Building system, method and components

Abstract

A building system, method and components are provided. A beam has two or more co-extensive planar lengthwise portions, each planar lengthwise portion defining a pitch of a different adjacent side of a roof. A connector assembly is provided for cooperatively connecting to the beam, where the connector assembly includes a support member, and one or more tabs extending radially from the support member. A plane of the tab corresponds to an angle of a hip or ridge or valley between respective different adjacent sides of the roof. The tab connects to the support member, and includes a connection receiving portion for connecting to the beam. The beam is cantilevered away from the connector assembly when cooperatively connected thereto.

Description

FIELD OF THE INVENTION

The present invention relates in general to building systems, and more specifically to providing a framing system for use in connection with a building, and components used in the framing system.

BACKGROUND OF THE INVENTION

In nearly any neighborhood, there are roofs with many different shapes, such as gable, hip, mansard, gambrel, flat and shed roofs. It is not uncommon for a building to combine varying roof types on one roof, such as a hipped roof with gable dormers. Roof framing can be simple or complex, depending on the roof. Overhangs, hips and dormers can add greatly to the complexity of the roof framing by increasing the number of roofs and possibly varying the pitch of each section of a roof.

Most roofs of conventional buildings are framed using stick framing or truss framing. A stick frame roof utilizes individual rafters that span from the top of exterior walls to the ridge of the roof, whereas a truss frame roof is built from triangular-shaped, pre-made truss units. Gable roofs and hip roofs tend to be built primarily of trusses; other roof shapes, particularly those with dormers or on houses with cathedral ceilings or attic storage areas tend to be stick built.

An increasing number of buildings, however, are being built with foam core panels, which are slabs of foam insulation sandwiched between two facings made of, e.g., metal, drywall, plywood, waferboard, and/or oriented strand board (OSB). Foam core panels, also referred to in the industry variously as stress-skin panels, sandwich panels, structural foam panels, and structural insulated panels (SIPs), can be used in place of traditional stud framing in some building construction in appropriate situations.

Although foam core panels can be used for constructing simple houses similar to a traditional stick frame house, constructing a building with a complex roof using foam core panels may be unwieldy and/or too expensive. For example, taking into consideration support of roof beams, a builder may prefer to rely on beams which have a lesser roof span capacity, thereby limiting the complexity of the roof, and hence limiting the aesthetic appeal of a building. In such cases, a solution can be to use foam core panel walls in combination with standard truss roofs.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures where like reference numerals refer to identical or functionally similar elements and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate an exemplary embodiment and to explain various principles and advantages in accordance with the present invention.

FIG. 1 is an isometric diagram illustrating an exemplary building system in accordance with one or more exemplary embodiments;

FIG. 2A-FIG. 2C are perspective view diagrams illustrating exemplary beams in accordance with various exemplary embodiments;

FIG. 3 is a perspective view diagram illustrating an exemplary cap in accordance with various exemplary embodiments;

FIG. 4 is a side view diagram illustrating caps and a beam in accordance with various exemplary embodiments;

FIG. 5 is a perspective view diagram illustrating an exemplary connector assembly in accordance with various exemplary embodiments;

FIG. 6A-FIG. 6C are side view diagrams illustrating alternative exemplary embodiments of a connector assembly;

FIG. 7 is a perspective cut-away diagram illustrating a roof supported on a beam in accordance with various exemplary embodiments;

FIG. 8 is a side view diagram illustrating an exemplary portion of a process of constructing a building in accordance with one or more embodiments;

FIG. 9 is a perspective view illustrating a second exemplary portion of a process of constructing a building in accordance with one or more embodiments;

FIG. 10 is a perspective view illustrating an exemplary connection of a corner, in accordance with one or more embodiments;

FIG. 11 is a perspective view illustrating an extended cap in accordance with one or more embodiments; and

FIG. 12 is a side view illustrating a beam termination column in accordance with one or more embodiments.

DETAILED DESCRIPTION

In overview, the present disclosure concerns buildings, building components, building methods and/or building systems which are suitable for use in connection with construction panels, some of which are referred to as foam core panels and the like having a capability for use as roofs, exterior walls, and/or interior walls (some of which can be structural and/or non-structural), such as framing systems and components associated with a residential or commercial buildings utilizing construction panels. Such building systems, components, and methods may further provide for a framing system to support the construction panels. More particularly, various inventive concepts and principles are embodied in building systems, building components, and methods therein for providing framing associated with one or more construction panels.

The instant disclosure is provided to further explain in an enabling fashion the best modes of performing one or more embodiments of the present invention. The disclosure is further offered to enhance an understanding and appreciation for the inventive principles and advantages thereof, rather than to limit in any manner the invention. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.

It is further understood that the use of relational terms such as first and second, and the like, if any, are used solely to distinguish one from another entity, item, or action without necessarily requiring or implying any actual such relationship or order between such entities, items or actions. It is noted that some embodiments may include a plurality of processes or steps, which can be performed in any order, unless expressly and necessarily limited to a particular order; i.e., processes or steps that are not so limited may be performed in any order.

