Note: Descriptions are shown in the official language in which they were submitted.
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The present invention relates to an underfloor
assembly for a metal deck and concrete floor. In particular,
the present invention provides an underfloor asse~bly for a --
building, comprising a plurality of elongated, corrugated,
5 metal flooring units and a plurality o elongated, metal
cable distribution ducts, preferably arranged side-by-side
with said flooring units, said flooring units and said
cable distribution ducts being adapted to be supported by
~ the structural beams of the buildlng; and a plurality
10 of spaced-apart elongated cable trenches adapted to carry
cables of different types therein and extending over and
transversely across said flooring units and said cable
distribution ducts; and open pan means suspended from said
cable distribution ducts for storing electrical or electronic ~-.
i-'' accessory panels below the cable distribution duct at
desired intersections of the cable distribution ducts
and cable trenches; said trenches comprising a lon~itudinally
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extending U-shaped base pan means having a bottom portion
with apertures therein at said intersections of said
trenches and said distribution ducts for permitting -
direct access from said trench to the distribution duct
and the electronic or electrical accessory panel below.
As will be described in detail hereinafter, the housing
means also permits access to the trench and distribu-
tion duct from the ceiling below.
The present invention is illustrated in terms
of its preferred embodiments in the accompanying drawings,
in which: ??.
Fig. 1 is a diagrammatic top plan view of an
underfloor assembly according to the invention; -
Fig. 2 is an enlarged top plan view of the
intersection of a cable trench and a cable distribution duct
having an accessory pan according to the invention, with -`~
the trench covers removed;
Fig. 2A is an elevational view, in section,
taken along lines 2A-2A in Fig. 2;
Fig. 3 is a top plan view of the cable trench
according to the present invention;
Fig. 4A is an elevational view, in section,
taken along lines 4A-4A in Fig. 3; .
Fig. 4B is an elevational view, in section, '`
taken along lines 4B-4B in Fig. 3; ~'
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Fig, 5 is a view similar to Fig, 3 showing the
cable distribution duct according to the present in-
vention;
Fig. 6A is an elevational view, in section,
taken along lines 6A-6A in Fig. 5;
Fig. 6B is an elevational view, in section,
taken along lines 6B-6B in Fig. 5;
Fig. 7 is a schematic perspective view showing
a distribution duct wîth an accessory pan in place; '-
Fig. 8 is a schematic perspective view similar to
Fig. 7 of another embodiment of the invention; and
Fig. ~ is an elevational Yiew,~ in section, simila~ ,
to Fig~ 6B, of another embodi~ent of the in~ention. ;~
Referring to the drawings, Fig. 1 shows an
underfloor assembly 10 comprising conventional corrugated
metal flooring units 20 having alternating crests 21 and
troughs 22, joined edge-to-edge in a conventional manner
to distribution ducts 30 which are also made of metal. ~
The metal flooring 20 and the cable distribution ducts 30 ~-
are supported by structural beams 40, in a conventional
manner. r
A plurality of cable trenches 50 made of metaI D
rest on the metal flooring 20 and the distribution ducts ~'
30. Trenches 50 are tack-welded or bolted to the
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metal flooring 20 and ducts 30 as is conventional.
Trenches 50 have removable covers 51 to permit access to
the distribution ducts 30 as will be described in detail
hereinafter. After;the assembly 10 has been completed,
concrete is poured over the metal flooring 20 and cable
distribution ducts 30 so as to be level with the top of
the trenches 50, as is conventional. Covers Sl are kept
on the trenches 50 during the pouring of the concrete
so as to keep concrete from entering the trenches 50.
Referring to Fig. 2, it can be seen that the
metal flooring 20 and the distribution ducts 30 are in
side-by-side relationship. It is presPntly preferred that '-
ducts 30 be 12 to about 16 inches wide and be spaced apart
four feet center-to-center. However, it is within the J~
spirit of this invention to space them more or less than
four feet apart. Any conventional corrugated metal flooring
may be used as the metal flooring 20. Fig. 2 shows trenches
50 with the removable covers 51 removed fox clarity in
revealing the intersection of trench 50 and distribution
duct 30. As will be discussed in detail hereinafter, an
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accessory pan 90 is provided at desired intersections of ~!
ducts 30 and tFenches 50.
