FIELD OF THE INVENTION The invention relates generally to a standardized group of building construction components that can be assembled in many different configurations to provide a wide variety of different sizes and styles of stick built buildings.
SUMMARY OF THE INVENTION An aspect of the present invention is a kit adapted for assembling a composite building support, as well as the resulting assembled building support or a larger assembly including the assembled building support and other components. The composite building support is configured to be assembled with a series of spaced perpendicular building supports to provide a building sub-assembly.
The kit or composite building support includes at least a first plate and a second plate, and optionally at least a third plate.
The first plate has a length greater than its height and a height greater than its width. Its length and height define opposed first and second major faces. Its length and width define opposed first and second long edges.
The second plate is non-co-extensive with the first plate when the two are assembled. The second plate has a length greater than its height and a height greater than its width. Its length and height define opposed first and second major faces. Its length and width define opposed first and second long edges.
A non-coextensive feature of the first and second plates is that the first plate has a series of notches in a long edge at a series of points. At the corresponding series of points when they are assembled, the second plate is not notched. The notches in the first plate define a series of receptacles to receive tongues of building supports. The series of points where the second plate is not notched define a series of tongues to receive notches of building supports.
The respective plates can be assembled to form a structural member. This and the other assembled structural members described in this specification are all intended to be claimed, as well as kits for forming them.
Another aspect of the invention is a kit adapted for assembling a different type of building support. The kit comprises first and second building support plates, each having a length greater than its width and depth, and spacers adapted for insertion between the building support plates. The first and second building supports are configured to be joined in spaced parallel relation with the spacers between the first and second building support plates.
Another aspect of the invention is a kit adapted for assembling a corner stud. The kit includes a first plate and a second plate. The first plate has a height greater than its width and a width greater than its thickness. Its height and width define opposed first and second major faces and its length and width define opposed first and second long edges. The first plate has at least one notch in a long edge.
The second plate has a height greater than its width and a width greater than its thickness. Its height and width define opposed first and second major faces. Its length and width define opposed first and second long edges. The second plate has at least one tongue in a long edge complementary to the notch of the first plate.
Another aspect of the invention is a cantilever support. The cantilever support has a pair of major faces. The cantilever support is adapted for being installed in spaced oblong cut outs of first and second building supports running generally perpendicular to the cantilever support. The oblong cut outs have a major dimension and a minor dimension. The cantilever support comprises a first portion and a second portion. The first portion is configured to define a cantilever when installed. The second portion comprises a first pair of opposed notches configured for engaging an oblong cut out of the first building support. The second portion has a second pair of opposed notches for engaging an oblong cut out of the second building support.
The notches of each pair of opposed notches are separated from each other by a portion of the cantilever support no larger than the minor dimension of the corresponding oblong cut out. At least part of the major face of the second portion of the cantilever support is wider than the minor dimension of the corresponding cut out. Its configuration is such that the cantilever support can be inserted through the cut outs with its major faces generally parallel to the major (i.e. longest) dimension of the oblong cut out. The notches and cut outs are lined up, and then the cantilever support is rotated one quarter turn to engage the oblong cut outs with the corresponding notches.
BRIEF DESCRIPTION OF DRAWING FIGURES FIG. 1 is an isometric view showing a partial assembly of the respective components of FIGS. 3 to 24.
FIG. 2 is an exploded view showing the respective components of FIGS. 3 to 24.
FIGS. 3A through 3E show several views of a wall corner stud 1.
FIGS. 4A through 41 show several views of a shorter wall corner stud 2.
FIGS. 5A through 5H show several views of an end roof sub-panel 3.
FIGS. 6A through 6C show several views of a foundation chair 4.
FIGS. 7A through 7D show several views of a floor joist 5.
FIGS. 8A through 8D show several views of a floor joist 6 (an inverted view of the floor joist 5).
FIGS. 9A through 9E show several views of a floor joist 7.
FIGS. 10A through 10G show several views of a field roof sub-panel 8.
FIGS. 11A through 11D show several views of a gable rafter 9.
FIGS. 12A through 12D show several views of a rim header 10.
FIGS. 13A through 13D show several views of a rim header 11.
FIGS. 14A through 14D show several views of a sill 12.