Much of the inventive functionality and many of the inventive principles when implemented are best supported with or in components which can be fabricated from appropriate materials, such as materials with sufficient structural properties, e.g. 12, 14, 16 or 18 gauge steel, having e.g., welded steel components, break metal components, rolled metal components, and/or composite materials, and the like. It is expected that one of ordinary skill, notwithstanding possibly significant effort and many design choices motivated by, for example, available time, current technology, and economic considerations, when guided by the concepts and principles disclosed herein will be readily capable of fabricating, generating and/or utilizing such components with minimal experimentation. Therefore, in the interest of brevity and minimization of any risk of obscuring the principles and concepts according to the present invention, further discussion of such components, if any, will be limited to the essentials with respect to the principles and concepts used by the exemplary embodiments.

As further discussed herein below, various inventive principles and combinations thereof are advantageously employed to increase design flexibility so as to permit, e.g., a potentially more complex roof line, appropriate for use in connection with construction panels or other construction materials if desired.

Further in accordance with exemplary embodiments, greater design flexibility can be provided by utilizing a system incorporating beams and connector assemblies, such that the beams can be connected to support even a complex roof line. A shape of a framing system, e.g., for a roof, that is provided thereby can be adapted to a shape of the building and more particularly, to the shape and angles of a roof. The relevant portions of the framing system components, e.g., beams and connector assemblies, can reflect the pitch or pitches of the roof. Moreover, because a construction panel utilized in a roof can only span a certain amount of space, one or more components can support a middle of a panel, to reduce the unsupported length of a panel.

By way of background, a ridge of a roof can be used to generally refer to the intersection of two upper roof planes, and a ridge angle refers to the angle formed by the intersection of the planes, e.g., with respect to vertical. A hip angle can be used to generally refer to the angle formed by the intersection of two sloping roof planes at a hip of a roof, e.g., with respect to vertical. A valley angle can be used to generally refer to the intersection of two sloping roof planes at a valley of a roof, used e.g., to provide water runoff.

Referring now to FIG. 1, an isometric diagram illustrating an exemplary building system in accordance with one or more exemplary embodiments will be discussed and described. The building illustrated in FIG. 1 is representative of various buildings which can be provided in connection with one or more embodiments. In overview, a building system for a building 101 can include one or more components such as beams 103, a foundation 105, connector assemblies 107, first columns 109, and second columns 111.

A beam 103, discussed in more detail below, can provide a long structure for supporting, e.g., a roof. The beam 103 can have long top sides that can be adapted to the angles created between the pitches of two adjacent sections of a roof. For example, where the beam 103 is to be placed horizontally, such as at a ridge angle, the angles of long top sides of the beam directly follow the pitches of respective adjacent sides of the roof. As another example, where the beam 103 is to be placed at an angle, such as at a hip angle, the angles of the beam when placed at the angle, e.g., the hip angle, define the pitches of respective adjacent sides of the roof. Accordingly, the beam 103 can have at least two co-extensive planar lengthwise portions, each planar lengthwise portion defines a pitch of a different adjacent side of a roof, e.g., when the beam 103 is disposed at its placement in a roofing system.

As will be appreciated from FIG. 1, the beams 103 can be positioned to define the ridges, hips, and valleys of the roof. One or more construction panels (not illustrated), as is appropriate for the size of the roof, can be deployed spanning from one beam 103 to another beam 103 to provide a side of a roof.

The foundation 105 can be provided to form a basis for supporting the building system, according to various embodiments. Although a slab foundation is illustrated here, various other types of foundations can be utilized. Various first and/or second columns 109, 111 can be provided to be mounted to the foundation, so that the top ends of the columns 109, 111 can support the beams 103 directly or indirectly. In accordance with one or more alternative embodiments, the various columns 109, 111 can be mounted on a lower floor of a multiple-story building.

The connector assemblies 107 can provide a connection between beams 103, between a beam 103 and columns 109, 111, and can be connected to other connector assemblies 107.

Various embodiments can provide columns, e.g., first columns 109 and second columns 111, which can be disposed vertical to the horizon and provide support to the beams 103. A first column 109, discussed in more detail in connection with FIG. 12, can be attached to a connector assembly, e.g., a tab as illustrated, to connect to one end of a beam 103. A second column 11I can include a connector assembly with extension, discussed in more detail in connection with FIG. 11, to connect to an end of a beam 103 and to act as an extension of the beam.

A connector assembly 107 is described in greater detail in connection with FIG. 5 and FIG. 6A-6C. The connector assembly 107 can be connected to the beam 103 so as to be adapted to a ridge angle, a hip angle, or a valley angle of the roof that the beam 103 will support. Accordingly, the connector assembly 107 can cooperatively connect to the at least one beam 103.

