Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR FLOOR PANEL SYSTEM
_ackground of the Invention
Field of the_Invention
This invention relates to floor panel systems for use
in grain storage and drying bins. The flooring systems are
comprised of modular perforated floor panels each of which is
hemmed across the width of the panel at predetermined points
along its length. Side flanges of the panels can be fit into
slotted beams and a series of posts grip the beams and support
the floor. The resulting floor system supports a load of grain
or the like and provides a plenum chamber below the floor so that
drying air may be forced therethrough.
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Various flooring systems have been designed to
support grain in a storage and drying bin. It is generally
necessary to force heated air through the grain to dry the
grain and prevent it from spoiling. As a result, a plenum is
provided at the bottom of the bin to facilitate the entrance
of air. The air is then forced through perforations in a
false floor which forms the top of the plenum and provirles a
base for the grain.
The false floors typically used in such systems
are comprised of lengths of steel channels or planks which
can be joined along their longitudinal edges. The edges may
be joined directly in interlocking arrangement or the edges
may be joined by intermediary beams or rails. The steel
channels extend across the bin from wall to wall. The bins
very often are round, thereby requiring circular floors.
Grain can also be stored in existing buildings which are
rectangular or of varying shapes and sizes. The steel
planks for false floors are generally custom made at the
manufacturing location to fit into, for example, a round
bin. These planks are of varying lengths and for a large
diameter bin, some of the plan~s are substantially long
because they are substantially equal to the length o~ the
diameter. Conse~uently, transporting and storing these
long planks is difficult and the varying sizes of planks
make on~site assembly of the floor complicated and time
consuming. In addition, due to the large variation of plank
lengths, mistakes can arise during assembly of the floor,
e.g., having a four foot portion of the bin and only a six
foot piece remaining, thereby making it necessary to cut a
plank to a particular length to complete assembly.
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It is highly desirable to provide false floor
systems which are easy to assemble and install while pro-
viding adequate support for the floor. Moreover, it is
desirable to provide false floor planks or panels which are
uniform in design and length and which can be severed
readily into various lengths, e.g. for easy fitting and
assembly into floors wi~hin round bins. It is also
desirable to provide false floor planks or panels that can
be utilized economically by minimizing the amount of
flooring material required during the construction and
fabrication of the floor support system.
Objects of the Invention
It is an object of this invention to provide
improved floor panels meeting the abovestated requirements.
It is an object of this invention to provide a
modular floor panel for use in grain bins, and particularly
to provide such panels which will satisfy the
aforementioned requirements and meet the particular needs
for grain storage.
It is another object of this invention to provide
modular floor panels which are designed to facilitate
assembly of grain bin floor systems in grain bins of varying
shapes and sizes.
It is yet a further object of this invention to
provide modular floor panels which can be easily severed
into varying lengths and used in conjunction with a support
system so that the grain bin floor will remain stable while
the bin is empty and the floor is subjected to varying
stresses or vibrations.
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Further and additional objects of this lnvention will
appear from the following description, accompanying drawings and
appended claims.
Summary of the Invention
In accordance with a preferred embodlment of this
invention, the above requirements and objects are satisfied
through a modular floor support system that uses modular floor
panels which are perforated and employ transverse hems at regular
spacings along each panel so that panels of various lengths can
be provided readily by breaking standard panels along any
appropriate selected hem. Each modular floor panel may have a
complete hem at one and a half hem or flange at the other end
such that the panels can be readily aligned and interlocked end
to end by inserting the half hem or flange oE one panel into the
full hem of a succeeding panel. A transverse clip may be used to
hold together two abutted modular floor panels end to end where
one of the abutting ends is not a full hem, e.g., two half hems
or flanges. The same or similar clips also ma~ be placed over
the full hems for reinforcing purposes where high floor loads are
contemplated, e.q., in deep bins and/or with internal stirring
systems. Lips or flanges extend along the sides of the panels
except at the hems where there is a gap in each flange. Adjacent
panels are abutted together along their sides and are held
together by fittir.g the side lips or flanges into rails or
support beams. The rails or beams in turn are resiliently
gripped in notches cut into the top edges of the side walls of
V-shaped posts. These notches in each post are aligned and are
of a width such that the respective rail or support beam can be
gripped and accommodated in a binding fit in the two notches in
the general manner described in U.S. Patent 4,557,086 for Grain
Bin ~loor Support System issued to Allen C. Liefer et al. on
December lO, 1985.