FIGS. 15A through 15D show several views of a shed rafter 13.
FIGS. 16A through 16D show several views of a shed rafter outrigger 14.
FIGS. 17A through 17H show several views of a starter roof sub-panel 15.
FIGS. 18A through 18D show several views of a wall brace 16.
FIGS. 19A through 19D show several views of a wall stud 17.
FIGS. 20A through 20D show several views of a wall stud 18.
FIGS. 21A through 21D show several views of a wall stud 19.
FIGS. 22A through 22D show several views of a wall stud 20.
FIGS. 23A through 23D show several views of a wall stud 21.
FIGS. 24A through 24F show several views of a wall sub-panel 22.
FIG. 25 is an isometric view similar to FIG. 1, taken from a different direction.
FIG. 26 is an isometric view similar to FIG. 1, taken from a different direction.
FIG. 27 is an isometric view similar to FIG. 1, taken from a different direction.
FIG. 28 is an isometric exploded view showing the assembly of two floor joists 6 and 7 at a crossing.
FIG. 29 shows the assembled floor joists 6 and 7 of FIG. 28.
FIG. 30 is an isometric exploded view showing the assembly of two floor joists 6 and 7 and a wall stud 18 at a crossing.
FIG. 31 shows the assembled floor joists 6 and 7 and wall stud 18 of FIG. 30.
FIGS. 32A through 32F show several views of a ring truss for supporting a longer span than the spacing between foundation chairs in FIG. 1.
FIGS. 33A and 33B are diagrammatic views of an alternative ring truss.
The parts of the respective views are indicated by the following reference characters.
1 Wall corner stud
2 Gable wall corner stud
3 End roof sub-panel
4 Foundation chair
5 Floor joist (A)
6 Floor joist (A) inverted
7 Floor joist (B)
8 Field roof sub-panel
9 Gable rafter
10 Rim header (A)
11 Rim header (B)
12 Sill
13 Shed rafter
14 Shed rafter outrigger
15 Starter roof sub-panel
16 Wall brace
17 Wall stud, short
18 Wall stud, full
19 Gable wall stud (A)
20 Gable wall stud (B)
21 Gable wall stud (C)
22 Wall sub-panel
30 First plate
32 First major face (of 30)
34 Second major face (of 30)
36 First long edge (of 30)
38 Second long edge
40 Second plate
42 First major face (of 40)
44 Second major face (of 40)
46 First long edge (of 40)
48 Second long edge (of 40)
50 Butting Notch (of 30)
52 Butting Notch (of 30)
54 Butting Notch (of 30)
56 Butting Notch (of 30)
58 Butting Notch (of 30)
60 Butting Notch (of 30)
62 Butting Notch (of 30)
64 Butting Notch (of 30)
66 Butting Notch (of 30)
68 Butting Notch (of 30)
70 Butting Tongue (FIGS. 20A through 20D)
72 Butting Tongue (FIGS. 20A through 20D)
74 Butting Tongue (FIGS. 20A through 20D)
76 Butting Tongue (FIGS. 9A through 9F)
78 Butting Tongue (FIGS. 9A through 9F)
80 Butting Notch (FIGS. 20A through 20D)
82 Building support plate (of 18)
84 Building support plate (of 18)
86 Cut out support plate (of 18)
88 Cut out support plate (of 18)
92 First plate (of 1)
94 Major face (of 92)
96 Major face (of 92)
98 Long edge (of 92)
100 Long edge (of 92)
102 Butting notch (of 92)
104 Second plate (of 1)
106 Major face (of 104)
108 Major face (of 104)
110 Long edge (of 104)
112 Long edge (of 104)
114 Butting tongue (of 104)
116 First portion (of 14)
120 Major face (of 14)
122 Major face (of 14)
124 First portion (of 14)
126 Second portion (of 14)
128 Butting notch (of 14), first pair
130 Butting notch (of 14), first pair
132 Butting notch (of 14), second pair
134 Butting notch (of 14), second pair
136 Portion (of 14), between notch
140 Fastener hole
142 Fastener bolt
144 Fastener nut
146 Crossing notch (of 30)
148 Crossing notch (of 30)
150 Crossing notch (of 30)
152 Tab
154 Tab
156 Common point
158 Cut out (of FIGS. 20A through 20D)
160 Pin (FIG. 30)
170 Ring truss
172 Upper chord
174 Lower chord
176 Center truss ring
178 Flanking truss ring
180 Saddle
182 Horizontal tension member
184 Vertical tension member
186 Ring truss
DETAILED DESCRIPTION The present invention will now be described more fully with reference to the accompanying drawings, in which preferred embodiments are shown. This invention can, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth here. Rather, these embodiments are examples of the invention, which has the full scope indicated by the language of the claims. Like numbers refer to like or corresponding elements throughout. The following disclosure relates to all embodiments unless specifically limited to a certain embodiment.