When an end of the beam 103 is connected to the connector assembly 107, and the connector assembly 107 is connected (directly or indirectly) to a first or second column 109, 111, the beam 103 can be extended. Generally, the beam 103 can be connected at each end to a structure, e.g., a connector assembly 107, another beam 103, or a first or second column 109, 111. The beam 103 can then be cantilevered away from the connector assembly 107 when cooperatively connected thereto.

One or more embodiments provide for a method of constructing a building or parts of a building, e.g., a framing system for a roof, described with reference to FIG. 1. Initially, first and second columns 109, 111 can be positioned on a foundation, and connected thereto (such as by being bolted). The first columns 109, particularly those with a unidirectional connector assembly angled upward, can advantageously be positioned on exterior walls. The second columns 111, such as those that have a multiple direction connector assembly or where the connector includes an extension cap, can be positioned in the interior of the building. Various beams 103 can be connected to connector assemblies 107.

The beams 103 can be positioned along the hip angles, ridge angles, and valley angles. The top side of the beams 103 can include two lengthwise parts, with each of the parts defining a pitch of a different side of a roof. The lengthwise parts can be co-extensive, and can be planar.

Once the relevant beams 103 are in place, construction panels, e.g., foam core panels, can be placed atop the beams 103 to form the roof; the lines of the roof will be parallel to the lengthwise parts of beams 103. One or more embodiments provide that constructions panels can be additionally positioned, e.g., between first columns 109, so as to define at least some of the exterior walls, and can provide further support for the construction panels forming the roof. The angles of the roof can be defined by the beams 103. Accordingly, a building can be constructed so that at least a frame for one or more roofs of the building includes the beam or beams 103 and the connector assembly 107, when they are cooperatively connected.

Each beam 103 can be cooperatively connected to one, two or more connector assemblies 107, e.g., at one or both ends of the beam 103 or in the middle of the beam 103. Optionally, a beam 103 can be directly connected to another beam 103.

One or more embodiments provide that the connector assemblies 109 can provide one or more tabs extending, e.g., from a support member. A first plane of the tab, e.g., created by a top of the tab, can correspond to an angle of a hip or ridge or valley between respective different adjacent sides of the roof. Further description of an embodiment of the connector assembly 107 is provided below.

When the beam 103 (or beams) are connected with the connector assembly 107 (or assemblies), the beam 103 can be cantilevered away from the connector assembly 107. This cantilever action is illustrated, for example, in FIG. 1.

The first and second columns 109, 111 can be provided upright on (or vertical to) a foundation 105. Optionally, the columns 109, 111 can be connected to the foundation 105, e.g., by being bolted. Optionally, the columns 109, 111 can be formed so that a base of the column 109, 111 is reinforced and/or can include a connection, such as an angle bracket to be bolted to the foundation 105. The beam 103 (or beams) can be connected to the columns 109, 111. As illustrated, two (or more) beams 103 can be connected at their ends to a single connector assembly 107, where the connector assembly 107 is not connected to a column 109, 111. This can allow a larger span of a roof.

One or more embodiments contemplates that various components can be provided as part of a kit for constructing a building. Such a kit could include, for example, connector assemblies 107 and beams 103, wherein the angles of the connector assemblies 107 and beams 103 are selected so that they together form the proper angles for a particular roof. As another example, a kit could be sold for forming a particular roof or part of a particular roof, e.g., a mansard roof, hip roof, gable roof, gambrel roof, flat roof, or shed roof.

Referring now to FIG. 2A-FIG. 2C, perspective view diagrams illustrating exemplary beams in accordance with various exemplary embodiments will be discussed and described. FIG. 2A illustrates a beam for a continuous ridge roof, FIG. 2B illustrates a beam for a ridge roof, and FIG. 2C illustrates a beam for a valley.

Referring now to FIG. 2A, one or more embodiments of the beam generally has at least two lengthwise portions 201, 203. Each of the two lengthwise portions 201, 203 can follow the angle of a side of the roof. For example, the angles α1 and α2 in this illustration represent 113° with respect to horizontal. The lengthwise portions 201, 203 can be planar. The lengthwise portions can also be co-extensive. Each planar lengthwise portion 201, 203 can define a pitch of a different adjacent side of a roof.

One or more embodiments can provide more than two planar lengthwise portions. Also, a beam can be provided with a single planar lengthwise portion, if appropriate to the roof to be constructed.

The beam can be formed in multiple parts, as illustrated in FIG. 2B and 2C, or the beam can be formed as a single piece 217, as illustrated. One or more embodiments provide that the beam can be formed to include opposing horizontal sides 205, 207, which can be connected together, e.g., by bolting and/or spot welding. Advantageously, the opposing horizontal sides 205, 207 can be vertical.

