerial surface and extending into said channels and forming an integral rigid structure which interlocks with said deck panel.
8. The roofing assembly of claim 7, wherein each channel has two opposite anchoring cavities, each with an upper wall and a lower wall, and said LWIC extends into said anchoring cavities.
9. The roofing assembly of claim 8, wherein each channel is symmetric about a central longitudinal plane through said channel.
10. The roofing assembly claim 7, wherein a said channel has a transverse profile segment having a generally inverted T-shape.
11. The roofing assembly claim 7, wherein a said channel has a said transverse profile segment having a general L-shape.
12. The deck panel of claim 7, wherein a said anchoring cavity has a transverse profile segment having a bulbous shape.
13. A process for constructing a decking structure comprising:
- providing a panel having an aerial surface for receiving LWIC and longitudinally extending between first and second edges, and a multitude of transversely spaced parallel channels traversing said panel and longitudinally extending between said edges, said panel having a transverse profile defined by the geometry of said channels wherein at least one channel has at least one longitudinally extending, transversely protruding anchoring cavity with an upper and a lower wall;
- pouring flowing light weight insulating concrete LWIC over the panel so that the flowing LWIC substantially fills each channel and protrusion and forms a relatively flat surface along the aerial surface of the panel; and
- allowing the LWIC to harden in a said anchoring cavity to form an integral structure which interlocks with said panel.
Type: Application
Filed: May 11, 2009
Publication Date: Nov 12, 2009
Inventor: Stanley W. Choiniere (Southwick, MA)
Application Number: 12/387,991
International Classification: E04B 7/00 (20060101); E04C 2/06 (20060101);