Truss-like cavity plate structure and bridge deck structure

Abstract

This application discloses a truss-type hollow slab structure and bridge deck structure, solving the problems of low prefabrication and heavy weight in existing hollow slab manufacturing. The key technical points are: a top slab and a bottom slab, with a sandwich layer between them; multiple connecting web members and multiple supporting web members; the connecting web members are corrugated, having crests, troughs, and diagonal web members located between adjacent crests and troughs, with pre-drilled holes in the crests and troughs; the supporting web members are columnar, with at least one end of each supporting web member passing through the pre-drilled holes to press and fix the crests and troughs of the connecting web members to the top or bottom slab, and both ends of the supporting web members are fixedly connected to the top and bottom slabs respectively. The corrugated connecting web members and vertical supporting web members form a truss structure capable of bearing loads in all directions, achieving a highly efficient hollow slab structure without the need for concrete pouring.

Description

Technical Field

[0001] This application relates to the field of cavity plate structures, and in particular to a truss-type cavity plate and its applications. Background Technology

[0002] A hollow panel is a structure consisting of two or more layers of panels and connectors within the interlayer between the panels. Hollow panel structures offer advantages such as light weight, simple construction, excellent mechanical properties, and modular construction. Furthermore, the interlayer can be filled with materials such as concrete to form a composite structure; a commonly used example is the double steel plate-concrete composite structure. This structure comprises steel plates on both sides, a concrete core, and shear connectors, combining the advantages of both concrete and steel structures. Therefore, it is widely used in nuclear power reactor shells, bridge engineering, and shear walls of high-rise buildings.

[0003] Traditional hollow panel connectors are mainly used to connect and constrain the panels on both sides. In some pressure-bearing applications, such as floor decking and bridge decking, the hollow panels need to be filled with concrete or other materials to form a composite structure, with the concrete bearing the pressure. Filling with concrete will make the hollow panel composite structure too heavy, making it unsuitable for some lightweight and high-strength applications.

[0004] In constructing a lightweight, high-strength hollow panel, connectors are crucial. The connection points between the connectors and the side panels are the most critical and sensitive nodes in the hollow panel, and also the most labor-intensive parts of its manufacturing. Existing hollow panel connectors typically use studs, bolts, and channel steel. Due to their structural limitations, these connectors struggle to achieve a proper stiffness match with the outer steel plate. For example, solid rods like studs have high inherent stiffness; using large-diameter studs with stiffness far exceeding that of the outer steel plate can cause cracking. Therefore, in practical applications, a large number of small-diameter, slender studs are often used. However, slender rods are prone to buckling due to insufficient stiffness. The sheer number of connectors leads to extensive welding work. Because existing connectors have low levels of assembly and industrialization, the welding quality at the connection points is difficult to guarantee, resulting in high residual stress and other problems that directly affect the service life of the hollow panel. Therefore, the design of the connectors and how they connect to the side panels are key to constructing high-performance hollow panels and their combined structures. Summary of the Invention

[0005] The purpose of this invention is to address the problems of low prefabrication rates, high workload, and heavy weight in existing hollow cavity panels due to their poor compressive and shear resistance, which often require the addition of filler. This invention provides a truss-type hollow cavity panel, which forms a truss structure capable of bearing loads in all directions through zigzag-shaped connected web members and vertical supporting web members. This eliminates the need for concrete pouring, enabling the formation of a highly efficient hollow cavity panel structure. This structure is lightweight and high-strength. Furthermore, the connected web members and supporting web members are assembled to quickly form connection nodes, improving installation efficiency. A bridge deck structure using this truss-type hollow cavity panel is also provided.

[0006] To achieve the above-mentioned objectives, this application adopts the following technical solution:

[0007] This application provides a truss-type hollow plate structure, including a top plate and a bottom plate, with a sandwich layer between the top plate and the bottom plate, and also including multiple connecting web members and multiple supporting web members; the connecting web members are corrugated, having crests, troughs, and oblique web members located between adjacent crests and troughs, with pre-drilled holes in the crests and troughs; the supporting web members are columnar, with at least one end of each supporting web member passing through the pre-drilled hole to press and fix the crests and troughs of the connecting web members to the top plate or the bottom plate, and both ends of the supporting web members are fixedly connected to the top plate and the bottom plate respectively.