Optionally, the beam can include a bottom piece 209. The bottom piece can include opposing horizontal sides 211, 213. The bottom piece can extend along the beam, or can be provided in multiple pieces along portions of the beam. The bottom piece 209 can be fitted to the beam and connected thereto, e.g., by welding or bolting or other connection means. Accordingly, the beam 217 can have opposing sides 205, 207 with parallel planes which are vertical to horizontal and a bottom portion 209 separating the opposing sides.

Reference is now made to FIG. 2B, illustrating a beam for a ridge roof. This beam also includes the bottom piece 209, previously discussed. The beam generally has at least two lengthwise portions 221, 223, where each of the two lengthwise portions 221, 223 follows the angle of a side of the roof. For example, the angles α3 and α4 in this illustration represent 113° with respect to horizontal. A similar beam can be formed for use in connection with other roof configurations. For example, for an embodiment supporting a hip roof, an appropriate angle would be 106°. In the illustrated embodiment, the beam can include opposing horizontal sides 225, 227.

In this example, the beam was formed in multiple parts, including a left side 231 and right side 229, which can be assembled together or connected using, e.g., bolts or spot welding. In this illustration, the beam includes the optional bottom piece 209, previously described.

In accordance with one or more embodiments, the beam can include a projection 229, for later use in positioning the construction panels and/or for providing an attachment surface between the parts. A one-inch projection can be sufficient where the construction panels are about six inches thick, although any desired size can be appropriate. The projection 229 can be formed separately from the beam or can be unitary therewith, and can be formed as a planar lengthwise portion (as illustrated), as multiple fingers, or the like. The projection 229 advantageously projects vertically. Consequently, the beam can further include a third planar lengthwise portion 229 extending from a midline between the first and second lengthwise portion, the third planar lengthwise portion having a plane which is vertical to horizontal with respect to the pitch.

Reference is now made to FIG. 2C, illustrating a beam for a valley. This beam also includes the bottom piece 209, previously discussed, and two lengthwise portions 261, 263 following the angle of a side of the roof. For example, the angles α5 and α6 in this illustration represent 67° with respect to horizontal. The illustrated beam includes opposing horizontal sides 265, 267. This beam was also formed in multiple parts, here, a left side 251 and right side 249. In accordance with various embodiments, the beam can include a projection 269, for later use in positioning the construction panels and/or for providing an attachment surface between the parts. Other details are omitted which can be understood from the foregoing discussion.

All or part of one or more beams can be made lighter than the connector assembly and/or the columns. As a result, the framing system can be lighter and/or more economical than conventional beams. For example, where the connector assembly is made of 14 gauge steel, the beam can be formed of 16 gauge steel. Accordingly, the beam can be formed from a metal which has a gauge lighter than a gauge of a metal forming the connector assembly.

FIG. 3 and FIG. 4 illustrate an example of a cap, used in connection with a beam. Referring now to FIG. 3, a perspective view diagram illustrating an exemplary cap 300 in accordance with various exemplary embodiments will be discussed and described. The illustrated cap 300 can be positioned at the end of the beam, as illustrated for example in FIG. 4.

The cap 300 can provide a projection 305 for the beam which can then be attached to the connector assembly. In the illustrated embodiment, a connection receiving portion of the connector assembly (not illustrated) contemplates utilization of bolts. The projection 305 hence includes through-holes 307 that match through-holes of the connector assembly, for use in bolting the projection 305 and the connector assembly together. However, alternative embodiments contemplate utilization of mating portions, such that the projection 305 and the connector assembly can use corresponding male and female connectors. Accordingly, if different connection means are utilized in alternative embodiments, the projection 305 can be adapted. In one or more alternative embodiments, the projection 305 can be unitary with the beam.

The cap 300 can conveniently be generally formed in a rectangular shape, with a flat top portion 303 and flat sides 301, although alternative shapes are possible. The shape of the cap 300 can allow for insertion into the beam, or alternatively for inserting the beam into the cap. Advantageously, the body 309 of the cap 300 can be inserted into the beam so that the projection 305 remains outside the beam.

Referring now to FIG. 4, a side view diagram illustrating caps and a beam in accordance with various exemplary embodiments will be discussed and described. Each end of the beam 400 can have a cap 300 placed thereon or therein. The projection portion of the cap 300 can extend from the beam 400. Advantageously, the cap 300 can fit into the beam 400 so that it can support the beam 400 against the bottom part of the lengthwise portions 403 that are angled.

The cap 300 and beam 400 can be permanently connected, e.g., by fusing or welding. The illustrated example beam also includes the optional top projection 401 for positioning the construction panel(s).

When the cap 300 is mounted on the end of the beam 400, the cap 300 can be attached or cooperatively connected to the connection receiving portion of the connector assembly (not illustrated). In the illustrated example, the process of connecting can include, e.g., bolting the pieces together.

For reasons previously given, it may be desirable to form the beam 400 of a lighter gauge metal, e.g., 18 gauge steel than is customary or than is used in other structural portions of the frame for the roof. In such a situation, it may still be desirable to form all or part of the cap 300 from the normal gauge metal, e.g., 16 gauge steel. Accordingly, the beam 400 can be formed from a metal which has a gauge lighter than a gauge of a metal forming the cap 300, and/or the connector assembly.

