Purlin construction and mounting system for flat roof structures
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Solution Overview
Problem
The process of positioning purlins on the upper surface of beams in flat roof structures is difficult and time-consuming, often requiring multiple workers to manually hold and attach them, which complicates the installation process.
Innovation Solution
A purlin design featuring a flat mounting wall with perpendicularly extending upright walls and mounting shelves, combined with a positioning and mounting device that nests within a vertical channel, allowing for easy and quick attachment to roof beams without the need for special tools or on-site welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional bolted purlin mounting is used on flat roof structures, then the connection strength is sufficient, but the installation process becomes difficult and time-consuming requiring multiple workers
Solution Approach 1:
The purlin is segmented into distinct functional portions: a mounting portion with channel structure for attachment to beams, and a shelf portion for supporting roof sections. This segmentation allows each portion to be optimized independently, with the mounting portion featuring integrated channels that receive positioning devices for rapid alignment and attachment without requiring multiple workers to hold the purlin in place during installation
Solution Approach 2:
Positioning devices serve as intermediaries between the purlin mounting portion and the beam. These devices nest within the channels of the mounting portion and attach to the beam, providing a mechanical intermediary that simplifies the attachment process. The positioning devices enable quick placement and secure attachment without requiring complex manual positioning or multiple workers
2Manufacturing precision
If manual positioning and holding of purlins is required, then accurate positioning can be achieved, but multiple workers are needed increasing labor requirements
Solution Approach 1:
The mounting portion of the purlin is designed to be self-positioning through its channel structure. When the positioning devices are attached to the beam, they automatically nest within the channels, providing self-alignment and self-positioning capabilities. This eliminates the need for manual positioning and holding by multiple workers, as the structure itself guides and secures the purlin in the correct position
Solution Approach 2:
The positioning devices nest within the channels of the mounting portion, creating a nested configuration that provides both positioning and attachment functions. This nesting arrangement ensures accurate positioning while simplifying the installation process to a single-worker operation, as the nested structure naturally guides the components into proper alignment during attachment
3Ease of manufacture
If simple purlin design is used, then manufacturing is easier and less expensive, but additional mounting structure is needed for easy attachment
Solution Approach 1:
The mounting portion and shelf portion are merged into a single integrated purlin structure formed from one piece of metal stock. This merging eliminates the need for separate mounting brackets or additional components, simplifying manufacturing to a single forming process. The integrated design provides both structural support and mounting functionality without increasing overall device complexity
Solution Approach 2:
The mounting portion serves multiple functions: it provides structural attachment to the beam, enables positioning through channel reception of positioning devices, and supports the shelf portion for carrying roof sections. This multi-functionality is achieved within a simple formed structure that requires minimal manufacturing steps and no additional mounting components
Data Source
AI summary
A purlin mounting system for use in a flat roof structure includes a purlin with a flat mounting wall and an upright wall extending perpendicularly from the mounting wall. First and second mounting shelves are attached to the upright wall and extend outwardly in opposite directions. Each mounting wall is positioned to receive an edge of a roof section thereon. The flat mounting wall and the upright wall define a vertical mounting channel extending from a lower surface of the flat mounting wall a distance less than the distance of the first and second mounting shelves from the mounting wall. A purlin positioning and mounting device is designed to be attached to a roof beam and includes a vertically extending support wall designed to extend upwardly from a supporting roof beam when attached to the supporting roof beam and to nest within the mounting channel.