[0008] Preferably, the supporting web members are fixedly connected to the top and bottom plates by friction welding. The friction welding of the two ends of the supporting web members to the top and bottom plates forms an efficient joint. The friction welding connection not only completes the synchronous welding of the two ends of the panel and bottom plate, but also effectively connects the web members, forming a more efficient cavity plate structure. It has the characteristics of fewer parts, high degree of assembly and industrialization, and less welding.

[0009] Preferably, the supporting web member includes a body and a clamping end. The clamping end of the supporting web member has a limiting step. An installation hole is formed on the top plate, through which the clamping end passes. The limiting step is friction-welded to the inner wall of the mounting hole on the top plate. The friction welding equipment applies a forging force from the external top plate, pressing the supporting web member through the limiting step. A friction welding section is formed on the side of the pre-reserved hole in the integrated web member, further pressing the supporting web member. Simultaneously, the crest of the wave is pressed against the top plate, and the trough is pressed against the bottom plate, allowing the supporting web member, the integrated web member, the top plate, and the bottom plate to be simultaneously welded by friction welding, forming a stable and efficient cavity structure. Welding multiple parts at once not only facilitates manufacturing but also solves the difficulty of welding within the cavity of the cavity plate.

[0010] Preferably, the integrated web members include integrated web members arranged side-by-side in the transverse direction and side-by-side in the longitudinal direction. The transverse integrated web members and the longitudinal integrated web members are interwoven, with the crests of the transverse integrated web members aligned with the troughs of the longitudinal integrated web members, and the troughs of the transverse integrated web members aligned with the crests of the longitudinal integrated web members. In this application, the integrated web members are connected to the supporting web members at their crests and troughs, while further arranged with integrated web members in another direction that intersects or is perpendicular to them, forming a two-way spatial network structure. The number of supporting web members and the number of welded ends are not increased, thus forming an economical and efficient structure where both ends of the supporting web members have integrated web members. This achieves an innovative and efficient, economical, and stable hollow two-way plate structure.

[0011] Preferably, the integrated web member is made of a single steel pipe. This application flattens the connection fulcrum at the crest or trough, reducing rotational resistance without decreasing the component's cross-section, creating a hinge-like rotational fulcrum. This reduces stress in the weld at the connection point, while the hollow tube in the middle remains unflattened, maintaining its anti-instability function. This construction achieves a perfect functional match and fit between the fulcrum and the middle of the integrated web member, resulting in a stable and efficient structure.

[0012] Preferably, the supporting web member is a hollow column. The stability of the supporting web member and the flexibility of the connecting end are matched by using a hollow tubular end face with a large diameter, resulting in good stability. This solves the problem of mid-section stability in the hollow web member. Furthermore, the rotational flexibility of the connecting end can be adjusted using two parameters: diameter and wall thickness, achieving the most reasonable match with the top and bottom plates. In friction welding, since the rotational linear velocity of the center of the circular end face is 0 when rotating, the probability of incomplete or low-grade fusion in this area is relatively high. In this application, the supporting web member is a hollow column with an annular welding end face, whose tubular radial linear velocity is basically consistent and far from the circular part, greatly reducing the probability of welding defects.

[0013] Preferably, the integrated web members are made of strip steel plates, shaped steel sections, or steel bars. The various forms of integrated web members provide more flexibility in selecting the internal structure of the cavity plate.

[0014] This application also provides a bridge deck structure, including the aforementioned truss-type hollow slab structure, and a panel parallel to the top slab. The top slab is located between the panel and the bottom slab, and multiple shear members are disposed between the panel and the top slab. The space between the panel and the top slab is filled with concrete. The lower part of this bridge deck structure employs a truss-type hollow slab construction. On the outer side of the top slab, which bears the load initially, a double-steel-plate concrete composite structure is further fabricated. This composite structure gives the panel high rigidity while consuming very little material. Its high rigidity further disperses the stress of external loads, causing the stress in the various components of the lower hollow slab structure to tend to be dispersed and reduced. The overall structural stability and efficiency are improved.

