Note: Descriptions are shown in the official language in which they were submitted.
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1 SIDE LAP SEAM ATTACHMENT TOOL
2
3 Background of the Invention
4 1. Field of the Invention
The present invention relates generally to shear resistant steel decking, and
more
6 particularly, to an apparatus for forming a shear-resistant side lap seam
attachment in
7 steel decking.
8
9 2. Description of the Relevant Art
It is common in the construction of commercial buildings to create floors and
11 roofs from steel deck panels. Such steel deck panels might include
ribbed, or "fluted",
12 steel deck panels as well as cellular steel deck panels. Examples of
fluted steel deck
13 panels are shown, for example, in U.S. Patent Nos. 4,186,535 and
4,894,967. Such steel
14 deck panels are typically welded to underlying structural support beams,
although
mechanical fasteners, such as power-actuated pins or screws may also be used.
When
16 properly assembled, such fluted steel deck panels provide a cost-
effective diaphragm for
17 forming floors and roofs of commercial buildings. These steel deck
panels are often
18 referred to in the trade by the names A-deck, B-deck, F-deck, N-deck, W-
deck, etc. Such
19 panels are often provided in different thicknesses, or gauges, ranging
from relatively thin
22 gauge stock to more rigid 16 gauge stock. Panel widths are typically 24
inches to 36
21 inches, depending upon the type of steel deck being used. Individual
panel lengths can
22 vary from as little as three feet to over 40 feet. Reinforcing ribs, or
"flutes", are formed
23 in such panels. One edge of each such panel, extending parallel to such
ribs, includes an
24 upwardly-extending lip. The opposite edge of the panel includes a
downwardly-
extending inverted U-shaped lip for extending over, and receiving, the
upwardly-
26 extending lip of an adjacent panel to form a seam. The two adjacent
panels are attached
27 along such seam. Various methods have been used to form the seam
attachment,
28 including button punching, crimping, screwing, riveting, welding, as
well as shearing and
29 deformation of the deck seam.
Building codes of many geographic areas require buildings to be able to
withstand
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1 lateral shear forces of specified minimums. This is particularly true for
regions known to
2 be subject to high winds (e.g., the Eastern United States), earthquakes
or other seismic
3 activity (e.g., the Western United States). Steel roof decks, when
properly secured to the
4 underlying building frame, form a diaphragm. In order for the diaphragm
to resist lateral
shear forces without failure, the seam attachment securing the sides of
adjacent panels to
6 each other must be able to effectively resist relative sliding movement
of adjacent panels
7 along the seam joining the two panels. Often, side-lapped joints of a
steel deck
8 diaphragm must be inspected for consistency and integrity before further
construction of
9 a building may proceed. To avoid construction delays, such side-lapped
joints should be
formed in a manner that allows such joints to be inspected quickly and easily,
preferably
11 from the top side of the decking.
12 Each different seam attachment method presents benefits and
disadvantages. For
13 example, button punch tools for deforming "buttons" within the
overlapped lips of
14 adjacent panels along the side seam are relatively easy to use, and a
number of such
attachments can be formed in relatively little time. One such pneumatically-
assisted tool
16 for crimping and dimpling the side seam of steel decking is disclosed in
U.S. Patent No.
17 5,878,617 to Parker. However, such button punches do not form a very
secure
18 connection, and are not very effective at resisting lateral shear
forces.
19 Other seam attachment tools actually shear and deform portions of the
seam. For
example, in U.S. Patent No. 182,193 issued in 1876, Holeton discloses a method
of
21 forming triangular notches in the side-lapped joint and then folding
over such triangular
22 notches to interlock the joint. In U.S. Patent No. 3,641,729, inventor
Irvin discloses the
23 use of lip-clenching dies operated by a clinching tool to cut a slit
through the side-lapped
24 joint, and to form opposing lobes for securing the side-lapped joint.
U.S. Patent No. 6,212,932 to Parker discloses a pneumatic shear for forming
26 structural louvers. In one embodiment, a pneumatically-operated tool
selectively opens
27 and closes a pair of jaws that are pivotally connected to each other
about a common pivot
28 axis. One such jaw includes a single blade having first and second
opposing sides
29 forming first and second blunt edges. The second jaw includes two spaced
blades that are
spaced from each other by the thickness of the single blade on the first jaw,
also having
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1 blunt edges. Thus, the two spaced blades on the second jaw form a "die"
for receiving the
2 single blade on the first jaw when the first and second jaws are pivoted
to their closed
3 position. With the jaws in their opened position, the first and second
jaws are inserted
4 over a side-lapped seam of a steel deck. The pneumatic tool is then
activated to close the
jaws toward each other. The single blade of the first jaw passes between the
two "die"
6 blades of the second jaw, forming a pair of cuts in the overlapped seam.