Advantageously, the beam 400 and/or the cap 300 can be formed utilizing various structural or non-structural materials, e.g., break metal, aluminum, fiberglass, reinforced plastics, combinations thereof, and the like, while the connector assembly (not illustrated) can be formed of welded steel components, as well as the foregoing materials.

FIG. 5 and FIG. 6A-6C provide example illustrations of connector assemblies. FIG. 5 provides a perspective view, whereas FIG. 6A-6C provide side view of other connector assemblies, to illustrate various types of positioning of tabs.

Referring now to FIG. 5, a perspective view diagram illustrating an exemplary connector assembly 500 in accordance with various exemplary embodiments will be discussed and described. The illustrated example includes three tabs 501, 503, 505, representative of any number of tabs that can be used in a connector assembly.

It can be appropriate to provide the tabs 501,503, 505 on a support member 507, for example in order to provide a connection between the tabs 501, 503, 505. One or more alternative embodiments can provide the tabs connected to a column and omitting the support member, as illustrated for example in FIG. 11 and FIG. 12.

Advantageously, the use of a cylindrical form for the support member 507 permits ready distribution of tabs 501, 503, 505 at various radial angles. One or more embodiments provide that the support member 507 can be conveniently formed with an opening 509 to accept a temporary or permanent post, e.g., a column. Thus, the support member 507 can include an opening 509 defined therein for removably receiving a column. Advantageously, the support member 507 can be tubular, e.g., formed of round tubular steel such as a pipe column, or formed of a box tubular column.

In the present example, each of the tabs 501, 503, 505 can be disposed at a different angle to horizontal. For example, a plane of tab 501 formed by the top portion of the tab is generally horizontal, a plane of tab 503 extends downward, and a plane of tab 501 extends upward. One or more embodiments can provide any appropriate combination of angles for tabs. Thus, the connector assembly 500 can have tabs 501, 503, 505, wherein the plane of two or more of the planar tabs is different. Tabs 501, 503, 505 can be provided having the same planes.

For example, it can be desirable to have a connector assembly utilizing tabs connected at 90° to vertical; the number of tabs could be two or more. As another example, for a connector assembly at the top of a hip roof, there can be included a tab connect at 90° to vertical, and two tabs connected at 74° to vertical. Each tab can be connected to a different beam (not illustrated), with the 90° tab connected to a beam forming the ridge angle, and the 74° tabs connected to respective beams forming respective hip angles.

Accordingly, one or more embodiments can provide connector assembly 500 for cooperatively connecting to the beam (not illustrated), the connector assembly including a support member 507, and one or more tabs 501, 503, 505, extending radially from the support member 507. A plane of the tab 501, 503, 505 can correspond to an angle of a hip or ridge or valley between respective different adjacent sides of the roof. The tab 501, 503, 505 can connect to the support member 507, and the tab 501, 503, 505 can include a connection receiving portion (discussed below) for connecting to the at least one beam (not illustrated).

One or more connector assemblies 500 can be provided for use in connection with columns and beams (not illustrated). The tab 501, 503, 505 of a connector assembly 500 can be connected to a beam. In accordance with one or more alternative embodiments, the tab 501, 503, 505 can be attached to a column instead of a support member 507, and can then be connected to a beam. Accordingly, one or more embodiments can include providing multiple connector assemblies 500 for cooperatively connecting to one or more beams, where the connector assembly 500 includes a support member 507 and one or more tabs 501, 503, 505 extending radially from the support member 507, a first plane of the tab(s) 501, 503, 505 corresponding to an angle of a hip or ridge or valley between respective different adjacent sides of the roof, the tab(s) 501, 503, 505 connecting to the support member 507 , and the tab(s) 501, 503, 505 comprising a connection receiving portion for connecting to the beam(s).

Referring now to FIG. 6A -FIG. 6C, side view diagrams illustrating alternative exemplary embodiments of a connector assembly will be discussed and described. As illustrated in FIG. 6A, the connector assembly can include a support member 603 and one or more tabs 605. The tab 605 can include a connection receiving portion for connecting to the at least one beam. In the illustrated embodiment, a connection receiving portion contemplates utilization of bolts. The tab 605 hence includes through-holes 607 that match through-holes of to be connected to, e.g., a cap of a beam, for use in connecting the tab 605 and the beam (not illustrated) together.

A linear axis 601 of the support member 603 can be parallel to a second plane defined by each of the planar tabs 605. More particularly, the planar tabs 605 advantageously can be formed of a flat rectangular or polygonal structural. The rectangular or other polygonal structure can be place vertical, and parallel to the linear axis 601 of the support member 603.