As used in this specification, the terms “height” and “width” are used broadly to refer to dimensions of a part other than its length, and are not limited to parts oriented with the “height” dimension vertical or in any other orientation, or the “width” dimension horizontal or in any other orientation. These terms in some instances may have specific meaning as the orientation of a part that has been assembled into a building or other structure, but in no case do they relate to the orientation of the part before it is incorporated into a structure.
Dimensions are given for exemplary parts as shown in the figures. The dimensions of each part can vary but the proportions and relations to other system components optionally can be adjusted in tandem. They can be scaled up and down in the horizontal axis and/or vertical axis, either together or independently within certain tolerances.
FIGS. 1 and 2 show all of the parts 1-22 identified above.
The parts in the illustrated embodiments are generally described below. For convenience, some of the parts 1-22 are related as follows for economy of description. This description is not intended to provide limits on what the respective parts can be used for or how they can usefully be oriented. For example, certain components described as posts can function as beams, and vice versa, and certain parts can be used either singly or in sub-assemblies of two or more such parts.
Parts 1 and 2 are generally composite building supports in the nature of wall corner studs, which are broadly categorized as posts as they stand vertically and primarily bear a load lengthwise.
Parts 3, 8, 15, and 22 are generally wall and roof (or skin) panels.
Parts 5, 6, 7, 9, 10, and 11 are generally composite building supports in the nature of beams. The categorization of these components as beams does not require them to be horizontal in use, as the gable rafter 9, for example, is neither horizontal nor vertical when used as illustrated.
Parts 17-21 are generally composite building supports in the nature of studs. These components can alternatively be used singly, analogous to FIGS. 15A through 15D, or as an assembly with another, optionally identical, part of the same kind, as shown in FIG. 1 or FIGS. 19-23.
A corner stud (1) is illustrated in FIGS. 3A through 3F. The first and second plates (92 and 104) of the corner stud can be provided separately as a kit, optionally including fasteners or excluding fasteners that can be obtained separately. Alternatively, a corner stud (1) can be provided as the assembly shown in FIGS. 3A through 3F. The kit or assembly includes a first plate (92) and a second plate (104). The first plate (92) has a height greater than its width and a width greater than its thickness. Its height and width define opposed first and second major faces (94, 96) and its length and width define opposed first and second long edges (98, 100). The first plate has at least one notch (e.g. 102) in a long edge (e.g. 100). The first plate illustrated in FIG. 3 has three notches, and the first plate illustrated in FIGS. 4A through 41 has one notch.
The second plate (104) has a height greater than its width and a width greater than its thickness, its height and width defining opposed first and second major faces (106, 108) and its length and width defining opposed first and second long edges (110, 112). The second plate has at least one tongue (114) in a long edge (e.g. 110) complementary to the notch of the first plate.
FIG. 3 illustrates a wall corner stud 1.25 units in thickness by 4.5 units in width by 94 units in length.
This wall corner stud locks in to the floor system in similar fashion as the twin stud system described below. The corner stud is designed to be inserted where perpendicular wall stud arrays intersect. The stud is shaped with identical voids evenly spaced to provide horizontal chases for integration of mechanical systems up to 1.5 units×4 units in size. The result is the studs require no drilling for integration of most conventional wiring and plumbing systems.