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The projected width of the notches, i.e., as measured normal to a
line passing through both notches, is less than the width of a
support beam to be engaged therein, while the actual width of
each notch is greater than the width of the channel. The beam
can then be fit into and resiliently held by the legs of the
post, as when the post is squeezed and then released.
Description of the Drawings
For a more complete understanding of this invention,
reference should now be made to the embodiments illustrated in
greater detail in the accompanying drawings and described below
by way of examples of the invention.
Figure 1 is a partial perspective view of a modular
false floor support system in a round bin and embodying teachings
o~ this invention.
Figure 2 is a top perspective view of a portion of a
modular floor panel broken along line 2-2 of FIG. 4.
Figure 3 is a bottom view of a portion of a modular
floor panel of Fig. l.
Figure 4 is a section view through line 4-4 of Figure 2
with phantom lines showing a modular floor panel being severed at
its hem, and with the center embossment exaggerated in depth.
Figure 5 is a partial exploded perspective view of a
modular floor support system showing portions of the notched
post, support beams and modular floor panel.
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Figure 6 is a partial exploded view of another
embodiment of a false floor support system using support
posts with L-shaped notches to provide additional gripping
of the rails.
Figure 7 is a partial perspective view of the
preferred modula~ floor sys~em using an inverted T-rail.
Figure 8 is a section through the support post of
a modular floor system as in Figure 7 showing the post
supporting the rail.
Figure 9 is a section through the hem of a modular
floor system as in Figure 7, showing a rail which supports
adjacent hems.
Figure 10 is an exploded side view of two modular
floor panels which can be interlocked end to end showing a
half hem at one end of a modular floor panel and the full hem
at the other end of a succeeding modular floor panel.
Figure 11 is an exploded perspective view of the
half hem flanges or machined severed hems of two modular
floor panels being attached with the use of a transverse
clip having an inverted T configuration.
Figure llA is an exploded perspective view of an
alternative configuration of a transverse clip.
It ~hould be understood that the drawings are not
necessarily to scale and that an embodiment is sometimes
illustrated in part by phantom lines and fragmentary views.
In certain instances, details of the actual structu~e which
are not necessary for an understanding of the present
L~
invention may have been omitted. It should be understood,
of course, that the invention is not necessarily limited to
the particular embodiments illustrated herein.
Detailed Desc~iption
Turning first to Flgure 1, there is illustrated a
perforated modular floor system 100 supported on thc base
102 of a grain bin 104, within the bin. The bin 104 may be of
conventional round bin construction fabricated of
corrugated steel panels. Alternatively, such floor systems
may be used in other buildings of varying shapes and si~es,
such as are used to store grain or the like. An air supply
system (not shown), such as a fan with or without an
auxiliary heat source, typically is provided to force air
into the plenum between the false floor 100 and base 102.
This air is forced to flow upward through the perforate
floor and through the grain supported on floor 100 for
drying and conditioning purposes. The modular floor
support system 100 is comprised of multiple independent
notched floor supports or posts 106 gripping the bottom
portion of support beams or rails 108 which accomodate the
abutting edges 110 of hemmed modular floor panels or planks
112. Several pieces of floor to wall flashing 114 are shown
in place on top of the ends of the assembled panels 112 to
close the floor-to-wall gaps. The posts 106 and rails 108
and their general manner of assembly with one another in a
floor system 100 as well as the flashing 114 and the grain
bin 104 are presented to illustrate a preferred embodiment
for the modular floor panels of the invention.
Referring to Figures 2-4 and 10, each modular
plank 112 is formed of sheet metal, e.g., steel, and employs
a plurality of transverse hems 116 (shown by phantom lines
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in Fig. 2) at unitary spacings along the plank. One end,
sometimes referred to herein as the "front" end, of each unbroken
plank 112 has a half hem or flange and the opposite or "back" end
of each plank has a full hem so that the adjacent ends of aligned
modular floor panels 112 may be interlocked (see Figure 10). The
transverse hems 116 are located between the ends of a modular
floor panel and include means for facilitating severance of the
panels into predetermined lengths. Each hem is formed as an
integral depending U-shaped reverse bend defining a distal bight
portion 116a and side portions or walls 116b which join the bight
to the respective adjacent body portions of the plank. The
distance between these side portions 116b is exaggerated in these
drawings for illustrative purposes, but in practice the side
portions 1116b are contiguous to one another at the top to close
the hem against entry of grain into the hem. Planks or panels of
various lengths can be provided readily by breaking standard
panels along an appropriate selected hem or hems 116. A line of
spaced scores or slits 117 preferably is provided along the bight
116a extending over the length of the hem, that is, the width of
the panel, to facilitate such severance. A severed hem 121 is
shown in Figure 2 illustrating one of the side portions 116b and
a plurality of tongues 116c resulting from the splitting of the
bight portions 116a when the panel is broken along a hem. The
severed hems 121, transverse hems 116, as well as the full hems
and half hem flanges tillustrated in Figure 10) all provide
transverse support for the respective plank panel and prevent the
flooring from sagging at the center of the modular plank.