The top of the tab 605 defines a plane. The plane in this example is disposed at an angle α7 of about 90° to the linear axis 601. This angle corresponds to a ridge angle. One or more embodiments provide that the plane of the tab 605 can correspond to an angle of a ridge (e.g., FIG. 6A) or hip (e.g., FIG. 6B) or valley (e.g., FIG. 6C) between respective different adjacent sides of the roof.

FIG. 6B illustrates an example of a connector assembly for use with a ridge angle. Parts which have been described in connection with FIG. 6A will not be repeated here, to avoid obscuring the description. A tab 609 is connected on the support member 603. The top of the tab 609 defines a plane, and in this example is disposed at an angle α8 of about 106° to the linear axis 601. This angle corresponds to one of several hip or valley angles. One of skill will appreciate that the angle selected depends on the lines of the roof.

FIG. 6C illustrates an example of a connector assembly for use with a hip or valley angle. Parts which have been described in connection with FIG. 6A-6B will not be repeated here, to avoid obscuring the description. A tab 611 is connected to the support member 603. The top of the tab 611 defines a plane, and in this example is disposed at an angle α8 of about 74° to the linear axis 601. This angle corresponds to one of several valley angles.

Referring now to FIG. 7, a perspective cut-away diagram illustrating a roof supported on a beam in accordance with various exemplary embodiments will be discussed and described. A beam 700, here represented by a ridge beam, can support construction panels, here represented by first and second foam core panels 701, 703. The beam 700 includes first lengthwise portion 707 and second lengthwise portion 709, which extend in the direction of the pitch of the roof. The beam 700 can includes opposing portions 717, 719, and a bottom piece 715, as discussed above. In order to be attached to connector assembly, the beam 700 can be coupled to a cap 711, advantageously with a projection portion 713 extending therefrom for attachment to a connector assembly. The two (or more) foam core panels 701, 703 can be supported respectively by the first and second lengthwise portions 707, 709. The first and second lengthwise portions can extend in the direction of the pitch to define the at least one roof.

In the illustrate example, a third planar lengthwise portion 705 is provided, extending from a midline between the first and second lengthwise portion 707, 709. Advantageously, the third planar lengthwise portion 705 can extend vertically to horizontal with respect to the pitch. The two (or more) foam core panels 701, 703 can be positioned to abut opposite sides of the third planar lengthwise portion 705. The ends of the foam core panels can, if desired, be trimmed or evacuated to provide a space for the third planar lengthwise portion 705 and/or to adapt to the angle of the roof.

Referring now to FIG. 8, a side view diagram illustrating an exemplary portion of a process of constructing a building in accordance with one or more embodiments will be discussed and described. Only a portion of the building is illustrated, to simply the explanation. A foundation 815 is provided, and one or more columns 111 are connected thereto, and positioned vertically. The column 811 can include a connector assembly, here including a tab 813 disposed at the proper angle as discussed elsewhere in this description. A first beam 805, including a projection portion 807 is connected at one end to the column 811 at the tab 813. The first beam 805 includes a projection portion 807, e.g., provided in connection with a cap, which is connected to another connector assembly 801. The connector assembly of this example includes first and second tabs 813, 815, which are disposed at the proper angles. The first beam 805 is connected at the other end to the connector assembly 801 via the projection portion 807 and the first tab 813. The second tab is connected to a second beam 803 via a projection portion 807 provided on the end of the second beam 803.

A process for constructing a building in accordance with one or more embodiments includes connecting the beam(s) 803, 805 and the connector assembly 801, wherein the beam(s) 803, 805 are cantilevered away from the connector assembly 801 when cooperatively connected thereto. The second beam 803 can be connected at the other end thereof to, e.g., another connector assembly or a column.

The method for constructing a building according can further include disposing two or more columns including a first column 811 and a second column (not illustrated vertical to a foundation 815. Also provided is connecting one or more beams 805 to the first column, connecting another beam 803 to a second column, and connecting the first beam and second beam 803, 805 at the connector assembly 801. In the illustrated embodiment, it is possible to omit a column below the connector assembly, thereby permitting an expanded span.

Referring now to FIG. 9, a perspective view illustrating a second exemplary portion of a process of constructing a building in accordance with one or more embodiments will be discussed and described. Illustrated in this example embodiment is a column 907 provided on a foundation 915, connected via a connector assembly 905 to one end of a beam 903. The beam 903 is further connected at the other end to a connector assembly 901, which can be connected to a combination of beams, connector assemblies, and columns (not illustrated).

Construction panels, such as foam core panels 909a, 909b, 909c can be positioned along a wall, such as the illustrated exterior wall. The panels 909a, 909b, 909c can be secured to the foundation, e.g., utilizing sill plates 913a, 913b, in accordance with techniques that are known in the industry. Alternative embodiments can provide, e.g., traditional frame wall systems, or masonry components such as concrete masonry units (CMU), bricks, etc., used as the interior and/or exterior walls.