Further closing
7 of the jaws deforms a central tab in a first direction, while deforming
regions on either
8 side of the central tab in the opposite direction. Side-lapped joints
formed by use of this
9 apparatus have been shown to securely fasten the side-lapped seams and to
satisfactorily
resist deformation due to horizontal shear loading.
11 In U.S. Patent No. 7,434,314, issued to Morton, a further tool for
reliably
12 fastening together side-lapped edges of adjacent deck panels is
disclosed. The '314
13 patent describes a seam attachment tool that includes four jaws, two of
which are
14 positioned on one side of the seam, and the other two of which are
positioned on the
opposite side of the seam. Two of the opposing jaws cooperate with each other
to shear a
16 first cut line through the seam. The other two opposing jaws cooperate
with each other to
17 shear a second cut line through seam parallel to, and slightly spaced
apart from, the first
18 cut line. The material bounded between the first and second cut lines
forms a louver or
19 tab. This material is deformed in a first direction adjacent the first
cut line, and deformed
in the opposite direction adjacent the second cut line. It has been found that
prototypes of
21 the seam attachment tool disclosed in the '314 Morton patent form a
relatively secure
22 seam attachment, and attain significantly higher shear resistance values
than other known
23 punching tools.
24 Applicant has more recently come to realize that the four-jaw punch tool
disclosed in the '314 patent could be further improved. For example, the
aforementioned
26 four-jaw tool is not perfectly symmetrical. As a result, when a deck
installer triggers the
27 pneumatic actuator on a working prototype of such tool, a torque, or
twisting motion, is
28 applied to the handle of the tool, which the operator must resist. Since
the deck installer
29 typically makes many of such attachments continuously along the deck
seam on a roof,
the hands, wrists, and arms of the deck installer can tire easily. In
addition, it was found
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1 that, when using the working prototype, the jaws of the four-jaw tool
would sometimes
2 bind in the deck seam, even after pneumatic pressure was released from
the actuator of
3 the tool. This binding of the jaws may be due to the torque exerted upon
the seam by the
4 jaws in a non-symmetrical fashion.
One of the stated objects of the invention set forth in the specification of
the '314
6 patent is to provide a punching tool having a blade assembly that
equalizes the wear on
7 the blades, and which avoids excessive stress on any particular blade, to
extend the usable
8 life of the tool. Applicant has found that, in regard to the
aforementioned working
9 prototype, though the addition of the fourth jaw lessened the likelihood
of jaw failure, it
did not eliminate the problem of jaw failure. When one or more of the jaws
fail, the
11 punching tool must essentially be disassembled; the jaw with the broken
blade must be
12 detached from the actuator and replaced with a new jaw having a fresh
blade. Apart from
13 the need to keep the rather bulky replacement jaws on hand for such
instances, significant
14 time is required to disassemble the tool and repair it. During such down
time, work on
attaching the deck seam necessarily halts. Jaw failure can be reduced somewhat
by using
16 a harder steel to form the jaw; however, making the entire jaw from
specially hardened
17 steel significantly increases the cost of the tool; it also makes the
entire jaw assembly
18 more brittle, which allows for failures in the jaw at points other than
the working blade
19 end.
Accordingly, it is an object of the present invention to provide a punching
tool for
21 forming an attachment in an interlocking side-lapped seam of a steel
deck structure which
22 provides a solid attachment capable of resisting significant horizontal
shear loads.
23 It is a further object of the preSent invention to provide such a
punching tool
24 which can be operated relatively quickly and easily by a deck installer
to attach
interlocking side-lapped seams of a steel deck structure.
26 It is a still further object of the present invention to provide such a
punching tool
27 which produces an attachment that can be quickly and easily inspected by
an inspector
28 standing atop the assembled steel decking.
29 Another object of the present invention is to provide such a punching
tool having
jaws that generally equalize the wear on the blades of such jaws, and which
avoids
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1 excessive stress on any particular blade, to extend the usable life of
the tool.
2 A yet further object of the present invention is to provide such a
punching tool
3 which can be repaired quickly and easily if a blade formed on the working
end of the jaw
4 should break.
Still another object of the present invention is to form a side-lapped seam
6 attachment that provides higher shear values by forming an attachment
which is more
7 resistant to slippage when subjected to a horizontal load along the
longitudinal axis of the
8 side-lapped seam.
9 A still further object of the present invention is to provide such a
punching tool
which is less likely to bind in the deck seam following actuation of the tool
and
11 subsequent release of compressive forces upon the jaws of the tool, to
facilitate easier
12 disengagement of the tool from the deck when air pressure on the tool is
released.
13 Yet another object of the present invention is to provide such a
punching tool
14 wherein the jaw assembly is symmetrical in nature, and wherein there is
no twisting
torque force exerted upon the tool handle as the punch tool is actuated.
16 These and other objects of the invention will become more apparent to
those
17 skilled in the art as the description of the present invention proceeds.