[0015] Preferably, the shear-resistant component is a double connector that is fixedly connected to both the panel and the top plate. The connector can be made by turning the panel material outwards towards the panel and welding it to the panel to form a double connector. This connector has stable performance, strong shear resistance, and can be welded to the panel through the external opening of the top plate, thus solving the problem of internal welding of the cavity plate.

[0016] Preferably, the shear-resistant member is a single connector that is fixedly connected to either the panel or the top plate. A single connector is simple, practical, economical, and efficient.

[0017] Compared with existing technologies, the above technical solution has the following beneficial effects:

[0018] 1. Traditional hollow slabs typically require the addition of concrete to form a composite structure, with the concrete bearing the load under compression and shear. The hollow slab of this application, however, utilizes a truss structure composed of zigzag interconnected web members and vertical supporting web members to form a truss structure capable of bearing forces in all directions. The top and bottom slabs of this hollow slab structure essentially constitute the upper and lower chords of numerous combined truss structures, with the truss structure serving as a stable support structure between the upper and lower chords. The truss structure replaces concrete in bearing compression and shear forces, eliminating the need for additional concrete pouring to form a highly efficient hollow slab structure. This structure is lightweight, high-strength, and can be applied to various applications such as bridge decks, industrial steel platforms, and aircraft wings.

[0019] 2. The connection between the web members and the upper and lower chords is the most critical and sensitive node of the truss, and also the part with the largest workload in truss manufacturing. Typically, truss nodes are made from irregularly shaped parts cut from cutting, resulting in significant material waste, low levels of assembly and industrialization, a large workload, and high sensitivity to performance changes due to manufacturing processes. This application uses a zigzag-shaped integrated web member to form multiple diagonal web members. This reduces the number of parts and the workload of connecting the web members to the upper and lower chords. Most importantly, the integrated web member has pre-drilled holes at the crests and troughs for the supporting web members to pass through and be fixed, making the through-hole installation in this area convenient and efficient. Due to the large number of connecting parts, this efficient installation method significantly reduces the workload. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of a truss-type hollow plate structure according to Embodiment 1 of this application;

[0021] Figure 2 This is a three-dimensional structural diagram of a truss-type hollow plate structure without a top plate, according to Embodiment 1 of this application.

[0022] Figure 3 This is a three-dimensional structural diagram of the conjoined web members in Embodiment 1 of this application;

[0023] Figure 4 for Figure 3 A magnified view of a portion of the image;

[0024] Figure 5 This is a three-dimensional structural diagram of a truss-type hollow plate structure according to Embodiment 1 of this application, wherein the interconnected web members are interwoven.

[0025] Figure 6 for Figure 5 A plan view of a truss-type hollow plate structure;

[0026] Figure 7 for Figure 6 A magnified view of a portion of the image;

[0027] Figure 8 This is a schematic diagram of the three-dimensional structure of the interconnected web members arranged horizontally and vertically in Embodiment 1 of this application.

[0028] Figure 9 This is a planar schematic diagram of the interwoven web members arranged horizontally and vertically in Embodiment 1 of this application;

[0029] Figure 10 This is a plan view of the bridge deck structure in Embodiment 2 of this application.

[0030] Reference numerals: 1. Top plate; 2. Bottom plate; 30. Connected web member; 301. Crest; 302. Trough; 303. Diagonal web member; 304. Reserved hole; 31. Supporting web member; 311. Member body; 312. Clamping end; 313. Limiting step; 4. Panel; 5. Shear-resistant component Detailed Implementation

[0031] The present application will now be further described with reference to the accompanying drawings. It should be noted that in the description of the present application, the terms "lateral", "longitudinal", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present application.

[0032] Example 1:

[0033] like Figure 1 As shown, a truss-type hollow plate structure includes a top plate 1 and a bottom plate 2, with a sandwich layer between the top plate 1 and the bottom plate 2, and also includes a truss structure located in the sandwich layer, including multiple interconnected web members 30 and multiple supporting web members 31.