Additional construction panels, such as foam core panels 911a, 911b can be positioned along the beam 903 to form the roof If desired, the foam core panels 911a, 911b can be support along their lower edge by the top edge of the foam core panels 909a, 909b, 909c forming the walls. Alternative embodiments can provide for conventional framing instead of construction panels used to form the roof.

The beam 903 includes the lengthwise portions previously described extending in the direction of the pitch, so as to define the roof. Optionally, the beam 903 can include the third lengthwise potion, against which the foam core panels 911a, 911b can be butted to more readily construct the roof.

A method of constructing the building can include disposing two or more wall panels 909a, 909b, 909c between the first column 907 and the second column (not illustrated). The method further includes disposing two or more roof panels 911a, 911b to be supported by at least some of the wall panels 909b, 909c and respectively by respective first and second lengthwise portions of the beam 903 and a second beam (not illustrated). The wall panels can be ay type of construction panel, as discussed herein. Further, the method of construction the building can include disposing two or more foam core panels 911a, 911b to be supported respectively by the first and second lengthwise portions of the beam 903, so that the foam core panels 911a, 911b extend in the direction of the pitch to define the roof. Optionally, a plate can be provided on top of the wall panels 909a, 909b, 909c to support and/or to position the roof panels 911a, 911b.

Alternative embodiments can provide for the walls to be entirely or primarily made of conventional framing.

Referring now to FIG. 10, a perspective view illustrating an exemplary connection of a corner, in accordance with one or more embodiments will be discussed and described. One or more embodiments provide for a corner connect piece 1000, to connect two construction panels 1009a, 1009b at an upper corner, while providing a connector assembly 1005. The corner connect piece 1000 includes an approximately L-shaped horizontal top portion 1001, to be placed atop the panels 1009a, 1009b. Optionally, a portion of the panels can be removed to allow for the top portion to be securely placed thereon.

A vertical support member 1003 can be provided, which follows the interior angle of a corner formed by the panels 1009a, 1009b. The vertical support member 1003 can conveniently be connected to the top portion 1001 and extends downwardly therefrom.

A tab 1005 can be connected to the vertical support member 103 at the appropriate angle, e.g., a hip angle, a ridge angle, or a valley angle, and can include a connection portion 1007, such as through-holes for bolts. A beam (not shown) can be connected to the tab 1005.

Referring now to FIG. 11, a perspective view illustrating an extended cap will be discussed and described. A column 1107 can be connected to an extended cap 1101, where the extended cap 1101 includes an extension 1105 with a tab 1103 which can be connected to a connector assembly (not illustrated). The column can include, e.g., a box post or other suitable support structure.

The extension 1105 can be constructed in generally in a rectangular box shape. A tab 1103 can be provided on the end of the extension 1105. The tab 1103 is intended to be connected to the connector assembly, and hence can include through-holes 1109 that match through-holes of the connector assembly, for use in bolting the tab 1103 and the connector assembly together.

Advantageously, the tab 1103 can be welded to the extension 1105.

The extended cap 1101 can be positioned on the column 1107 and permanently connected thereto, e.g., by welding or by being bolted. The first angle of the extended cap 1101 can follow the angle of the roof that it is to support.

The base of the column 1107 can be connected or formed with a shoe 1111. Optionally, the shoe 1111 can be formed of a plate with a collar and welded to the column 1107. The shoe 1111 can be utilized for connection to the foundation (not illustrated).

Referring now to FIG. 12, a side view illustrating beam termination column 1201 will be discussed and described. The beam termination column 1201 generally includes a column 1205, and a tab 1203 as illustrated, to connect to one end of a beam or cap on the beam. The column 1205 can include, e.g., a box tube post or other suitable support structure.

The tab 1203 can be provided on the upper end of the column 1205. The tab 1203 is intended to be connected to the beam (or cap on the beam), and hence can include through-holes 1207 that match through-holes of the beam (or the cap of the beam), for use in bolting the tab 1203 and the beam together.

Advantageously, the tab 1203 can be permanently attached to the column 1205, e.g., by welding. An angle α9 of the extension 1101 can follow the angle of the roof that it is to support.

The base of the column 1205 can be connected or formed with a shoe 1209, for a sturdy connection to a foundation. The shoe 1209 can be formed of a plate with a collar and welded to the column 1205.

It should be noted that the term construction panel may be used interchangeably herein with foam core panels, stress-skin panels, sandwich panels, structural foam panels, and structural insulated panels (SIPs), or the like. Each of these terms can denote a structural or non-structural panel ordinarily associated with panel construction and typically is a slab of foam insulation or other plastic material sandwiched between two facings made of, e.g., metal, drywall, plywood, waferboard, oriented strand board (OSB), combinations thereof, or equivalents thereof.

The buildings of particular interest are those for residential or commercial use, including those having simple roofs or complex roofs incorporating complex angles, e.g., gable roofs, hip roofs, mansard roofs, gambrel roofs, flat roofs and/or shed roofs, and combinations, variants or evolutions thereof.