FIGS. 4A through 41 illustrate a gable wall corner stud 1.25 units in thickness×4.5 units in width×29.75 units in length. Note: dimensions can vary but proportions and relations to other system components adjust in tandem. They can be scaled up and down in the horizontal axis and/or vertical axis, either together or independently within certain tolerances. This stud locks in to the floor system or rim header system (FIG. 12) in similar fashion as the twin stud system. This is simply an abbreviated version of the corner wall stud. The corner gable or wall stud is designed to be inserted where perpendicular wall stud arrays intersect. The stud is shaped with identical voids evenly spaced to provide horizontal chases for integration of mechanical systems up to 1.5 units×4 units in size. The result is the studs require no drilling for integration of most conventional wiring and plumbing systems.
FIGS. 5A through 5H illustrates an end roof sub panel 0.5 units in thickness×24 units in width×20.75 units in length. This component is designed to be the last roof sub-panel placed when running roof sub-panel courses. It is to be inserted at the highest vertical point on the shed rafters (FIG. 15). It is secured in place via pinning through aligning holes. The panel features 2 integral clip/hook configurations located on the panel sides, which face down toward the primary roof plane. This shape acts as a guide, spacer and joining mechanism for associated components. The top surface of the sub panel features keyhole-shaped voids, spaced to occur repetitively every eight units horizontally and every 12 units vertically, to facilitate connection of various roof-finishing systems. The sub-panel also has a unique edge profile that when placed side by side form additional larger key hole shaped openings that both allow for penetration of wiring from solar panels as well as connection points for additional surface fixtures and or treatments.
FIGS. 6A through 6C illustrates a foundation chair sized at 12 units by 12 units. This vertically oriented unit is made of material 1.125 units thick. The assembly is constructed by placing 2 flat “A style” pieces into 2 “B style” flat pieces to form a free standing, stable assembly. The primary function of the foundation chair is to provide an elevated self-squaring transition and locking point from level ground or level concrete piers to the underside of the floor joists corners and key intersection bearing points within the floor system. The foundation chairs also form 90-degree angles to insure proper squaring of the floor system. The heights of the foundation chairs can be increased to achieve a desired elevation. The foundation chairs are designed with a tapered edge to provide added stability. A series of pre-made holes assist in proper placement of units and provide securing points that allow for integration of horizontal pinning rods where the joists can be secured to the foundation chairs and the chairs can be secured to the ground and or foundation.
Each of FIGS. 7, 8, 9, 11, 12, and 13 show an assembled composite building support, embodied as floor joists 5, 6, and 7, a gable rafter 9, and rim headers 10 and 11 in the several illustrated embodiments. These building supports are made from first and second plates 30 and 40.
A floor joist kit containing the individual unassembled or partially assembled components (the first and second plates 30 and 40 and optionally fasteners for joining them together, supplied as part of the kit or separately obtained) of FIGS. 7A through 7D is specifically contemplated.
A floor joist kit containing the individual unassembled or partially assembled components (the first and second plates 30 and 40 and optionally fasteners for joining them together, supplied as part of the kit or separately obtained) of FIG. 8 is specifically contemplated.
A floor joist kit containing the individual unassembled or partially assembled components of FIGS. 9A through 9F (the first and second plates 30 and 40 and optionally fasteners for joining them together, supplied as part of the kit or separately obtained) is specifically contemplated.
A gable rafter kit containing the individual unassembled or partially assembled components of FIGS. 11A through 11D (the first and second plates 30 and 40 and optionally fasteners for joining them together, supplied as part of the kit or separately obtained) is specifically contemplated.
A rim header kit containing the individual unassembled or partially assembled components of FIGS. 12A through 12D (the first and second plates 30 and 40 and optionally fasteners for joining them together, supplied as part of the kit or separately obtained) is specifically contemplated.
A rim header kit containing the individual unassembled or partially assembled components of FIGS. 13A through 13D (the first and second plates 30 and 40 and optionally fasteners for joining them together, supplied as part of the kit or separately obtained) is specifically contemplated. Each kit and the corresponding assembly are separately contemplated as a novel feature of the disclosed embodiments.
Each of these composite building supports is further adapted for assembling with a series of spaced perpendicular building supports (any one or more of a wall corner stud 1 or 2, a foundation chair 4, a shed rafter 13, a wall stud 17, 18, 19, 20, or 21, or another floor joist 5, 6, or 7 or gable rafter 9).