[0034] like Figure 3As shown, the conjoined web member 30 is corrugated, having a crest portion 301, a trough portion 302, and an oblique web member 303 located between adjacent crest portions 301 and trough portions 302. Pre-drilled holes 304 are provided on the crest portions 301 and trough portions 302.

[0035] like Figure 2 As shown, the supporting web members 31 are columnar. Each supporting web member 31 has at least one end that passes through the reserved hole 304 of the connecting web member 30. The crest portion 301 and trough portion 302 of the connecting web member 30 are pressed against the top plate 1 or the bottom plate 2 through the end of the supporting web member 31. The two ends of the supporting web member 31 are fixedly connected to the top plate 1 and the bottom plate 2 respectively. The two ends can be simultaneously welded and fixed by friction welding. At the same time, the crest portion 301 or trough portion 302 sleeved on the end of the supporting web member 31 is also fixed.

[0036] Traditional hollow slabs typically require the addition of concrete to form a composite structure, with the concrete bearing the load under compression and shear. In this embodiment, the hollow slab utilizes a truss structure 3 capable of bearing forces in all directions, formed by zigzag-shaped interconnected web members 30 and vertical supporting web members 31. The top plate 1 and bottom plate 2 of this hollow slab structure essentially constitute the upper and lower chords of a truss structure composed of numerous combined chords. The truss structure 3 then serves as a stable support structure between the upper and lower chords. The truss structure 3 replaces concrete in bearing compression and shear forces, eliminating the need for additional concrete pouring to form a highly efficient hollow slab structure. This structure is lightweight, high-strength, and can be applied to various applications such as bridge decks, industrial steel platforms, and aircraft wings.

[0037] The connection between the web members and the upper and lower chords is the most critical and sensitive node of the truss, and also the part with the largest workload in truss manufacturing. Typically, truss nodes are made from irregularly shaped parts formed by cutting, resulting in significant material waste, low levels of assembly and industrialization, and a large workload. Furthermore, the performance is highly sensitive to process variations. This embodiment uses a polygonal integrated web member 30 to form multiple oblique web members. This reduces the number of parts and the workload of connecting the web members to the upper and lower chords. Crucially, the integrated web member 30 has pre-drilled holes at its crests and troughs for the support web members 31 to pass through and be fixed, making the perforation installation at this location convenient and efficient. Due to the large number of connectors, this efficient installation method significantly reduces the workload. Preferably, the pre-drilled holes 304 are prepared by enlarging the holes. During enlarging, the material expands outwards without decreasing, and the effective cross-section of both the support web members 31 and the pre-drilled holes in the integrated web member 30 is actually increased at this node, thus enhancing performance.

[0038] like Figure 2 As shown, multiple interconnected web members are arranged side-by-side at intervals, either laterally or longitudinally. Figure 5 , 6As shown, the conjoined web members 30 are divided into those arranged side-by-side at intervals in the transverse direction and those arranged side-by-side at intervals in the longitudinal direction. The transverse conjoined web members 30 and the longitudinal conjoined web members 30 are interwoven to form a mesh-like structure. Figure 8 , 9 As shown, the crests 301 of the transverse connecting web members 30 are aligned with the troughs 302 of the longitudinal connecting web members 30, and the troughs 302 of the transverse connecting web members 30 are aligned with the crests 301 of the longitudinal connecting web members 30. In this embodiment, while the crests 301 and troughs 302 of the connecting web members 30 are connected to the supporting web members 31, connecting web members 30 in another direction that intersect or are perpendicular to them are further arranged, forming a two-way spatial network structure. The number of supporting web members 30 and the number of welded ends are not increased, thus forming an economical and efficient structure in which connecting web members 30 are present at both ends of the supporting web members. This completes the innovation and manufacturing of an efficient, economical, and stable cavity two-way plate structure.

