Patent Publication Number: US-2005138880-A1

Title: Variable pitch corrugated support sheet with accompanying support beam

Description:
This application claims priority based on provisional application 60/532,520 filed Dec. 29, 2003 
    
    
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The invention relates generally to construction material but more particularly to a corrugated supporting sheet which can vary its load bearing capacity by varying the pitch of its corrugated configuration.  
      2. Background of the Invention  
      There are a number of inventions related to structural support means such as:  
      An improved louvered ceiling construction in which louver channel members are suspended from runner channel members by means of outwardly bent tabs on the ends of the channel members.  
      A louvered ceiling construction especially suited for parabolic louvers. Runners, of the same hollow channel shape as the louver members, are provided with openings into which extensions carried by the louver members are secured.  
      A modular unit for use in constructing a framework of a building consisting of a plurality of modular units in connected relationship having a floor portion with longitudinal and lateral perimeter members.  
      A modular structural section for use in support structures such as load bearing decks or highway bridges. The modular structural section includes at least one beam and a load bearing deck preferably formed of a polymer matrix composite material. The deck includes a core having elongated core members having side walls positioned generally adjacent one another.  
      The prior art does not teach a simple singular structural system capable of altering its load bearing capabilities just prior to installation. There is therefore a need for an improved load bearing sheet structure.  
     SUMMARY OF THE INVENTION  
      Although the use of corrugated panels has been known for years, a fundamental aspect of the accordion shape of such a structure has never been exploited. By varying the angle, or pitch, of the corrugated pattern of the variable pitch corrugated support sheet, its load carrying capacity can be altered. In order to maintain a given angle, a series of accompanying structural beams with specific angles are designed to receive the variable pitch corrugated support sheet and give it its angle. That given angle is thus maintained and a top layer of pre finishing or finishing can be applied to the variable pitch corrugated support sheet such as concrete, foam, plywood or any other such covering suitable for the function of that structure whether a floor, a ceiling or a roof. The corrugated pattern of the variable pitch corrugated support sheet can take various shapes which can all be elongated, which of course will impart a shift in the shape. A given shift in shape, which corresponds to a given elongation, has an accompanying structural beam to match it.  
      Applications in walls, bearing or not, can also be considered. The advantage of being able to vary the angle is that the more the angle is flattened, the larger the sheet area covered which lowers cost in material when the need for strength is not high.  
      There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.  
      In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.  
      As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.  
      Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.  
      These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.  
    
    
     BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       FIG. 1   a  Isometric view of the variable pitch corrugated support sheet contracted.  
       FIG. 1   b  Isometric exploded view of the variable pitch corrugated support sheet protracted with two support beams resting on a foundation wall.  
       FIG. 2   ab  Side view of a variation of the embodiment wherein the flat top and bottom parts are wider and showing two extreme angles that various embodiments of the variable pitch corrugated support sheet can have. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      A variable pitch corrugated support sheet ( 10 ) is made of a durable flexible material whether a polymer, metal, or composite materials, and can be elongated according to a set of predetermined angles determined by any given one of a plurality of possible preset angles of a support beam ( 12 ). Load bearing capacity is determined by two ways: the given angle of the variable pitch corrugated support sheet ( 10 ) and the inherent strength of the material selected to make the variable pitch corrugated support sheet ( 10 ). Factors such as cost of raw material and specific application needs dictate the choice of material and pitch angle, therefore, although steel may appear a good choice cost wise newer material could replace steel as technology allows. Moreover steel may not be recommended in highly corrosive environments and even if replacement material is more costly, it may be the only option possible.  
      The support beams ( 12 ) can be made of a variety of strong and resilient materials selected from the group comprising but not limited to woods, metals, polymers, or composite materials and have a saw tooth pattern configured and sized for a given angle that will impart the desired angle to the variable pitch corrugated support sheet ( 10 ). The distance between each support beams ( 12 ), the material they are made of, their overall thickness along with the angle that they impart to the variable pitch corrugated support sheet ( 10 ) (itself having its intrinsic strength as described above), all contribute to providing a specific load bearing capacity.  
      The variable pitch corrugated support sheet ( 10 ) comprises a base ( 24 ), a top ( 26 ) and sides ( 28 ) joining the base ( 24 ) with the top ( 26 ), all joined integrally in a repeating pattern to create the variable pitch corrugated support sheet ( 10 ). The relative angle between the base ( 24 ) and any one of the two the sides ( 28 ) can be from between 90 to 180 degrees as illustrated in  FIG. 2   ab  wherein  FIG. 2   b  shows angles substantially close to 180 degrees. Of course, the closer to 90 degrees the variable pitch corrugated support sheet ( 10 ) is, the stronger its supporting strength, and the closer to 180 degrees, the least is its supporting strength. Also,  FIG. 2   ab  show a wider base ( 24 ) and top ( 26 ) than in  FIG. 1   b . Other non illustrated examples of variations could in fact go as far as totally eliminating base ( 24 ) and top ( 26 ) parts leaving only the sides ( 28 ) joined together in true “accordion” fashion. Also there could be two or more pattern variations combined into a single variable pitch corrugated support sheet ( 10 ). Such variations in patterns are all within the scope of a single invention.  
      In one embodiment, the support beams ( 12 ) are made of metal and have a receiving surface ( 14 ) which lays on the upper edge ( 16 ) of a saw tooth cut ( 18 ). In this particular embodiment the base of the support beams ( 12 ) creates an “L” shaped base ( 20 ). A thicker support beam (not shown) would have its entire thickness like the receiving surface ( 14 ) and would not need an “L” shape base ( 20 ). This would be likely for a wooden beam exhibiting a uniform thickness throughout and having a saw tooth cut ( 18 ) to receive the variable pitch corrugated support sheet ( 10 ). The type and specific structure of the support beams ( 12 ) can vary depending upon the material used to create it but the common element to all support beams ( 12 ) is the saw tooth cut ( 18 ) which is configured and sized to receive and give the desired angle to the variable pitch corrugated support sheet ( 10 ).  
      The variable pitch corrugated support sheet ( 10 ) is installed according to the following method: At least one support beam ( 12 ) having a saw tooth cut ( 18 ) is generally laid, positioned, and affixed to a load bearing structure ( 22 ) such as a foundation wall or a supporting wall and then, the variable pitch corrugated support sheet ( 10 ) is laid over the support beam. Finally, any of a variety of finishing or pre finishing materials can be applied over the variable pitch corrugated support sheet, this last step being generally well known in the construction trade.  
      As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.  
      With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.  
      Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.