This disclosure is intended to explain how to fashion and use various embodiments in accordance with the invention rather than to limit the true, intended, and fair scope and spirit thereof. The invention is defined solely by the appended claims, as they may be amended during the pendency of this application for patent, and all equivalents thereof. The foregoing description is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The embodiment(s) was chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims, as may be amended during the pendency of this application for patent, and all equivalents thereof, when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims

1. A building system comprising:

at least one beam comprising at least two co-extensive planar lengthwise portions, each planar lengthwise portion defining a pitch of a different adjacent side of a roof; and

a connector assembly for cooperatively connecting to the at least one beam, the connector assembly including a support member, and at least one tab extending radially from the support member, a plane of the at least one tab corresponding to an angle of a hip or ridge or valley between respective different adjacent sides of the roof, the at least one tab connecting to the support member, and the at least one tab comprising a connection receiving portion for connecting to the at least one beam; and

wherein the at least one beam is cantilevered away from the connector assembly when cooperatively connected thereto.

2. The system of claim 1, further comprising a cap mounted on an end of the at least one beam, the cap being cooperatively connected to the connection receiving portion.

3. The system of claim 1, wherein the at least one beam is formed from a metal which has a gauge lighter than a gauge of a metal forming the connector assembly.

4. The system of claim 2, wherein the at least one beam is formed from a metal which has a gauge lighter than a gauge of a metal forming the cap.

5. The system of claim 1, wherein the beam further comprises a third planar lengthwise portion extending from a midline between the first and second lengthwise portion, the third planar lengthwise portion having a plane which is vertical to horizontal with respect to the pitch.

6. The system of claim 1, further comprising at least two foam core panels, the at least two foam core panels being supported respectively by the first and second lengthwise portions and extending in the direction of the pitch to define the at least one roof.

7. The system of claim 1, wherein the at least one beam further has opposing sides with parallel planes which are vertical to horizontal and a bottom portion separating the opposing sides.

8. The system of claim 1, wherein the system is part of a kit for constructing a building.

9. The system of claim 1, further comprising a building wherein at least a frame for a roof of the building includes the at least one beam and the at least one connector assembly, cooperatively connected.

10. A method of constructing a building, comprising:

first providing a plurality of beams including at least one beam comprising at least two co-extensive planar lengthwise portions, each planar lengthwise portion defining a pitch of a different side of a roof;

second providing a plurality of connector assemblies including at least one connector assembly for cooperatively connecting to the at least one beam, the at least one connector assembly including a support member and at least one tab extending radially from the support member, a first plane of the at least one tab corresponding to an angle of a hip or ridge or valley between respective different adjacent sides of the roof, the at least one tab connecting to the support member, and the at least one tab comprising a connection receiving portion for connecting to the at least one beam; and

connecting the at least one beam and the at least one connector assembly, wherein the at least one beam is cantilevered away from the at least one connector assembly when cooperatively connected thereto.

11. The method of claim 10, further comprising providing a cap mounted on an end of the at least one beam, the cap being cooperatively connected to the connection receiving portion, wherein the connecting includes attaching the cap to the connector assembly.

12. The method of claim 10, wherein the at least one beam is formed from a metal which has a gauge lighter than a gauge of a metal forming at least one of the cap and the at least one connector assembly.

13. The method of claim 10, wherein the at least one beam further comprises a third planar lengthwise portion extending from a midline between the first and second lengthwise portion, the third planar lengthwise portion having a plane which is vertical to horizontal with respect to the pitch, further comprising positioning at least two foam core panels to abut opposite sides of the third planar lengthwise portion.

14. The method of claim 10, further comprising disposing at least two foam core panels to be supported respectively by the first and second lengthwise portions and extending in the direction of the pitch to define the roof.

15. The method of claim 10, further comprising disposing a plurality of columns including a first column and a second column vertical to a foundation, connecting the at least one beam to the first column, connecting a second beam of the plurality of beams to a second column, and connecting the first beam and second beam at the at least one connector assembly.

16. The method of claim 15, further comprising disposing a plurality of wall panels between the first column and the second column, and disposing a plurality of roof panels to be supported by the plurality of wall panels and respectively by respective first and second lengthwise portions of the first beam and second beam.

17. A connector assembly for constructing a building, comprising:

a support member; and

a plurality of planar tabs radially disposed on the support member, a first plane of each planar tab corresponding to an angle between a hip or ridgeline or valley between adjacent roofs, each of the planar tabs permanently connected to the support member, and each of the planar tabs comprising a connection receiving portion for connecting to a support beam, wherein a linear axis of the support member is parallel to a second plane defined by each of the planar tabs.

18. The connector assembly of claim 17, wherein the support member includes an opening defined therein for removably receiving a column.

19. The connector assembly of claim 17, wherein the first plane of at least two of the planar tabs is different.

20. The connector assembly of claim 17, wherein the support member is tubular.