Lips or flanges 118 extend along the side edges of the
modular panels 112 except at each hem 116 where there is a gap in
each flange 118, as at 119 in Fig. 2. Generally, the depth of
the hems 116 and flanges 118 are equal and are about 3/4 inch.
The width of the modular panels is typically about twelve inches
and the hems 116 may be spaced about
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every twelve inches. A standard panel or plank 112 is about
ten feet long, and thus is of a long narrow rectangular
con~iguration. Each segment between adjacent hems 116 or
between a hem and an end of the panel 112 forms a module 120.
In the center of each module 1~0 is an embossed annulus 122,
shown of exaggerated depth in the drawings for illustrative
purposes. This annulus 122 is formed by stamping the
surface of the module 120 and causing the annular portion of
the module to be raised above the remaining portion of the
module. This annulus 122 creates increased planar tension
over the area of each module 120 and provides additional
stability of the panel.
Figure 3 shows a plan view of the bottom of the
modular floor panel 112 and the annulus 122 which is in-
dented from the bottom side of the panel. A hem 116 is shownwhich has a plurality of cuts or slits 117 in it along the
bight portion of 116a of the hem. The hems 116 are of
slightly less length than the panel width and thus are inset
slightly at their ends from the sides of the modular plank
112.
In Figure 4, phantom lines show the first module
120 being separated from a modular panel 112. This
separating or severing can be effected by repeatedly
bending the module 120 at the bight of a hem 116 in a down
and up movement. This movement weakens the hem 116 until
the steel breaks and the module 120 can be separated from
the remaining panel 112. The remaining portion of the panel
112 is illustrated in Figure 2 which also shows the severed
hem 121. Alternately, the hem 116 can be cut with an
appropriate cutting tool to effectuate the separation. The
slits 117 facilitate and ease the bending and severing which
occurs along the segments between the slits, i.e.,
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corresponding to the resulting tongues 116c projecting from
the severed hem 121.
Figure 5 shows a partial exploded view of the
modular floor system 100 in Fi~1re 1. The modular floor
panels 112 are abutted along the side flanges 118. The
abutting flanges are placed in the central trough portion
126 of the support rail 108. The rail 10~ defines two outer
channels 128 and the central trough 126. The depth of the
trough 126 is greater than the depth of the outer channels
128. The notches 130 of the post or floor support 106 are
designed to accomodate the rail or beam 108 and are located
in the upper portion of the sides of the post 106. These
notches 130 are aligned with one another and will
resiliently grip the rail 108. The actual width of the
notches 130 is such that the two outer channels 128 and the
central trough 126 of the rail 108 can be force fit into the
notches 130 and resiliently gripped by the notch edges. To
this end, it will be observed that each notch 130 has an
actual width w" measured along the divergent sides of the
post 106 and a projected width w' as measured normal to a
center line passing through both notches. The actual width
w" is greater than the width w of the rail 108 between the
outer channels but the projected width w' is slightly less
than the width w of the rail 108 and substantlally less than
the actual width w" of the notches. When the sides of the
post 106 are resiliently flexed toward one another, as by
squeezing, the rail 108 can be fit into the notch 130 of the
post 106. When the sides are released the rail 108 is
resiliently gripped by the post 106.
The floor system 100 of Figure 5 may be assembled
by placing a rail or beam ~08, in inverted position on a saw
horse or other suitable support and attaching a
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predetermined number of posts 106 along its length by their
resilient gripping engagement thereon. The post and beam
assembly is then turned over so that the posts support the
rail 108. The rail rests on the posts at the bottom of the
notches. A series of these post and rail assemblies can be
placed in parallel relation to one another and at a spacing
corresponding to the width of the modular floor panels 112.