18
19 Summary of the Invention
Briefly described, and in accordance with a preferred embodiment thereof, the
21 present invention relates to a punching tool for forming an attachment
in an interlocking
22 side-lapped seam of a steel deck structure. The steel deck structure
includes at least first
23 and second steel deck panels, each such deck panel including an upturned
lip along one
24 side edge thereof, and a downwardly-directed U-shaped channel along the
opposing side
edge thereof. Adjacent deck panels are arranged so that the downwardly-
directed U-
26 shaped channel along a side edge of one panel is inserted over the
upturned lip extending
27 from the side edge of the adjacent deck panel.
28 In one preferred embodiment, the punching tool includes first and second
jaws
29 spaced apart from each other, and each having a seam-engaging blade for
engaging a first
wall of the seam. The tool further includes third, fourth and fifth jaws
spaced apart from
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1 each other, and each having a seam-engaging blade for engaging the
opposing second
2 wall of the seam. Each of the jaws provides a cutting blade on the
working end thereof
3 for engaging the seam to be attached. An actuator, which may be
pneumatically
4 powered, selectively moves the first and second jaws either toward the
third, fourth and
fifth jaws to a closed position, or away from the third, fourth and fifth jaws
to an opened
6 position. As the first jaw moves from the opened position to the closed
position, the
7 seam-engaging blade of the first jaw passes at least partially between
the seam-engaging
8 blades of the third and fourth jaws. Similarly, as the second jaw moves
from the opened
9 position to the closed position, the seam-engaging blade of the second
jaw passes at least
partially between the seam-engaging blades of the fourth and fifth jaws.
11 The seam engaging blades of the third and fourth jaws are spaced apart
from each
12 other by approximately the width of the seam-engaging blade of the first
jaw. In this
13 manner, the third and fourth jaws collectively form a die for receiving
the seam-engaging
14 blade of the first jaw. Likewise, the seam engaging blades of the fourth
and fifth jaws are
spaced apart from each other by approximately the width of the seam-engaging
blade of
16 the second jaw. In this manner, the fourth and fifth jaws collectively
form a die for
17 receiving the seam-engaging blade of the second jaw. Finally, it should
also be noted
18 that the first and second jaws likewise form a die for receiving the
seam-engaging blade
19 of the fourth jaw. The result is that three bowed louvers are formed
simultaneously side-
by-side within the deck seam each time the punching tool is actuated; the
center-most
21 louver is bowed outward in a first direction, and the two surrounding
louvers are bowed
22 outward in the opposite direction. This seam attachment is highly
resistant to horizontal
23 shear forces applied along the longitudinal axis of the deck seam.
24 Preferably, a taper is provided on each of the above-described seam-
engaging
blades to aid in the release of such blades from the deck seam when the
actuator of the
26 punching tool is released. In this regard, the seam-engaging blade of
the first jaw
27 preferably includes a base region as well as a peak region that projects
beyond the base
28 region. Likewise, the seam-engaging blade of the second jaw preferably
includes a base
29 region as well as a peak region that projects beyond the base region.
Ideally, the width of
the peak regions of such blades is slightly less than the width of the base
regions of such
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I blades to facilitate the release of the seam engaging blades of the first
and second jaws
2 from the side-lapped seam of the steel deck structure. Stated another
way, the spacing
3 between the peak regions of the first and second jaws is slightly greater
than the spacing
4 between the base regions of the first and second jaws.
In another preferred embodiment of the invention, the punching tool includes
6 detachable blade inserts that allow broken blades to be repaired quickly,
and without
7 disassembly of the punching tool. The detachable blade inserts are
removably coupled to
8 the working ends of the jaws, preferably by a dovetail joint. Preferably,
the jaws of the
9 tool are pivotally mounted about a jaw pivot axle, and each such dovetail
joint extends
along an axis that is oriented generally perpendicular to the jaw pivot axle.
Providing
11 detachable blade inserts allows for the jaws to be made of a relatively
elastic type of steel
12 or other metal having a first hardness rating on the Rockwell C scale,
while allowing the
13 detachable blade inserts to be made of a metal having a higher hardness
rating on the
14 Rockwell C scale to better shear the deck seam.
In the preferred embodiments of the present invention, the seam-engaging
blades
16 of the jaws each include a generally semi-cylindrical portion. When the
actuator moves
17 the first and second jaws toward the third, fourth and fifth jaws to the
closed position, the
18 semi-cylindrical portion of the seam-engaging blade of the first jaw
passes at least
19 partially between the semi-cylindrical portions of the seam-engaging
blades of the third
and fourth jaws. Likewise, the semi-cylindrical portion of the seam-engaging
blade of
21 the second jaw passes at least partially between the semi-cylindrical
portions of the seam-
22 engaging blades of the fourth and fifth jaws.