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As is most clearly seen in Figs. 3 ? 4A and 4B,
cable trench 50 is formed of a U-shaped base pan 52
having a horizontal bottom 52a and upright vertical sides
52b. Most desira~ly, the vertical sides 52b are inte~ral
with the bottom 52a of the base pan 52. Covers 51 are
removably secured to the top of trench 50 by suitable
fastening means (not shown), such as bolts, that are
used in cable trenches. Trenches 50 may be of any y
suitable width 7 such as from about 24 to about 60 inches
wide, and can be spaced apart at any suitable distance,
such as from about one toabout 100 feet apart, but usually
from about 50 to 80 feet apart.
While the ~ertical walls 52b of base pan 52 ~.
are continuous along the extent of trench 50, the bottom `-
52a of the base pan 52 has several access windows or
apertures 52c (Fig. 3) so that when cover 51 is removed,
access to the distribution duct 30 (Fig. 2~ is per- ,~
mitted through the aperture 52c. Aperture 52c extends
longitudinally along trench 50 for a sufficient dis-
tance such that the edges of the base pan bottom 52a
will lie approximately at the mid-point of a crest 21 ,j
of the metal cellular flooring 20 (Fig. 2A). In this ,.
way, there is some tolerance in the placement of trench
50 over the metal flooring units 20. Apertures 52c may
be from about 16 to about 20 inches long and from about
20 to about 50 inches wide.
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Preferably centrally located within trench 50
is a U-shaped trough 54 which is welded or otherwise
secured to the ~ase pan bottom 52a. Trough 54 will
usually carry electrical power cables 60 (Fig. 2),
but in a given system, any of the cells 56, 57, 58
(Fig. 4A) may be the power cable cell.
As is seen most clearly iII Figs. 3, 4A and 4B,
trench 50 is composed of sub-units 50a, which comprise
a pair of opposed side walls 52b, a centrally located
10 base pan bottom 52a, and a section of trough 54 co- -
extensive with side walls 52b. Components 52a, 52b
and 54 may be separately formed and then attached to-
gether or they may be all integrally formed, as by roll
forming. Sub-units 50a are preferably shipped with
15 covers 51 attached and they are field assembled to form
trench 50 by bolting adjacent ends of sub-units 50a to-
gether. In this way, each sub-unit 50a has sufficient
structural integrity for transport and field assembly.
Each sub-unit 50a has part of an aperture 52c `-
20 at each end, the ~ull extent of each aperture 52c
being formed when adjacent sub-units 50a are connected. ~
Alternatively, trenches 50 may be formed of sub-units -
(not shown) having one or more apertures 52c shop-cut
therein.
As best seen in Figs. 5, 6A and 6B, the dis-
tribution duct 30 comprises a corrugated unit providing
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elongated cells 31~ 32 and 33 formed ~y alternating
crests 31a, 32a and 33a and valleys 34, The corrugated
unit is secured to an elongated con~inuous bottom plate
35 by any suitable means, such as welding. However, as
in the case of trench 50, duct 30 may be roll-formed
as an integral unit.
At suitable intervals along the length of
duct 30, walls 31a and 33a are omitted (or cut away)
to provide apertures 36, so that these apertures 36
will provide access to cells 31 and 33 at the areas of
intersection between trench 50 and cable distribution
duct 30 (Fig. 2A). Preferably, the apertures 36 will
be preformed and not field cut. A preformed access
port 32b may be provided in crest 32a to allow electri-
cal cable 60 (Fig. 22 lying in member 54 of trench 50
to pass from the trench 50 through port 32b and thence
into power cell 32. Most likely, port 32b will be field ~`
drilled.