Referring in particular to FIGS. 7A through 7D, each kit or assembly includes a first plate (30) having major faces (32, 34) and first and second long edges (36, 38) and a second plate having first and second major faces (42, 44) and first and second long edges (46, 48). The second plate (40) is non-co-extensive with the first plate when assembled.
The first plate (30) has at least one notch, and as illustrated a series of notches (e.g. 52-66 or 50 and 68), in a long edge (e.g. 36 or 38) at a series of points where the second plate (40) is not notched when they are assembled. The notches (e.g. 52-66) define a series of receptacles to receive tongues (e.g. 70, 72, and 74) of building supports (e.g. 18). The series of points where the second plate is not notched define a series of tongues (e.g. 76, 78, FIG. 9E) to receive notches (e.g. 80) of building supports (e.g. FIGS. 20A through 20D).
FIGS. 7 and 8 illustrate a floor joist style A, which is 96 units in length by 9 units in depth by 2.25 units in thickness, as part of a floor system. The floor system has been created to provide for infinite expansion, based on a pre-set equal-distant grid. (presently a square grid 24 units on a side). All components are placed on grid centerlines and center points. The floor joists are laid out to first create a perimeter by inserting style floor joists (FIGS. 7A through 7D) into the foundation chairs (FIGS. 6A through 6C).
The joist features unique three-dimensional joints that allow for insertion of perpendicular similar joists equally spaced along the horizontal axis while simultaneously forming a pocket for insertion of the vertical studs along the vertical axis. The assembly of perpendicular floor joists 6 and 7 is illustrated by FIGS. 28 and 29. The further assembly of perpendicular floor joists 6 and 7 and a mutually orthogonal wall stud 18 at a three-way intersection is shown in FIGS. 30 and 31, illustrating how the crossing joists 6 and 7 assemble to form four receptacles for the four tongues such as 70, 72, and 74 of the wall stud 18. FIG. 30 also shows the use of fasteners 160, which optionally are hollow tubes such as roll pins, to join the assembly.
The horizontal joints are designed to penetrate the primary structural member 50% to allow the opposing member to fit creating a flush surface. The flanking joints are designed to only penetrate the primary structural component on the outer thirds in both the top and bottom areas.
The joist is secured by placing a universal designed pin through the aligned holes on both chairs and joists. The first sets will run parallel to one another with the B style floor joist (FIGS. 9A through 9F) running perpendicular and placed second. With the placement of the B style joists the primary perimeter is formed, squared and secured to foundation chairs. The rest of the B style joists (FIGS. 9A through 9F) are then placed in pre-notched areas on the A style joists in a perpendicular fashion. The final step for placing the floor joists is by placing the remaining A style joist (FIG. 8) with the primary notches facing down to insert into the B-style joists in a perpendicular fashion. This placement provides additional squaring of the floor system while also providing critical structural reinforcement of the system. All joists are pre-cut and have identical penetrations to allow for mechanical chases, insertion of pre-spaced wall studs and pre-made floor panels. The system can be used with essentially zero waste.
Alternatively, instead of a criss-cross joist pattern, the perimeter joists of one structural floor unit as shown in FIG. 1 and filling joists could be laid in one direction, as in conventional construction. The criss-cross arrangement is preferred, however.
The specific shape and orientation of the A style joist (FIGS. 7A through 7D) requires it is the first style of joists to be placed that spans from one foundation chair (FIG. 6) to the other. Once placed it forms the perimeter or spine that will receive other opposing joists (FIGS. 9A through 9F). The system requires the identical placement of a second parallel floor joist and chair assembly to form the first two sides of a primary grid perimeter. This placement is then followed by the insertion and securing of the B style (FIGS. 9A through 9F) in a perpendicular fashion creating the primary square or grid. This grid can be repeated and expanded many times over to achieve the desired overall size. Remaining open notches are in filled with additional joists, thus forming the secondary grid that also creates superior structural reinforcement while allowing for mechanical integration without drilling additional holes in the beams.