[0039] like Figure 3 The integrated web member 30 shown is made by bending a long steel pipe. The steel pipe is partially flattened at the crests 301 and troughs 302, while the middle section between the crests 301 and troughs 302 remains unflattened, forming a diagonal web member 303. The long cylindrical pipe is further bent into multiple zigzag shapes, creating multiple reciprocating diagonal web members 303. The sensitive area for web member instability is mainly in the middle section, and the sensitive area for web member rotation is mainly at the connecting fulcrum. Flattening the connecting fulcrum at the crest or trough reduces rotational resistance without reducing the cross-section of the component, forming a hinge-like rotational fulcrum, thereby reducing stress in the weld at the connection. The hollow tube in the middle remains unflattened, maintaining its anti-instability function. This structure achieves a perfect functional match and fit between the fulcrum and the middle section of the integrated web member 30, resulting in a stable and efficient structure. The integrated web member 30 can also be made of strip steel plates, shaped steel, or steel bars. These various forms provide more flexibility in selecting the internal structure of the hollow plate.

[0040] like Figure 6 , 7As shown, the support strut 31 is preferably a hollow column. Matching the stability of the strut with the flexibility of the connecting end has always been a point of contention in the industry. The larger the diameter of the strut, the better the stability and the less prone it is to buckling. However, the larger the diameter, the greater the stiffness, which can easily cause damage to the panel at the connection point. At the same time, the larger the diameter, the more material is consumed. In this embodiment, the support strut 31 is hollow columnar. The rotational flexibility or stiffness of its connecting end can be adjusted by two parameters: pipe diameter and wall thickness. Even if a large diameter is used, it will not cause excessive stiffness. At the same time, it also ensures the stability of the middle section of the hollow strut. Furthermore, in friction welding, since the rotational linear velocity of the center part is 0, the probability of friction welding failure or low degree of fusion is relatively high. Since the welding end face of the hollow support strut 31 is annular, the radial linear velocity of the annular end face is basically consistent and far away from the center part, greatly reducing the probability of welding defects and fully solving this problem.

[0041] The internal welding of the cavity is also a challenge in the fabrication of the cavity plate. In this embodiment, the friction welding equipment clamps the supporting web rod 31 from the outside and performs rotational welding. Figure 6 , 7 As shown, the support strut 31 includes a strut body 311 and a clamping end 312. A mounting hole 11 is provided on the top plate 1, and one end of the support strut 31 has a clamping end 312 that passes through the mounting hole 11. The support strut 31 also has a limiting step 313. When the supporting web member 31 passes through the connecting web member 30, the friction welding equipment applies a forging force from the external top plate. Through a limiting step, typically conical, the applied forging force presses the supporting web member 31 through the connecting web member. By rotating the limiting step and allowing it to wear down appropriately, a friction welding section is formed on the side of the enlarged hole in the connecting web member, further pressing the supporting web member 31. Simultaneously, since the crests 301 and troughs 302 of the connecting web member are fitted onto the ends of the supporting web member 31, with the crests 301 pressing against the top plate 1 and the troughs 302 pressing against the bottom plate 2, the supporting web member 31, the connecting web member 30, the top plate 1, and the bottom plate 2 are simultaneously welded together via friction welding, forming a stable and efficient cavity structure. Compared to traditional cavity plates, this structure features simpler parts, easier manufacturing, and more stable connections. Furthermore, the process parameters of this welding method are controllable and visible, and the equipment is easy to manufacture and operate.

[0042] Example 2:

[0043] like Figure 10As shown, Embodiment 2 is a bridge deck structure. The lower part adopts the truss-type hollow slab structure of Embodiment 1, and also includes a panel 4. The panel 4 is parallel to the top plate 1, located above the top plate 1, and has a sandwich structure between the panel 4 and the top plate 1. Multiple shear-resistant members 5 are provided between the panel 4 and the top plate 1. The shear-resistant members 5 can take various forms. They can be flanges turned outwards from the base material of the panel 4 towards the top plate 1, and welded to the top plate 1 to form a double connector. This connector has stable performance, strong shear resistance, and can be welded to the top plate 1 through the external flange of the panel 4, solving the problem of internal welding of the hollow slab. Alternatively, external components can be connected as connectors. It can also be as follows... Figure 10 The single connector shown connects only to panel 1. When combined with the aforementioned double connector, the connection performance is both economical and efficient, and it is simple and practical. Furthermore, concrete is used to fill the space between panel 4 and top plate 1.