Figs. 2, 2A and 7 show a distribution duct 30
that ~as modified to include an accessory pan 90. In
particular, the bottom plate 35 is shop-cut or field-
cut in both, or preferably one, of the free areas 35a,
35b (Fig. 5) to provide aperture 37, shown in dotted
line in Fig. 5, after which pan 90 is placed into the ~-
aperture and the flange or rim 91 is tack welded or
otherwise secured to bottom plate 35. Accessory pan 90
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will generally occupy the full space provided by the
free area 35a or 35b. The large apertures 36 in duct
30 permit free and easy access of cables 61 and 62 into
cells 31 and 33, respectively. In addition, the large
aperture 36 enables free and easy access of cable 62
into the pan ~0 and facilitates connecting cable 62
to an electrical or electronic accessory panel 92
{Fig. 2A~ carried inside pan 90. -
While the cross-section of cell 32 remains the
same along duct 30, cells 31 and 33 have greatly enlarged
cross-sectional areas where ducts 30 intersect trenches ';
50, because the walls 31a and 33a are removed at the
intersections of ducts 30 with trenches 50. As seen most
clearly in Fig. 2A, cells 31 and 33 each extend from the ~!'
inclined side of cell 32 to the opposed inclined wall 22a
of the adjacent flooring unit 20. The free areas 35a,
35b on bottom plate 35 enable the field assembly of a
large open pan 90 to duct 30.
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If cell 32 is centrally Iocated in duct 30 as `--
shown in Figs. 1-7, either or both of the free areas `
35a, 35b on the bottom plate 35 can be used to provide '-
the aperture 37. If cell 32 is located off-center as ^~
shown in Figs. 8 and 9, aperture 37 can have a larger
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width. Thus, Fig. 8 shows a cable distribution duct 30'
having a bottom plate 35 to which is attached an inverted
U-shaped housing or top 38. Inverted U-shaped divider
39 within housing 38 provides cells 31, 32 and 33.
Housing 38 is interrupted or omitted to proyide the aper-
tures 36 at the intersections of ducts 30' and trenches
50. Duct 30' thus provides the large area of access be- -
tween duct 30' and trench 50 at their intersection. Bot-
tom plate 35 will have free areas of different sizes
on either side of the off center power cell 32. Pan 90
is field assembled to duct 30' in the same way as it is
assembled to duct 30, preferably by providing the aperture
37 in the larger free area 35b as shown. -
Fig. 9 shows duct 30" witn the of center power
cell 32 being located at the edge of bottom plate 35
so that it is an outer cell. Divider 39a extends
throughout housing 38 to provide cells 31 and 33. Housing
38 and divider 39a are omitted at the intersections of
duct 30" and trenches 50 to provide an aperture 36 on
one side of power cell 32, and to provide a free area !`
on plate 35. Pan 90 extends through the aperture 37 cut -
in the free area on bottom plate 35 and is secured to
plate 35.
If desired, divider 39a can be onitted entirely,
in which case cells 31 and 33 are combined together to
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form one large closed cell.
At present, aperture 37 may suitably be from
about 6 to about lS inches wide and from about 12 to
about 48 inches lon~. Pan 90 may suitably be from
about 3 to about 9 inches deep, the maximu~ depth of
the pan being a function of the location of the ceiling
C (Fig. 9~ below. It is presently preferred to locate
power cell 32 off center as in duct 30' or 30" and to use
a pan 90 of about 12 inches wide, 16 inches long and about
5 to 6 inches deep.