FIGS. 8A through 8D illustrate a floor joist style A 96 units in length by 9 units in depth by 2.25 units in thickness. This joist is identical in shape, specs and function as the prior (FIGS. 7A through 7D) style B joist. The only difference is that it is to be rotated 180 degrees along the horizontal x axis resulting in the primary field notches facing in the down direction. This rotation will allow for proper insertion into the B style joists that feature upward facing notches.
FIGS. 9A through 9F illustrates a floor joist style B 96 units in length by 9 units in depth by 2.25 units in thickness. This joist has the same specifications and functional features as the prior style A joist (FIGS. 7 and 8). The only difference is that the ends are oriented opposite the A style ends. This design feature on the B style joist requires it to be placed second in sequence to the original A style thus forming a completed primary grid perimeter. The end shape allows the joist to be placed from the top and slide down over the perpendicular A style ends while leaving the field notches in an upward open state ready to receive the identical joist in a perpendicular direction. The overall design is created to form an intuitive assembly process. The more components placed the easier it becomes.
Several optional features are shown in the illustrated embodiments. For example, the joists of FIGS. 7-9 as illustrated are made up of three plates: two of the first plates sandwiching a second plate between them to define a composite beam (i.e. an A-B-A arrangement of plates). This construction has the advantage of providing closed recesses for receiving the butting tongues of studs as illustrated in FIGS. 19-23 and further described below.
It will be understood that other combinations of the first and second types of plates could optionally be used, with corresponding adjustments in the dimensions of other parts as needed. For example, two second plates could be sandwiched between two first plates (A-B-B-A), or all the plates could be doubled (A-A-B-B-A-A). Alternatively, a single plate having all the features of two joined plates can be made as one piece, although this may require more complicated milling, molding, or 3-dimensional printing or powder fabrication techniques. Many other arrangements and combinations will occur to those of ordinary skill.
Further, joists are just one example of structural beams that can be made according to the joist construction of FIGS. 7-9. Some other types of beams are described below.
FIGS. 10A through 100 illustrate a field roof subpanel shown as 24 units in width by 18 units in height by 0.5 units in thickness. It has two clips on each end that serve to hook into place in a parallel manner to the rafters (FIGS. 15A through 15D). The component is designed to be the second roof sub-panel placed when running roof sub-panel courses. It can be inserted immediately above the roof starter panel (FIGS. 17A through 17H). It is secured in place via pinning through aligning holes. The panel features two integral clip/hook configurations located on the panel sides, which face down toward the primary roof plane. This shape acts as a guide, spacer, and joining mechanism for associated components. The top surface of the sub panel features key hole shaped voids spaced to occur repetitively every eight units horizontally and every 12 units vertically to facilitate connection of various roof-finishing systems. The sub-panel also has a unique edge profile that when placed side by side form additional larger key hole shaped openings that both allow for penetration of wiring from solar panels as well as connection points for additional surface fixtures and or treatments.
FIGS. 11A through 11D illustrate a gable rafter. The overall length is 92.5 units, depth is 9 units, and thickness is 2.25 units. The component is designed to be positioned directly above the rim header and gable studs, with one end resting on the corner gable stud and upper rim header. The opposite end inserts into the lower perpendicular rim header and is secured in the standard fashion with pinning of the aligned holes. This component is designed to facilitate the transition between the shed rafters (FIGS. 15A through 15D) and the gable studs (FIGS. 21A through 21D-22). Its unique shape enables it to join with the gable studs in the same fashion the studs would typically join with other joist and rim header components. Simultaneously the component creates a termination point for the shed rafter array. The gable rafter will fall on the same primary grid axis as the rim headers (FIGS. 13A through 13D) and perimeter joists (FIGS. 7A through 7D and 11A through 11D).
FIGS. 12A through 12D illustrate a rim header, which is another composite beam as described above. The rim header is shown as 96 units in length by 9 units depth by 2.25 units in thickness. It is designed to be placed directly above and rest on the wall studs and corner studs (FIGS. 20 and 3) and directly under the gable and gable rafters. The rim header is used to secure the tops of the wall studs. Additionally, the rim header provides an upper perimeter that facilitates the squaring and securing of the wall system and provides the base for shed rafters and gable studs via the pre-spaced notches that only allow for insertion where the opposing shapes match. Like a double top plate in conventional framing or a belt course in concrete block wall construction, the rim header perimeter has as its primary function to tie multiple wall panes together while providing key connection/expansion points for interior or exterior soffits, gable rafters, roof trusses, roof rafters and gable studs. Another key function the rim header performs is to serve as a structural window or door header. By design as a single component it is stronger than similar looking floor joists (FIG. 8) primarily because it only has secondary notches and no primary, field, or crossing notches (three names for the same type of notch). The exact shape of this and other building components does not change even if the material changes. Therefore a hybrid system can easily be delivered where the material for a particular header or other building component, especially to cross a long span or carry a heavy load, is a higher strength material such as steel that fits identically into a wood system.