The abutting flanges 118 of the contiguous modular floor
panels 112 can be placed in the central trough 126 whereby
the panels are supported by the post and rail assemblies and
are held together by the rails. The inset ends o~ the hems
accommodate this engagement of the panels in the rail beams.
Figure 6 shows a partial exploded view of a floor
system 200 similar to that of Figure 5 and with an addi-
tional interlocking feature. The floor system 200
comprises the modular floor panels 112 of this invention and
rails 204 gripped by the floor support posts 206 where each
rail 204 has two L-shaped outer flange edges 208 in addition
to a central trough por-tion 220. Each L-shaped outer edge
has an inwardly extending tab 210. Each post 206 has a
central notch 212 in the top edge of each side and two outer
L-shaped notches 214 having vertical legs 216 and inwardly
extending lower portions 218. The notches in the post 206
accommodate the central trough 220 and the outer edges 208
of the rail 204. The spacing between the tabs 210 o a rail
204 is slightly less than the spacing between the inner
vertical edges 222 of notch portions 216. Thereby the
flanges are flexed outward slightly during assembly and
provide snap engagement of the tabs 210 in slot portions 218
when the rail and post are fully seated, in addition to the
gripping of the sides of the notches on rail 204. Thus,
this design provides additional support to the rail 204 and
provides a locking action of the rail 204 to the posts 206
by accommodating the tabs 210 of the rail.
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Figures 7 through 9 show views of the preferred
floor support system 300 to be used with the modular floor
panels 112 of this invention. Figure 7 is a partial per-
spective view of the modular floor support system 300 and
S shows the side flange 118 of a section of a modular floor
panel 112 in place with a rail 302. The rail 302 is sup-
ported and gripped by posts 304. The center embossment of
the floor panel modules are shown in exaggerated relief.
Figure 8 is a section across a rail and floor panels where a
10 post 304 supports a rail 302. Figure 9 shows a sectional
view across the floor support system 300 at the hems 116 of
two abutting modular panels 112. The rail 302 is an
elongated member generall~ similar to the rails in Figures 5
and 6, but of a preferred cross section. It is of an
inverted T-shape comprising a central open vertical trough
306 with a throat 307 located at the entry of the trough 306
and laterally extending ledges 308 at its bottom portion.
As seen in Figure 9, these ledges 308 support the ends 309 of
each of the transverse hems 116 which are located at unitary
spacings along the length of each modular panel 112. Figure
9 also shows that the ends 309 of the hems 116 are tapered
such that the hems 116 of abutting modular panels 112 are
closer at the top than at the bottom where the hems 116 are
supported by the ledges 308. This taper enables the flanges
25 118 of the modular panels 112 to be easily inserted into the
trough 306 of the rail 302 without interference from the
transverse hems 116. In addition, the tapered hems of
abutting modular panels 112 provide a locking action which
holds the sides of the throat 307 of the trough 306 together
and prevents the abutting modular panels 112 ~rom being
separated or dislodged. The side flanges 118 extend along
the sides of the panel 112 except at each hem 116 where there
is a break or space between the flanges 118 of adjacent
panel modules. Figures 8 and 9 show the 1anges 118 of two
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modular pane!s 112 abutting each other and fit into the
central trough 306 of the rail 302, as occurs along the
entire length of the rail 302 except at each hem 116 where
there is the break in the flanges 118 as previously noted.
The support post 304 as shown in Figures 7 and 8
is of the same general cross section as the other posts
described above and has notches 310 cut into the top
diverging edges of the post sides. Each notch 310 has a
lower gripping portion 312 and an entry or throat portion
314. The actual width of the entry portion 314 is narrower
than the actual width of the lower portion 312 but is
greater than the width of the bottom portion of the rail 302
where the rail ledges 308 are located. The projected width
of the entry portion 314 as measured normal to a center line
passing through both notches 310 is less than the width of
the bottom portion of the rail where the ledges 308 are
located but is sufficiently wide that when the sides of the
post 304 are resiliently squeezed, the bottom portion with
the laterally extending rail ledges 308 can be accommodated
by the entry portion 314 of the notch. When the rail is
placed in the lower gripping portion 312 of the notch 310
and the sides of the post 304 are released, the bottom
portion of the rail 302 is resiliently gripped in the lower
portion 312 of the notch 310. In addition, since the entry
portion 314 of the notch 310 is narrower in projected width,
the rail 302 is locked into place by the resulting shoulders
and prevented from being dislodged from the post 304.