Completing the underfloor assembly 10 are plugs
70 (Fig. 2A), which are installed as by welding before
the concrete is poured so as to prevent concrete from
otherwise entering the open apertures 36 and 52a during the
cement pour. !-
The underfloor assembly 10 according to the
invention is assembled as follows. For simplicity, the
distribution duct will be referred to as duct 30, but the
following description applies with the same effect to ,'
ducts 30' and 30'l as well. First the metal flooring 20
and the distribution ducts 30 are secured in place and
joined together on beams 40 (Fig. 1) by securing the toes -
22b of a unit 20 to platc 35 (Fie. 2 and 2A) or to the -`
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toes 22b of an adjacent unit 30 or 20, respectively, by
conventional means used in constructing corrugated metal
flooring, such as by clinching ~ogether mating flanges
(not shown~ on the edges of plate 35 and toe 22b. Aper-
tures 37 are field-cut or shop-cut in bottom plate 35 at
the desired locations, and pans 90 are placed into the
apertures and fastened to plate 35. Usually, pan 90
will not be required at each intersection of ducts 30
and trenches S0. Then the trench sub-units 50a, with c
10 covers 51 attached, are set down, connected together and
secured to ducts 30 and to the crests 21 of the metal ',
flooring 20. After the concrete is poured and set,
covers 51 are removed and cables 60, 61 and 62 are then
fed through the trenches 50 and the ducts 30. Electrical
15 or electronic panels 92 ~Fig. 2A~ may be placed in r'
pans 90 and spliced to the desired cable in trench 30.
For example, cable 62 (Figs. 2 and 2A) can be brought
from trench 50 into cell 33 and can also be spliced to
panel 92 via splice 62a. Interconnections between the
20 cables in trenches 50 and ducts 30, are easi-ly-~adP at -
the desired point of interconnection, because the full
extent of the cells 31, 32 and 33 is readily accessed. -
Bulky splices in the cables 61 and 62 in the trenches
50 and the ducts 30 are accommodated below trench 50 in
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the large cells 31 and 33. The large access space at
the intersections of ducts 30 and trenches 50 also
enables the desired ca~le, e.g. cable 62, to be spliced
to a panel 92 (Fig. 2A~ via splice 62a. The pro~ision
of the panels 92 greatly simplifies the connection of
cables in the ca~le distribution duct 30 to electronic
and/or electrical operating units above the floor. Thus,
it is conventional to splice the large cable 62 in cell
33 to units above the floor. With panel 92, small cables
run from panel 92 through cell 33 to the above-100r
units. Connecting the above-floor units to cable 62
can thus be done at one location using easily handled
small cables. Only one splice or connection to cable
62, e.g. via splice 62a, is needed. Also, as described .
lS hereinafter, pan 92 can be accessed through the ceiling ,;
C (Fig. 9) of the floor below.
After the concrete floor is poured, and usually
after the cables 60, 61, 62 are run through the trenches !.50 and ducts 30, 30' or 30", a con~entional ceiling C ,~is suspended from the floor as diagrammatically shown ,:'
in Fig. 9. As is known, the space between ceiling C
and the flooring 20 and ducts 30, 30' or 30" may be used .
for heating and airconditioning ducts, lighting fixtures /~and wires and the like. However, in the present in-
vention, the ducts 30, 30' and 30" and trenches 50 may
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now be accessed from the floor below by opening ceiling
C, as by re~oving a ceiling panel (not shown) to reveal
the accessory pan 90 above the ceiling. The bottom of
the pan 90 may then be cut to form an aperture through
5 which cables or the like can be fed. As stated above,
the depth of pan 90 can be such as to extend to ceiling
C, but access to pan 90 can readily be obtained by re- -
moving one or more ceiling panels even if pan gQ is
shallow. ,-
In practice, the number and size of cables
that provide electrical and other services per unit area
of floor, is limited by the number and size of trenches
50. Thus, in the present in~ention, the larger storage
area at the intersections of the trenches 50 and ducts ,~
1530, 30' or 30" enables the trenches 50 to carry larger
size and/or a larger member of cables than heretofore -
possible, as well as to provide pans 90, while-maintaining
the trenches 50 at a giyen size and number. This is be-
cause the larger storage area is below the trench 50,
20which in turn enables the splices of cables in trench 50
to the cables in duct 3Q, 30' or 30" and the necessary
bends in these cables, to be located below the trench 50
without using the limited space in the trench 50 for
these purposes. In addition~ useful storage space is
25created below ducts 30, 30' or 30" by the pans 9Q.
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