23 It is preferred that the semi-cylindrical portions of the first and
second jaws
24 extend about central axes that are coaxially aligned with each other. In
other words, the
central axis of the semi-cylindrical portion of the seam-engaging blade of the
first jaw is
26 coaxial with the central axis of the semi-cylindrical portion of the
seam-engaging blade
27 of the second jaw. Similarly, it is preferred that the semi-cylindrical
portions associated
28 with the third, fourth and fifth jaws extend about central axes that are
coaxially aligned
29 with each other. In addition, it is preferred that, when the jaws of the
tool are compressed
to the closed position, the central axes of the semi-cylindrical blade
portions associated
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1 with the first and second jaws lie proximate to the central axes of the
semi-cylindrical
2 blade portions associated with the third, fourth and fifth jaws.
3 If desired, such semi-cylindrical blade portions may be provided upon
detachable
4 blade inserts of the type described above. As noted above, such
detachable blade inserts
may be coupled to their respective jaws by dovetail joints; each of such
dovetail joints
6 preferably extends generally perpendicular to the central axis of the
generally semi-
7 cylindrical blade portion coupled thereto. The detachable blade inserts
may also be
8 attached by mechanical fasteners, epoxy cement, solder, etc.
9 While the above-described embodiment of the invention using detachable
blade
inserts is described in conjunction with a five-jaw tool, those skilled in the
art will
11 appreciate that it could also be used with a three-jaw tool or a four-
jaw tool. In the case
12 of a three-jaw tool, the first jaw is associated with a first blade
insert detachably coupled
13 thereto for engaging a first wall of the seam. Second and third jaws are
also provided,
14 being spaced apart from each other, and generally facing the first jaw.
Second and third
detachable blade inserts are associated with the second and third jaws,
respectively, and
16 detachably coupled thereto for engaging the second opposing wall of the
seam. As noted
17 above, the detachable coupling is preferably achieved by using a
dovetail joint.
18 An actuator is again provided to selectively move the first jaw relative
to the
19 second and third jaws, either moving the first jaw toward the second and
third jaws into a
closed position, or moving the first jaw away from the second and third jaws
toward an
21 opened position. The detachable blade insert coupled to the first jaw is
initially spaced
22 apart from the second and third jaws when the tool is in its opened
position for insertion
23 about the seam. Upon operating the actuator, the detachable blade insert
coupled to the
24 first jaw advances at least partially between the second and third blade
inserts coupled to
the second and third jaws. As before, the second and third detachable blade
inserts form
26 a die for receiving the first detachable blade insert. Also, as noted
above, such detachable
27 blade inserts may be tapered to be of slightly lesser widths at their
peaks than at their
28 bases to facilitate the release of the tool from the seam when the
actuator of the tool is
29 released. As also noted above, the first, second and third detachable
blade inserts may be
made of a "harder" steel than that used to make the first, second and third
jaws.
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1 As also noted above, the detachable blade inserts may each include a
generally semi-
2 cylindrical portion extending therefrom.
3
4 Brief Description of the Drawings
Fig. 1 is a perspective view of a steel roof deck including two ribbed steel
deck
6 panels having overlapped side edges forming a side-lapped deck seam.
7 Fig. 2 is a detailed perspective view of a seam attachment formed in
the deck
8 seam by using a five-jaw tool of the type described herein.
9 Fig. 2A is a sectional view of the side-lapped deck seam attachment
shown in Fig.
2, taken through lines 2A-2A in Fig. 2.
11 Fig. 3 is a perspective view of a five-jaw punching tool being
inserted over the
12 side-lapped seam preliminary to forming the seam attachment.
13 Fig. 4 is a detailed perspective view of a first embodiment of a five-
jaw punching
14 tool wherein the cutting blades are integral with the jaws.
Fig. 5 is a detailed perspective view of a second embodiment of a five-jaw
16 punching tool wherein all five jaws include detachable blade inserts.
17 Fig. 6 is an enlarged perspective view of the working end of one of
the jaws
18 shown in Fig. 4.
19 Fig. 7 is an enlarged perspective view of the working end of one of
the jaws
shown in Fig. 5, including a detachable blade insert coupled to its jaw by a
dovetail joint,
21 and wherein the detachable blade insert includes a semi-cylindrical
portion
22 Fig. 8 is an end view of the detachable blade insert shown in Fig. 7.
23 Fig. 9 is a top view of the detachable blade insert shown in Fig. 7.
24 Fig. 10 is a schematic view of a five-jaw tool in its opened position,
i.e., wherein
the first and second jaws are spaced apart from the third, fourth and fifth
jaws.
26 Fig. 11 is a schematic view of the five-jaw tool of Fig. 10, but shown
in its closed
27 position, i.e., wherein the first jaw advances at least partially
between the third and fourth
28 jaws, and wherein the second jaw advances at least partially between the
fourth and fifth
29 jaws.
Fig. 12 is another schematic view of the five jaw tool of Fig. 10, but
including
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1 only the first, second and fourth jaws.
2 Fig. 13 is a further schematic view of the five-jaw tool illustrating
the orientation
3 of the five jaws relative to the deck seam before the actuator of the
tool is triggered.
4 Fig. 14 is a schematic view similar to Fig. 13 but illustrating the
orientation of the
five jaws relative to the deck seam just after the actuator of the tool is
triggered.
6 Fig. 15 is a simplified schematic view of three louvers formed in the
deck seam
7 after the actuator of the punching tool is triggered.
8
9 Detailed Description of the Preferred Embodiment
Referring to Fig. 1, steel roof deck 20 is formed by attaching multiple roof
deck
11 panels, including ribbed panels 22 and 24. Such ribbed steel deck panels
may be, for
12 example, type B-deck panels available from Verco Decking Inc. of
Phoenix, Arizona.
13 The overlapped side edges of panels 22 and 24 form a seam 26. Steel roof
deck 20 is
14 supported by underlying steel beam 28, and is secured thereto, for
example, by weld 30,
though power-actuated fasteners (pins), screws, or rivets, may also be used.
Side-lapped
16 seam 26 is secured against longitudinal sliding movement by seam
attachments 32 and
17 34.
18 As shown best in the detailed view of Fig. 2, steel deck panel 22
includes an
19 upturned lip 36 along one side edge thereof. Steel deck panel 24
includes a davvnward1y-
directed U-shaped channel 38 along one of its side edges. Channel 38 of panel
24 is
21 nested over, and receives, lip 36 of panel 22 to form deck seam 26. U-
shaped channel 38
22 includes a first wall 40 on one side of seam 26 and a second wall 42 on
the other side of
23 seam 26. First wall 40 and second wall 42 extend generally parallel to
each other,
24 forming downwardly-directed channel 38, with lip 36 extending upwardly
between first
wall 40 and second wall 42.
26 Also shown in Fig. 2 is seam attachment point 32. Seam attachment point
27 includes three deformed tabs, or louvers, two of which, 44 and 46, are
clearly visible in
28 Fig. 2. The third louver is disposed between louvers 44 and 46 and is
deformed in the
29 opposite direction. Turning briefly to Fig. 2A, the two louvers 44 and
46 are visible
bowing outward to the right (relative to Fig. 2A), and a third louver 48 is
visible bowing
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1 outward to the right (relative to Fig. 2A) directly between louvers 44
and 46.
2 In Fig. 3, the lower end of pneumatic punching tool 50 is shown. General
details
3 concerning the construction and operation of a pneumatic punching tool
may be found in
4 U.S. Patent No. 5,878,617 to Parker.
It should be sufficient to note that punching tool 50 includes two
6 jaw members on one side thereof, including jaw member 52 and three jaw
members on
7 the other side, including jaw members 54, 56 and 58. Each of such jaw
members is
8 mounted for pivotal rotation about pivot axle 60, which extends through
the lower end of
9 punching tool 50. A pneumatic actuator (not shown in Fig. 3) reciprocates
slide-action
drive bolt 62 within slot 64 of fixed support brackets 66 and 68 of punching
tool 50.
11 Jaws 52-58 are preferably made from S-7 tool steel that is heat-treated
to a hardness of
12 59-60 on the Rockwell "C" scale, and finished to a thickness of
approximately 0.450-
13 0.500 inch.
14 The upper ends of each jaw member are coupled by a link member to slide-
action
drive bolt 62. For example, the upper end of jaw member 52 is pivotally
coupled by link
16 70 and pivot pin 71 to slide-action drive bolt 62, and the upper end of
jaw member 54 is
17 pivotally coupled by link 72 and pivot pin 73 to slide action drive bolt
62. As slide-
18 action drive bolt 62 is forced downward within slot 64 toward pivot axle
60, links 70 and
19 72 cause the upper ends of jaw members 52-58 to rotate outwardly away
from support
brackets 24 and 26. This in turn causes the lower ends of jaw members 52-58 to
pivot
21 from their opened position to their closed position. Conversely, when
slide-action drive
22 bolt 62 is de-actuated, and pulled upwardly within slot 64 away from
pivot axle 60, the
23 lower ends ofjaw members 52-58 open back up.
24 Once again, suitable apparatus for controlling and powering
reciprocation of a
slide-action drive bolt is disclosed generally in prior U.S. Patent No.
5,878,617 to Parker.
26 The pneumatic actuator of punch tool 50 typically operates with
compressed air having a
27 pressure ranging between 100-140 psi; this develops approximately 4,200
pounds of
28 force on the lower ends of the jaws. Of course, the actuator used to
reciprocate slide-
29 action drive bolt 62 need not be hydraulic or pneumatic; for example, an
electric motor
could also be used to advance and retract slide-action drive bolt 62.
