Method And Tool for Joining Side-Lapped Seams Of Steel Deck Panels And Steel Deck Structure Incorporating Interlocking Side-Lapped Seams

Abstract

A steel deck structure can comprise a first steel deck panel including an upturned male lip and a second steel deck panel including a downwardly directed U-shaped female channel that can extend over and receive the upturned male lip to form a side-lapped seam. A tool can be used to form an attachment within the side-lapped seam to attach the steel deck panels together. The attachment can comprise one or more slit openings extending through the side-lapped seam and a pair of semi-conical shaped lobes that bulge in an opposite transverse direction from the longitudinal center of the side-lap seam and extend longitudinally along the side-lapped seam in opposite directions from the one or more slit openings. The tool can be powered by a linear actuator and can include a control system that controls the linear actuator for automatically forming the attachments.

1 . A steel deck structure incorporating an interlocking side-lapped seam, the steel deck structure comprising:
 a. a first steel deck panel, the first steel deck panel including an upturned male lip along one side edge thereof;   b. a second steel deck panel including a downwardly-directed U-shaped female channel along one side edge thereof, the U-shaped female channel extending over and receiving the upturned male lip of the first steel deck panel to form the side-lapped seam, the U-shaped channel including first and second walls generally parallel to each other; and,   c. an attachment formed within the side-lapped seam to attach the first steel deck panel to the second steel deck panel, the attachment comprising:
 i. one or more slit openings extending through the male lip and through the first and second walls of the female channel; and, 
 ii. a pair of semi-conical shaped lobes wherein each lobe bulges in an opposite transverse direction from the longitudinal center of the side-lap seam and extends longitudinally along the side-lapped seam, in opposite directions from the one or more slit openings, from a base located at the one or more slit openings towards an apex of each semi-conical lobe. 
   
     
     
         2 . The steel deck structure of  claim 1  wherein the attachment comprises two or more slit openings, and wherein each slit opening is formed at an angle relative to the adjacent non-linear slit openings. 
     
     
         3 . The steel deck structure of  claim 2  wherein the slit openings are formed at an angle relative to a vertical direction of the side-lapped seam. 
     
     
         4 . A method of forming an attachment in an interlocking side-lapped seam of a steel deck structure, wherein the steel deck structure comprises:
 a. a first steel deck panel, the first steel deck panel including an upturned male lip along one side edge thereof; and,   b. a second steel deck panel including a downwardly-directed U-shaped female channel along one side edge thereof, the U-shaped female channel extending over and receiving the upturned male lip of the first steel deck panel to form the side-lapped seam, the U-shaped channel including first and second walls generally parallel to each other;   the method of forming the attachment comprising the steps of forcing/pushing/punching a first punch tooth through the U-shaped channel first wall and into the side-lapped seam and a second die tooth through the U-shaped channel second wall and into the side-lapped seam and thereby forming:
 i. one or more slit openings extending through the male lip and through the first and second walls of the female channel; and, 
 ii. a pair of semi-conical shaped lobes wherein each lobe bulges in an opposite transverse direction from the longitudinal center of the side-lap seam and extends longitudinally along the side-lapped seam, in opposite directions from the one or more slit openings, from a base located at the one or more slit openings towards an apex of each semi-conical lobe. 
   
     
     
         5 . The method of forming an attachment of  claim 4  wherein the first punch tooth and the second die tooth each comprise a semi-conical shape defined by a half-cone shaped leading surface and a generally triangular flat surface, wherein a cutting edge is defined between the half-cone shaped leading surface and the generally triangular flat surface and wherein, during the step of forcing/pushing/punching the first punch tooth through the U-shaped channel first wall and into the side-lapped seam and the second die tooth through the U-shaped channel second wall and into the side-lapped seam, the triangular flat surface of the first punch tooth traverses parallel to and past the triangular flat surface of the second die tooth. 
     
     
         6 . The method of forming an attachment of  claim 5  wherein the pair of semi-conical shaped lobes are mirror images of the half-cone shaped leading surfaces. 
     
     
         7 . An apparatus for forming an attachment in an interlocking side-lapped seam of a steel deck structure, wherein the steel deck structure comprises:
 a. a first steel deck panel, the first steel deck panel including an upturned male lip along one side edge thereof, and,   b. a second steel deck panel including a downwardly-directed U-shaped female channel along one side edge thereof, the U-shaped female channel extending over and receiving the upturned male lip of the first steel deck panel to form the side-lapped seam, the U-shaped channel including first and second walls generally parallel to each other;   the apparatus comprising:
 i. a die member having one or more die teeth for engaging the first wall of the U-shaped channel; 
 ii. a punch member disposed adjacent to and generally facing the die member, the punch member having one or more punch teeth for engaging the second wall of the U-shaped channel; and, 
 iii. a linear actuator connected to the punch member for selectively moving the punch member towards or away from the die member; 
   wherein as the punch member is moved towards the die member, the die teeth and the punch teeth of the die and punch members are forced/pushed/punched into the side-lapped seam and extend at least partially past each other for thereby forming the attachment.   
     
     
         8 . The apparatus of  claim 7  further comprising a sensor for detecting the presence of the side-lapped seam between the die and punch members, wherein the actuator is prevented from selectively moving the punch member when the side-lapped seam is not located between the die and punch members. 
     
     
         9 . The apparatus of  claim 8  wherein the sensor further detects the position of the punch and die teeth relative to the side-lapped seam, and wherein the actuator is prevented from selectively moving the punch member when the punch and die teeth are not located adjacent to a selected portion of the side-lapped seam. 
     
     
         10 . The apparatus of  claim 8 , wherein the sensor comprises a first lever disposed between the die and punch members and operably connected to a first stop block member, wherein the first stop block member is disposed between the die and punch members for preventing the punch member from being selectively moved towards the die member, and wherein as the side-lapped seam is introduced between the die and punch members, the first lever engages the side-lapped seam and retracts the first stop block member from between the die and punch members. 
     
     
         11 - 53 . (canceled)