Acoustical roof deck

July 9, 1935

2,007,374

W. KUEHNE

ACOUSTICAL ROOF DECK

Filed July 25, 1932

Sheets-Sheet 1

<img file="US2007374A_D0001.tif" />

<img file="US2007374A_D0002.tif" />

July 9, 1935. _w. kuehne 2,007,374

ACOUSTICAL ROOF DECK Filed July 25, 1932 2 Sheets-Sheot 2

<img file="US2007374A_D0003.tif" />

<img file="US2007374A_D0004.tif" />

Patented July 9, 1935

2,007,374

UNITED STATES PATENT OFFICE

2,007,374

ACOUSTICAL ROOF DECK william Kuehne, Chicago, Di., assignor to United States Gypsum Company, Chicago, Π1., a corporation of Illinois

Application July 25, 1932, Serial No. 624,379

DI. 108—13) the longitudinal junction with an adjoining roof deck,

Fig. 7 is a sectional elevation through a tool for forming slots in the legs of the roof deck, and

Fig. 8 is a sectional elevation through a ma- ⁵chine for forming slots in the legs of the roof deck.

The roof deck element forming a part of my improved construction comprises a plate 10 on which are formed preferably a plurality of out- ¹⁰wardly extending, integral, U-shaped ribs 11. An outwardly extending, longitudinal flange 12 is formed on one edge of the plate 10 and an outwardly extending U-shaped rib or channel 13 is formed on the opposite longitudinal edge of said ^1Sdeck plate. Beads 14 are formed in the plate 10 between the ribs, said beads extending from one' end of the deck to a point short of the other end of the deck. The beads 14 serve to reduce the width of the plate section 10 adjacent one end ²⁰of the deck plate so that two deck plates have sufficient clearance to telescopically overlap end to end to form a roof. The roof decks also telescope along their longitudinal edges with the flange 12 of one roof deck position in the chan- 25 nel shaped rib 13 of the adjoining roof deck (Fig. 6). Roof deck plates are supported upon suitable steel framework 10α and are preferably covered on the upper surface by a sheet of fiber board 16 serving as heat insulation, this fiber ³⁰board being covered with asphalt shingles 17 or other suitable weather protective coating.

Supported between legs 18 of the ribs II, are provided elongated perforated metal membrane sections 19 which have outwardly extending 35 flanges 29 formed along each longitudinal edge thereof. Holes 21, preferably triangular shape or any other desired shape such as round, oval, etc., are formed uniformly over the surface of the membrane 19. In order to support the mem- 40 brane sections 19 between the ribs II, I form apertures 24 in the legs 18, said apertures in a given length being uniformly spaced .above the bottom of the ribs II. The apertures may be formed by a tool 26 having jaws terminating in- ⁴⁵inwardly extending, opposed punches 27. During the punching operation, an elongated die 28 having longitudinal grooves 29, is inserted in a rib in such a way that the punches 27 serve to force the metal of the rib legs 18 into the 50 grooves 29 and form severed shoulders 30 in the legs 18. If desired, all of the apertures 24 may be punched simultaneously in a roof deck sec' tion by means of rotary cam cutters 31 mounted _ upon shafts 32 which are rotatably mounted in ⁶⁵

Claims. (

This, invention relates to building constructions, and has reference more particularly to metal roof decks having sound absorbing materials assembled with the deck to form a unit.

In correcting acoustics in industrial buildings, schools, etc., I have found it desirable to utilize a combined metal roof deck having depending, u-shaped ribs, with a sound absorbing pad faced with a perforated metal membrane, the 10 whole being assembled at the factory and shipped to the job as a unit. In making such a unit, I prefer to have individual elongated perforated membranes having outstanding legs fitting between the legs of the roof deck, and support said membranes from the legs of the roof deck by members which are inserted into apertures formed in the roof deck legs. Some difficulty has been experienced in forming the apertures in the legs of the roof deck so that all of said 20 apertures are of equal distance from the connecting web of the roof deck legs.

An object of this invention, therefore, is to provide an acoustical roof deck unit which may be conveniently shipped in an assembled con²⁵ dition to the job for easy and quick erection.

Another object of the invention is to provide a method of forming apertures in the legs of metallic roof decks so that said apertures are all of equal distance from the webs of the roof ³⁰ deck ribs.

A further object of the invention is to provide an acoustical roof deck in which assembly • of the various parts of the~roof deck are conveniently made by means of elongated support ³“ members which support both the perforated membranes and the acoustical pads; also to improve building constructions and their method of manufacture in other respects hereinafter specified and claimed.

Reference is to be had to the accompanying drawings forming a part of this specification, in which

Fig.A is a perspective, sectional view of a roof 45 embodying my improved construction,

Fig. 2 is a perspective view of a roof deck section,

Fig. 3 is a perspective, sectional view of a perforated metal, membrane unit,

Fig. 4 is a sectional elevation through the acoustical roof deck. · ¹ Fig. 5 is a longitudinal sectional elevation through telescoping , acoustical roof decks;

Fig. 6 is a sectional elevation through a slight¢5 l_y modified form of the acoustical roof deck at

3,007,374 bearings 33 carried by a support plate 34. Each of the shafts 32 is provided with, a spur gear 35, said spur gears meshing in series, the last gear in the series meshing with the· spur gear 5 36 mounted upon a driven shaft 37. Dies 33 similar to dies 28 are mounted to engage within the ribs of the roof deck during the continuous movement of the roof deck after the rolling operation so the cam cutters 31 which are rotated continu10 ously or intermittently by means of automatic controls not shown associated with the shaft 37, form the apertures 24 by a single rotation of the cam cutters 3 i without stopping the movement of the roof deck.

In order to absorb the sound passing through the perforations 21 in the membrane 19,1 provide a fibrous pad 40 of sound absorbing material such as mineral wool, hair felt, etc. In order to support the pads 40 in spaced relation to the 20 membranes 19,1 provide U-shaped wire hangers having upstanding legs 42 which terminate in outstanding ends 43, the latter engaging in the apertures 24 to lie on top of the severed shoulders 30, the outward movement of the hanger ends 43 25 being limited by engagement with the offset metal pads 29α formed by the punches 27. When using pads 40 which are fairly flexible, it is preferable to provide zigzag sections 45 formed in the wire hangers 41 for the purpose of supporting abutting 30 ends of adjoining pads 40 where the ends of the roof decks telescope to prevent said pads from sagging between hangers and contacting with the perforated membranes 19. The outstanding hanger ends 43 also pass through apertures formed 35 in the membrane legs 20 which are positioned to register with the apertures 24. It will be noted that hangers 41 thus support both the membrane sections 19 and the fibrous pads 40 by engagement with the shoulders 30. The pads 40 are ₄₀ supported out of contact with the membranes so that the lower surface of said membranes may be washed or cleaned from time to time as they become soiled without causing the pads 40 to become wet by the wash water.

_4;. By the use of the punch 26 and dies 28, the apertures 24 are formed,at a uniform height above the bottom of ribs 11 at all times thus insuring that the bottom faces of membrane sections 19 all lie in a uniform plane slightly above _co the bottoms of ribs li. Where the longitudinal lap of roof decks occurs (Fig. 6) the outstanding hanger ends 43 may be made slightly longer to allow for the thickness of the roof deck flange _c 13 which will lie between the flange 12 of the 55 adjoining roof deck and upstanding legs 20 of one of the membrane sections 19. In Figure 6, the construction is slightly modified in that the metal is not severed adjacent shoulders 30α thus making the roof deck a water-shed immediately upon _β0 erection.

I would state in conclusion that while the illustrated example constitutes a practical embodiment of my invention, I do not wish to limit myself precisely to these details, since manifestly, 55 the same may be considerably varied without departing from the spirit of the invention as defined in the appended claims.