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1 Fig. 4 shows a first embodiment of the actual cutting blades provided at
the lower
2 working ends of jaws 52-58. First jaw 52 and second jaw 53 are spaced
apart from each
3 other. First jaw 52 terminates in a hooked blade 74, and second jaw 53
terminates in a
4 hooked blade 76. A more detailed view of the lower end of jaw 52, and
blade 74, is
shown in Fig. 6, wherein bore 84 is provided to receive pivot axle 60. The
hook-shaped
6 terminal end of blade 74 bends through a rounded, generally semi-circular
arc having a
7 radius of approximately 0.15 inch. As shown best in Fig. 6, an undercut
region 75 is
8 inset from blade 74; undercut region 75 forms an arcuate curve about a
radius of
9 approximately 0.1875 inch. Second jaw 53 and its blade 76 are preferably
formed in the
same manner as first jaw 52 and its blade 74.
11 Blades 74 and 76 are adapted to simultaneously engage a first wall of
the U-
12 shaped channel at deck seam 26. Third jaw 54 includes a rounded blade 78
at its lower
13 end; fourth jaw 56 includes a rounded blade 80 at its lower end; and
fifth jaw 58 likewise
14 includes a rounded blade 82 at its lower end. The third, fourth and
fifth jaws (54, 56, and
58) are spaced apart from each other, and generally face the first and second
jaws (52 and
16 53). Blades 78, 80 and 82 are adapted to simultaneously engage the
second wall of the
17 U-shaped channel at deck seam 26. Preferably, blades 78, 80 and 82 are
formed in the
18 same manner as blades 74 and 76.
19 As illustrated in Fig. 4, blades 74, 76, 78, 80 and 82 are in the opened
position for
allowing the respective jaws to be placed over and around deck seam 26. When
the
21 actuator of punching tool 50 is triggered, punching tool 50 selectively
moves blades 52,
22 53, 78, 80 and 82 toward each other and into a closed position. When the
actuator is later
23 released, punching tool 50 moves blades 52, 53, 78, 80 and 82 away from
each other and
24 back to the opened position shown in Fig. 4.
Turning briefly to the schematic of Fig. 10, the opened position of the jaws
is
26 shown. Blade 74 of the first jaw, and blade 76 of the second jaw, are
spaced apart from
27 blades 78, 80, and 82 of the third, fourth, and fifth jaws,
respectively. In the schematic of
28 Fig. 11, the closed position of the jaws is shown. In the closed
position, blade 74 of first
29 jaw 52 has passed at least partially between blades 78 and 80 of third
and fourth jaws 54
and 56, respectively. Likewise, in the closed position of Fig. 11, blade 76 of
second jaw
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1 53 has passed at least partially between blades 80 and 82 of fourth and
fifth jaws 56 and
2 58, respectively.
3 Referring again to the schematic drawing of Fig. 10, blade 74 of first
jaw 52 has a
4 width (W1) designated by arrow 86. Blades 78 and 80 of third and fourth
jaws 54 and 56
are spaced apart from each other by a spacing (Si) designated by arrow 88.
Preferably,
6 width 86 (W1) and spacing 88 (S1) are substantially equal to each other.
In this manner,
7 blades 78 and 80 provide a die that receives blade 74. Similarly, blade
76 of second jaw
8 53 has a width (W2) designated by arrow 90. Blades 80 and 82 of fourth
and fifth jaws
9 56 and 58 are spaced apart from each other by a spacing (S2) designated
by arrow 92.
Preferably, width 90 (W2) and spacing 92 (S2) are substantially equal to each
other. In
11 this manner, blades 80 and 82 provide a die that receives blade 76.
12 In a similar manner, blades 74 and 76 of first and second jaws 52 and 53
provide a
13 die that receives blade 80 of fourth jaw56. Turning to Fig. 12, blades
74 and 76 of first
14 and second jaws 52 and 53 are shown as having a taper, whereby blades 74
and 76 each
have a width that varies slightly. Near the base region of such blades, blade
74 has a
16 width designated by arrow 94, blade 76 has a width designated by arrow
96, and blades
17 74 and 76 are spaced apart from each other by a distance (D1) designated
by arrow 98.
18 However, at the tips, or peak regions, of such blades, blade 74 has a
width designated by
19 arrow 100, blade 76 has a width designated by arrow 102, and blades 74
and 76 are
spaced apart from each other by a distance (D2) designated by arrow 104.
Preferably,
21 distance 104 (D2) exceeds distance 98 (D1) to facilitate the release of
blades 74 and 76 of
22 first and second jaws 52 and 53 from the deck seam when the actuator of
punching tool
23 50 is released.
24 Still referring to Fig. 12, as was noted above, blade 74 of first jaw 52
has a width
94 (W1) near its base region, and a width 100 (W2) near its peak region.
Similarly, blade
26 76 of second jaw 53 has a width 96 (W1) near its base region, and a
width 102 (W2) near
27 its peak region. It has been found that making width W2 at least .005
inch smaller than
28 width W1 will facilitate the release of blades 74 and 76 from the deck
seam. Blade 80 of
29 fourth jaw 58 likewise has a slightly greater width 106 at its base
region than its width
108 near its peak region, the difference preferably being at least .005 inch
to facilitate the
13
CA 02934974 2016-06-30
1 release of blade 80 from the deck seam. In any event, distance 104,
separating blades 74
2 and 76 near their peak regions, is slightly greater than width 108, for
allowing the peak
3 region of blade 80 to advance into blades 74 and 76 when punching tool 50
is actuated.
4 Now turning to Fig. 5, an alternate embodiment of the present invention
is
illustrated wherein features corresponding to those already described above
relative to
6 Fig. 4 are designated by like primed reference numerals. First jaw 52'
includes an upper
7 end 112 and a lower end 114. Coupled to lower end 114 of first jaw 52' is
a detachable
8 blade insert 116 for engaging the deck seam when punching tool 50 is
actuated to the
9 closed position. Likewise, second jaw 53' includes an upper end 118 and a
lower end
120. Coupled to lower end 120 of second jaw 53' is detachable blade insert 122
for
11 engaging the deck seam when punching tool 50 is actuated to the closed
position. Similar
12 detachable blade inserts 124, 126, and 128 are coupled to the lower ends
of jaws 54', 56'
13 and 58', respectively.
14 As noted earlier, one of the advantages of using detachable blade
inserts is that
they can be formed of material that is relatively harder than the material
from which the
16 jaw itself is formed. For example, blade inserts 116-128 are preferably
made from S-7
17 tool steel that is heat treated to be fully hardened to within the range
of 56-58 on the
18 Rockwell "C" scale. On the other hand, jaws 52'-58' may be formed from
AISI Grade
19 4140, or Grade 4340, tool steel hardened to within the range of 45-48 on
the Rockwell
"C" scale. This allows the blades themselves to be relatively hard for
shearing the deck
21 seam, while allowing the jaws themselves to be made of a more elastic
material that is
22 not as brittle and less likely to break under repeated actuation cycles.
23 Of course, the other primary advantage of using such detachable blade
inserts
24 relates to ease of repair if one or more of such blade inserts should
break during use. It is
not necessary to disassemble jaws 52-58 from pivot axle 60' of punching tool
50 if one or
26 more of the detachable blade inserts should break. Rather, the broken
blade insert need
27 only be removed from its corresponding jaw, and replaced with a fresh
blade insert.
28 Likewise, if it is noticed, during routine maintenance of such tools,
that one or more
29 blade inserts are excessively worn, the worn blade inserts can easily be
removed and
replaced with fresh blade inserts before putting the tool back in the field,
all without
14
CA 02934974 2016-06-30
1 requiring disassembly of the tool.
2 As shown in Figs. 5 and 7, each detachable blade insert is preferably
coupled to
3 the lower end of its corresponding jaw by a sliding dovetail joint. As
shown in Fig. 7,
4 lower end 114 of jaw 52' includes a flattened plateau, or base region,
into which a
trapezoidal-shaped channel 130 is formed; channel 130 extends generally toward
pivot
6 bore 84' and preferably extends along an axis that is generally
perpendicular to the
7 central axis of bore 84', and hence, generally perpendicular to pivot
axle 60'.
8 Trapezoidal channel 130 is wider at the bottom of such channel than it is
when it reaches
9 the flattened plateau. Referring to Figs. 7,8 and 9, detachable blade
insert 116 includes
an essentially planar base region 132, the underside of which is supported by
the
11 flattened plateau formed upon jaw 52'. Extending from the underside of
base region 132
12 is a trapezoidal-shaped rib 134 that slidingly mates with channel 130 of
jaw 52'.
13 Preferably, blade insert is retained upon jaw 52' by maintaining tight
tolerances while
14 machining channel 130 and machining mating rib 134. Alternate methods of
ensuring
that rib 134 of blade insert 116 does not inadvertently slide out of channel
130 of jaw 52'
16 include the use of mechanical fasteners or the application of an epoxy
cement or heated
17 solder to the dovetail joint.
18 Those skilled in the art will appreciate that, while such detachable
blade inserts
19 have been described above in conjunction with a five-jaw punching tool,
such detachable
blade inserts can provide significant advantages even when used with earlier
three-jaw or
21 four-jaw punching tools.
22 Still referring to Figs. 7-9, detachable blade insert 116 includes a
generally semi-
23 cylindrical portion 136 projecting outwardly from base region 132.
Referring briefly to
24 Fig. 5, the other four blade inserts 122-128 also include generally semi-
cylindrical
portions 138, 140, 142, and 144, respectively. When punching tool 50 is
actuated, semi-
26 cylindrical portion 136 of blade insert 116 of first jaw 52' passes at
least partially
27 between the semi-cylindrical portions 140 and 142 of blade inserts 124
and 126 of the
28 third and fourth jaws 54' and 56'. Likewise, when punching tool 50 is
actuated, semi-
29 cylindrical portion 138 of blade insert 122 of second jaw 53' passes at
least partially
between the semi-cylindrical portions 142 and 144 of blade inserts 126 and 128
of fourth
CA 02934974 2016-06-30
1 and fifth jaws 56' and 58'. As shown best in Figs. 7 and 8, generally
semi-cylindrical
2 portion 136 of blade insert 116 extends along an axis that is generally
perpendicular to
3 the central axis of the dovetail joint formed by channel 130 and rib 134.
Though not
4 required, the use of such generally semi-cylindrical portions on the
blade inserts seems to
help create louvers formed in the deck seam in a preferred manner.
6 Though not required, it is preferred that the central axes about which
semi-
7 cylindrical portions 136 and 138 extend be coaxial with each other. It is
also preferred,
8 though not required, that the central axes about which semi-cylindrical
portions 140, 142
9 and 144 extend also be coaxial with each other. In this preferred
scenario, when
punching tool 50 is actuated to advance the jaws to the closed position, the
central axes of
11 semi-cylindrical portions 136 and 138, and the central axes of semi-
cylindrical portions
12 140, 142, and 144, lie generally proximate to each other.
13 Referring to Figs. 8 and 9, generally semi-cylindrical portion 136 rises
from base
14 region 132 to a peak 146. The width (WI) of generally semi-cylindrical
portion 136 at
the opposing ends of base region 132 is preferably greater than the width (W2)
of
16 generally semi-cylindrical portion 136 at the opposing ends of peak 146.
In Fig. 9, the
17 tapering of the ends of generally semi-cylindrical portion 136 is shown
in exaggerated
18 form by angled surfaces 148 and 150. In actuality, width W2 is
preferably made at least
19 .005 inch smaller than width WI to facilitate the release of first jaw
52' from the deck
seam after punching tool 50 is released. The other four blade inserts 138-144
are
21 preferably formed in a similar fashion.
22 Turning now to Figs. 13-15, Fig. 13 shows in schematic form the lower
ends of
23 jaws 52', 53', 54', 56' and 58', oriented as they would be when punching
tool 50 is
24 inserted over deck seam 26, and before punching tool 50 is actuated.
Fig. 14 shows in
schematic form the lower ends of jaws 52', 53', 54', 56' and 58', oriented as
they would
26 be just after punching tool 50 is actuated. First jaw 52' and third jaw
54' together shear a
27 first cut line 160 in deck seam 26. First jaw 52' and fourth jaw 56'
together shear a
28 second cut line 162 parallel to, and spaced apart from, first cut line
160. Similarly,
29 second jaw 53' cooperates with fourth and fifth jaws 56' and 58' to
shear third and fourth
cut lines 164 and 166, respectively, and parallel to cut lines 160 and 162.
The resulting
16
CA 02934974 2016-06-30
1 punched deck seam is shown schematically in Fig. 15. Louver 44 bows
upwardly
2 (toward the viewer of Fig. 15) between cut lines 164 and 166. Louver 48
bows
3 downwardly (away from the viewer of Fig. 15) between cut lines 162 and
164. Louver
4 46 bows upwardly (toward the viewer of Fig. 15) between cut lines 160 and
162. The
resulting deck seam attachment is very secure, and very resistant to sliding
relative
6 motion between the two joined deck panels along the axis of such seam.
7 Those skilled in the art will now appreciate that a punching tool for
forming an
8 attachment in an interlocking side-lapped seam of metal decking has been
described
9 which provides a reliable attachment with improved resistance to
horizontal shear forces
exerted along the length of the deck seam. A punching tool provided with jaws
of the
11 type described herein can be easily operated by a deck installer to form
such attachments
12 along the deck seam relatively quickly. The resulting seam attachments
can easily be
13 inspected by someone standing atop the assembled steel decking. By
providing five
14 jaws, the wear on the various jaws is better equalized for longer life.
Moreover, by using
the detachable blade inserts described above, any blades which do break can be
repaired
16 quickly and easily without requiring disassembly of all of the jaws from
the punching
17 tool. In addition, the disclosed jaws are less likely to bind in the
deck seam after the
18 punching tool is actuated and then released. The orientation of the jaws
is entirely
19 symmetrical, and no twisting torque force is produced upon actuation of
the tool.
While the present invention has been described with respect to preferred
21 embodiments thereof, such description is for illustrative purposes only,
and is not to be
22 construed as limiting the scope of the invention. Various modifications
and changes may
23 be made to the described embodiments by those skilled in the art without
departing from
24
the invention as defined by the appended claims.
17