[0044] While traditional orthotropic steel bridge decks offer advantages such as low steel consumption and quick fabrication, the problem of welding fatigue cracking is difficult to solve, leading to damage to the asphalt and other pavement layers. Consequently, the service life of orthotropic steel bridge decks is almost no more than 15 years, and the pavement layer only lasts 8 years. The bridge deck structure proposed in this application adopts a truss-type hollow plate structure in the lower part, which is lightweight and high-strength. The upper part is further fabricated with a double steel plate concrete composite structure to replace the traditional pavement layer. This composite structure gives the deck a high rigidity while consuming very little material. Its high rigidity further disperses the stress of external loads, making the stress of each component of the lower hollow plate structure tend to be dispersed and reduced.

[0045] The above description is the preferred embodiment of this application. For those skilled in the art, several modifications and improvements can be made without departing from the principle of this application, and these should also be considered within the scope of protection of this application.

Claims

1. A truss-type hollow plate structure, comprising a top plate (1) and a bottom plate (2), wherein a sandwich layer is provided between the top plate (1) and the bottom plate (2), characterized in that: It also includes multiple interconnected web members (30) and multiple supporting web members (31); The conjoined web member (30) is corrugated, having a crest (301), a trough (302), and an oblique web member (303) located between adjacent crests (301) and troughs (302). Pre-drilled holes (304) are provided on the crests (301) and troughs (302). The supporting web members (31) are columnar. Each supporting web member (31) has at least one end that passes through the reserved hole (304) to press and fix the crest (301) and trough (302) of the connected web members (30) to the top plate (1) or bottom plate (2). The two ends of the supporting web members (31) are fixedly connected to the top plate (1) and the bottom plate (2) respectively.

2. The truss-type hollow plate structure according to claim 1, characterized in that: The supporting web member (31) is fixedly connected to the top plate (1) and the bottom plate (2) by friction welding.

3. The truss-type hollow plate structure according to claim 2, characterized in that: The supporting web (31) includes a body (311) and a clamping end (312). The clamping end (312) of the supporting web (31) has a limiting step (313). An installation hole (11) is opened on the top plate (1). The clamping end (312) passes through the installation hole (11). The limiting step (313) is friction welded to the inner wall of the installation hole (11) of the top plate (1).

4. The truss-type hollow plate structure according to claim 1, characterized in that: The conjoined web members (30) include conjoined web members (30) arranged side by side in the transverse direction and side by side in the longitudinal direction. The conjoined web members (30) in the transverse direction and the conjoined web members (30) in the longitudinal direction are intertwined. The crests (301) of the conjoined web members (30) are aligned with the troughs (302) of the conjoined web members (30) in the longitudinal direction. The troughs (302) of the conjoined web members (30) are aligned with the crests (301) of the conjoined web members (30) in the longitudinal direction.

5. The truss-type hollow plate structure according to claim 1, characterized in that: The combined web member (30) is made of a single steel pipe.

6. The truss-type hollow plate structure according to claim 1, characterized in that: The supporting strut (31) is a hollow column.

7. The truss-type hollow plate structure according to claim 1, characterized in that: The connecting web members (30) are made of strip steel plates, shaped steel or steel bars.

8. A bridge deck structure, comprising the truss-type hollow slab structure as described in any one of claims 1-7, characterized in that: It also includes a panel (4), which is parallel to the top plate (1). The top plate (1) is located between the panel (4) and the bottom plate (2). Multiple shear members (5) are provided between the panel (4) and the top plate (1), and concrete is filled between the panel (4) and the top plate (1).

9. The bridge deck structure according to claim 8, characterized in that: The shear-resistant member (5) is a double connector that is fixedly connected to both the panel (4) and the top plate (1).

10. The bridge deck structure according to claim 8, characterized in that: The shear-resistant member (5) is a single connector that is fixedly connected to either the panel (4) or the top plate (1).

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