The planks of this invention may be aligned and
joined end to end to form runs of planks which extend across
the bin from wall to wall. Figures 10 and 11 illustrate the
attachment of aligned and successive modular floor panels
which are part of a run of panels. In partic~lar, Figure 10
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shows sections of first and second floor planks 1000, 1002
which have been aligned and are part of a run of planks. The
hem 1004 of the first plank lOOO is in the form of a half hem
flange, or a severe~ hem flange where its ton~ues have been
ground away. The second plank 1002 has a full hem 1006 so
that when the two planks lOOO, 1002 are aligned at their
respective ends, the half hem flange 1004 of the first plank
lOOO is inserted into the full hem 1006 of the second plank
1002. This results in an interlock of the two planks 1000,
1002.
Figure ll shows first and second modular planks
llOO, 1102 which are abutted at their end hem flang0s 1104,
1106. A transverse clip 1108 is used to attach these hems
1104, 1106 together. One or both of these hems 1104, 1106
can be in the form of severed hems as shown in Figure 2 where
the tongues 116c have been ground away to enable the side
portions 116b to be abutted. Alternatively, one or both of
these hems 1104, 1106 can be in the form of a simple flange.
Also, one of these hems could be in the form of a ground
severed hem and the other in the form of a half hem flange.
Any of these combinations can arise during the assembly of
the false floor in a bin where a full hem is not available to
provide the aforedescribed interlock for successive planks
of a run. Such a situation can arise where the number of
modules with severed or half hems which must be attached to
a successive plank is greater than the number of full hems
available for attachment. For example, the paneling may be
ormed as a continuous strip of indeterminate length and
then severed at the bights of appropriate hems as the strip
is formed or subsequently, to form panels of standard
lengths, for convenient shipment and handling, e.g., 10'
long. Under such circumstances the transverse clip 1108
holds these end flanges 1104, 1106 together.
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The transverse clip 1108 has a similar
configuration as the rail 302 in Figures 7N9 i.e., an
inverted T-shape with a throat 1110 and ledges 1112. The
transverse clip 1108 extends across the width of the plank,
between the side support rails, and each end of the clip may
rest on a separate su~port post. Alternatively, Figure llA
shows a simple U-shaped ~ransverse clip 1108A of slightly
less depth that may be used with each end of the clip resting
on the respective adjacent ledge of a corresponding rail
(not shown). In either event, the flanges 1104, 1106 of
Figure 11 or 1103A, 1106A of Figure llA are fit into the
throat of the clip and are held together in a similar manner
as are the side flanges of adjacent floor panels.
Transverse clips may be used at every transverse
hem in grain bins where the effective floor loading makes
such reinforcement desirable, e.g., where the grain is
greater than a specified depth, such as thirty feet.
The modular floor panels of this invention are
particularly economical and easy to assemble in round
storage bins which require circular floors or in other bins
such as a rectangular building. In round bins, the required
length of each run or series of aligned floor planks varies
with its position in the bin. Through the center of the bin,
the length of the floor plank run is substantially equal to
the diameter of the bin. The various runs at each side of
the centrally positioned run, however, are of lengths
progressively less than the diameter of the bin and
substantially equal to a cord at the respective location and
parallel to the diameter of the bin. Thus where the
diameter or particular cord of a bin is not a multiple of the
standard length of a floor panel, the modular floor panels
of the present invention are particularly useful. The
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ability of each modular floor panel to be easily severed or
separated at the bight of any hem permits readily satisfying
the varying length requirements for runs of panels or
individual panels and facilitates efficient floor
construction. In addition, the modules are readily
adaptable to grain bins of any shape and variations of the
grain bin size can be accommodated.
Thus a modular floor plan system and manner of
assembly have been provided which meet the aforestated
objects of this invention.
While certain embodiments of the invention have
been shown, it will be understood, of course, that the
invention is not limited thereto since modifications may be
made and other embodiments of the principles of this in-
vention will occur to those skilled in the art to which thisinvention pertains, particularly upon considering the
foregoing teachings. It is, therefore, contemplated by the
appended claims to cover any such modifications and other
embodiments as incorporate those features which constitute
the essential features of this invention within the true
spirit and scope of the following claims.
What is claimed is:
