Corrugated sheet

Nov. 27, 1934.

1,982,243

G. E. BLACK

CORRUGATED SHEET

Filed Nov. 13, 1930

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ATTORNEY.

Patented Nov. 27, 1934

1,982,243

UNITED STATES PATENT OFFICE

1,982,243 CORRUGATED SHEET George E. Black, Sewickley, Pa., assignor to Η. H. Robertson Company, Pittsburgh, Pa., a corporation of Pennsylvania

Application November 13,1930, Serial No. 495,454 1 Claim. (Cl. 189—85) v-beam corrugations 12 of substantial depth and at its opposite sides is provided with substantially V-beam corrugations 13, 14 of lesser depth.

The V-tjeam body corrugations 12 have sub- 00 stantJaiiy flat, and relatively short horizontal top walls 15 and relatively wide inclined side walls 16,17, which latter may and preferably will be at an angle of about 45°. - .

The V-beam side corrugations 13, 14 are pro- 65 vided with substantially flat top horizontal walls 15 and with outer-inclined side walls 20, 21, one or both of which is or are at a greater angle to the horizontal walls 15 than the side walls 16,17 and preferably at an angle of about 50°. 70

The side walls 20, 21 of the outside corrugations 13, 14 are narrower or of less width than the width of the side walls 16,17 of the body or deeper corrugations 12, and the side walls 20,.21 are preferably made of unequal width, that side 75 wall which is exposed to the weather when the corrugated sheet is in place on the building, being wider than the side wall which is covered by an adjacent corrugated sheet when in place on the building. ⁸⁰

Tn the present instance, the side wall 20 is the wider one and is illustrated as substantially twice as wide as the narrower side wall 21. The wider side wall 20 in accordance with this invention is inclined from the top wall 15 of its V-beam 85 corrugation to make therewith a greater angle than the side walls 16 of the deeper or body cor- . rugations make with their top walls 15, and preferably the side wall 20 is inclined at about 50° to the top wall 15. As a result the complementary 90 angle formed by. the side wall 20 with, a vertical plane normal to the horizontal top wall 15 is sharper or more acute than the complementary angle formed by the side wall 16 or 17 with a vertical plane normal to the top walls 15 of the 95 deeper corrugations. The side wall 21 may also be inclined at the sharper angle, as represented in Fig. 5, but inasmuch as the side wall 21 is covered by the overlapping sheet, as represented in Fig. 8, the shorter side wall 21 need not neces- 100 sarily be inclined at the sharper angle, although it may be preferred to so make it, for reasons as will be described, but may be made of the same inclination as the side walls 16, 17 of the main or deeper V-beam corrugations. ¹⁰⁵

The side wall 20 is exposed to the weather and it is highly desirable that it should make a weather-tight joint with the side wall 16 of the side corrugation of an adjacent V-beam corru- _ gated metal sheet, ¹¹⁰

This invention relates to a corrugated sheet and particularly to a corrugated metal sheet protected by asphalt or like bituminous material and such as now commonly employed as a roof5 ing and siding material for buildings and like structures.

The present invention has for its object to provide a superior corrugated sheet and particularly a superior protected metal sheet, which is of 10 maximum load-carrying capacity, is capable of making a superior weather joint as will be described, and which can be produced at a minimum expense.

The invention further has for its object to pro15 duce the improved corrugated sheet in a novel manner as will be described.

To these ends, the improved corrugated sheet, which will be hereinafter referred to as a corrugated metal sheet, is provided in its body portion SO with substantially V-beam corrugations of substantial depth and at its opposite sides with substantially V-beam corrugations of lesser depth, the outside walls of one or both of the side corrugations of lesser depth being inclined at a sharp25 er angle than correspondingly inclined walls of the intermediate deeper corrugations of said sheet, whereby a more effective weather-tight joint may be made between contiguous V-beam corrugated sheets, as will be described.

The outside walls of the V-beam corrugations of lesser depth may be made of unequal widths for purposes as will be described.

These and other features of this invention will be pointed out in the claim at the end of this 35 specification.

Fig. 1 is a plan view of a portion of a corrugated metal sheet embodying this invention and produced in a novel manner as will be described;

Fig. 2, an end view of the corrugated metal 40 sheet shown in Fig. 1;

Fig. 3, a sectional detail on a larger scale of a preferred construction of asphalt-protected metal sheet embodying the invention;

Figs 4 and 5, diagrammatic views to illustrate 45 a preferred method of making the improved corrugated metal sheet;

Figs. 6 and 7, diagrammatic views to illustrate certain reactions in the metal sheet subjected to the steps of the process by which a flat sheet is 50 converted into the improved sheet illustrated in Figs. 1, 2 and 5, and

Fig. 8, an end elevation of two of the improved protected metal sheets in overlapping relation.

The improved corrugated metal sheet 10 is 55 provided in its body portion with a plurality of

To this end the side wall 20 which may be designated the weather side wall is made at a sharper angle than the inclined wall 16 of the sheet with which it co-operates and overlaps as shown in Fig. 8, so that when the overlying and underlying v-beam corrugated metal sheets are secured to the building and are drawn toward each other by the bolts, rivets, or other fastening devices, not shown, but which are such as are now commonly used, the sharper side wall 20 and especially the outer edge thereof, will be pressed against the underlying side wall 16 of a different angularity to make a highly efficient and superior weathertight joint between the overlapping corrugated V-beam sheets.

Making the outer side walls of the v-hpam corrugations of lesser depth at a greater angle to the top walls 15 of said corrugations and at a sharper or more acute angle to the vertical than the corresponding side walls of the V-beam corrugations of greater depth, enables the improved V-beam corrugated metal sheets having the superior weather-tight joint above described to be made from flat metal sheets which vary materially in tensile strength, as, for instance, from 40,000 to 75,000 lbs. tensile strength, inasmuch as the sharper or more acute angle to the vertical of the outer side walls overcomes the tendency of these side walls of the V-beam corrugated metal sheet of lesser strength to spring back and assume a position more nearly approaching the” horizontal as represented in Figs. 6 and 7, wherein it will be seen that the outer side walls and particularly the weather side walls of the shallower V-beam corrugations are at a less angle to the top walls 15 than the side walls of the main or deeper corrugations of the V-beam corrugated sheet, which construction of V-beam corrugated sheet is not desirable in that a weather-tight joint cannot be made between the weather outer side wall and an underlying V-beam corrugated sheet, when embodied in the roof or side wall of a building.

The V-beam sheet having the weather side wall of a V-beam side corrugation of less width than the side walls of the deeper body V-beam corrugations and at a sharper or more acute angle to the vertical than side walls of the body corrugations, may and preferably will be formed by passing the flat metal sheet transversely through a corrugating machine having co-operating rolls provided with teeth suitably shaped to form the side walls of all the corrugations of the same angularity, which may be assumed to be 45° as ¹represented in Fig. 4. :

Owing to the variation in the hardness or ’ tensile strength of commercial flat steel sheets available bn the market for the production of the _______________ _________ unimproved V-beam corrugated metal sheet, the side walls of the shallower”v-beam corrugations shorter outside walls of the shallower V-beam enables a flat metal sheet of standard width to 135 corrugations in the hard steel sheets, when re- wit: 30” or 36”, to be converted into a V-beam leased by the corrugating machine, spring back corrugated sheet having a maximum number of or up toward the horizontal more or less and relatively deep v-beam corrugations provided with assume a more nearly flat position, after the substantially flat top and bottom walls in the body manner represented in Figs. 6 and 7. portion thereof and shallower V-beam corruga- 140

The corrugated metal sheet repretsented in tions at the sides of the corrugated sheet, in that Fig. 6 or 7, and produced by feeding the flat the flat sheet may be fed through the No. 1 mametal sheet transversely through the corrugat- chine in such manner as to provide the cornigated 70 whose teeth are of the same angu- sheet with the greatest number of deep v-hoam ηΖλ. ^Wit: 1⁵°’ ^{15 th}!^{n fed} ^Situdinally corrugations in the body portion thereof while pro- 145 through a second corrugating machine, having viding a side wall of a shallower corrugation of ^{Wlth te}!^{th of} angularities, sufficient width to enable the superior*weather which for the present purposes may be 45° and joint to be formed, and as a result a superior cor75 ThA ΓηττιισαΟησ mu, twated sheet can be produced which is of maxiThe corrugating roUs of the second machine mum load-sustaining capacity and has a weather 150

1,882,243 which may be designated the No. 2 machine, are provided between their ends with teeth having a 45° angularity which engage the 45° side walls of the V-beam corrugations of the sheet corrugated by the No. 1 machine, and serve to maintain the deeper body corrugations in their preformed condition.

The corrugated rolls of the No. 2 machine have their end teeth provided with a wall or surface which has a different angularity from the intermediate teeth and in the present case an angularity of 50°, and these walls or surfaces of the end teeth engage the side walls 20, 21 of the sheet corrugated in the No. 1 machine and illustrated in Figs. 6 and 7, and bend said side walls from an angle on one side of the 45° into an angle on the other side, as, for instance, from a 30° or 40° angle into a 50° angle, as represented in Figs. 5 and 8, and when so bent, said outer side walls of the corrugated sheet remain in the position of greater angularity to the top walls 15, to wit: 50°, and provide the V-beam corrugated sheet with side v-beam corrugations which are shnii lower or of less depth than the main or body Vbeam corrugations, and one or both of which side ' corrugations has its outer wall at a greater angle to the horizontal top wall 15 of said side corrugation and at a sharper angle to a plane normal to said top wall, after the manner represented in Fi*·⁵· , . 105

As represented in Fig. 5, both outside walls of the shallower corrugations are represented as bent to the greater angle, to wit: 50°, but it is not desired to limit the invention in this respect, as it may be sufficient to bend to the greater angle 110 only the outside wall which is to overlap the adjacent sheet and be exposed to the weather. In other words, in order to obtain the superior joint between two adjacent sheets of the character described having an overlapping relation, the 115 weather side wall 20 may be bent to the 50° angle, while the other outside wall, which is covered and protected from the weather when in use, need be bent only to the 45° angle, which condition is represented in Fig. 8. 120

By reference to Fig. 8, it will be seen that the weather outside wall 20 is at a greater angle to its top wall 15, to wit: 50°, than the 45° side wall of an underlying sheet, whereas the covered outside wall 21 of the underlying sheet is bent 125 to a 45° angle.

The improved V-beam corrugated sheet is preferably made with the weather side wall 20 of greater width than the covered outside wall 21, and it is preferred to make the weather outside 130 wall 20 substantially twice as wide as the covered wall.

This construction of weather and covered out85

ΙΟΟ side wall capable of making a tight joint with, a wah of a deep V-beam corrugation m an underlying sheet, and also is capable of maintaining said joint weather-tight by the spring action of ₆ the side wall due to the sharper spring action presses the weather wall against the underlying wan and resists movement of the weather wall toward the angularity of toecooperating wall of the underlying sheet. So also, the sharper angularity of the weather enables the weather-tight joint to be obtained with V-beam corrugated sheets whose weather waUs may be forced more or less out of shape in transportation or by a blow in handling toe sheet on the job, thereby avoiding toe necessity of restoring the angularity on toe job and careful fitting in order to avoid leaks in toe roof.

Tn the present instance, toe angularities of the side wans of toe deeper V-beam corrugation 12 and of toe outer walls of toe shaUower tide Vbeam corrugations 13, 14 have been referred to as 45° and 50° respectively, but .it is not desired to limit toe invention to these particular angularities, as they may be of other degrees having the same relation. _ .

The process herein described whereby toe flat sheet is first provided with V-beam c^^^ons of greater depth to toe body portion and of lesser depth at the sides, and having initially side walls of the same or substantially toe same angularity, and then imparting to one or both of the outer walls of toe shaUower side corrugations a sharper or more acute angularity, enables toe ^Proved v-beam corrugated sheet to be produced commercially at a minimum cost.

The improved V-beam corrugated sheet may

1,982,243 ® be a plain metal sheet, or it may be a Protect^ metal sheet and particularly a metal *eet detected against corrosion and acid and alkali fumes by asphalt or like bituminous material, and in Fig 3, such a protected metal tiieet is represented, wherein a steel sheet 10 is prodded with layers 30 of asphalt, to which is awflied.layers 3.1, 32 of fibrous material, preferably asbestos felt or toe like, and these layers are encased in a protective coating or envelop 33 of bituminous material. 80