FIGS. 13A through 13D illustrates a rim header down (“down” refers to the fact that the longer end hooks face down). The rim header down is shown as 96 units in length by 9 units depth by 2.25 units in thickness. It is designed achieve deliver all the functions of the standard rim header (FIGS. 12A through 12D) and to be placed directly above and rest on the gable studs and corner gable studs (FIGS. 23A through 23D and 4) and directly under the upper section of gable rafters (FIGS. 15A through 15D). The rim header down is placed with longest ends down connecting at each end into top of corner gable studs (FIGS. 4A through 41). The other down facing notches provide connection points for gable studs. After the down rim header is placed, a specific ledge or receiving platform is formed at each end for proper placement and securing of the gable rafter FIG. 11).
FIGS. 14A through 14D illustrate a sill shown as a single member 43.5 units in length by 4.5 units in width by 0.75 units thick. The sill is strategically perforated to allow easy placement on top of a wall brace (FIGS. 18A through 18D) when inserted over a section of less than full wall height studs (FIGS. 19A through 19D) it forms the base of a rough window opening. The sill is designed to offer various lengths and options to achieve a variety of openings.
Another feature illustrated in the figures is a building support generally but not necessarily serving as a column, stud, or rafter (e.g. 13, 17, 18, 19, 20, or 21), or a kit adapted for assembling any of the same. The kit comprises first and second building support plates (82, 84), each having a length greater than its width and depth, and spacers (e.g. 86 and 88) adapted for insertion between the building support plates. The first and second building supports are configured to be joined in spaced parallel relation with the spacers between the first and second building support plates.
Optionally, the spacers can be sized to allow a utility line (electric conduit, water supply or drain pipe, coaxial cable, etc.) to pass between the plates of the assembled building support.
Optionally, the first and second major faces of each building support plate are congruent and registered, as illustrated. The advantage of this construction is that it eases manufacture of the parts from standard material panels, like 4 foot by 8 foot sheets of plywood, using straightforward cutting tools.
Optionally, as illustrated in FIGS. 20A through 20D and others, each end of each building support plate comprises two butting tongues (e.g. 70, 72) and a butting notch (e.g. 80) located between the butting tongues. In the illustrated embodiments, for example, the butting notch (e.g. 80) is a compound notch having a deeper central portion to embrace a corresponding butting tongue (78) on a central plate (40) and shallower outside portions to abut long edges (e.g. 36) of a pair of outer plates (30) sandwiching the central plate (40).
Optionally, each longitudinal half of the cut outs in the vertical building supports has the same shape as the compound notch at the end of the beam.
Optionally, the butting tongues (e.g. 70, 72) and the butting notches (80) have substantially square sections.
Optionally, the pair of butting tongues (e.g. 70, 72) is spaced sufficiently to receive a stack of three plates of the same width as the building support plate between them, particularly to interface with the present three-stack beam embodiments.
FIGS. 15A through 15D illustrate a shed rafter, shown as a single component that is 132 units in length by 9 units in depth by 1.125 units in thickness. The shed rafter is an integral part of the roof frame. It is designed with the identical triple notch that the studs (FIGS. 20A through 20D) have at their ends. This triple notch profile is located at both key insertion points to the rim header (FIGS. 13A through 13D) and the elevated rim header down. The notches are located along the underside of the rafter and cause the rafter to be set at the proper pitch (4/12 as shown). The rafters are also designed with a series of holes and cut outs. The cut outs are shaped to provide a simple method for securing both perpendicular outriggers (FIGS. 16A through 16D) and horizontal bracing if needed. The cut outs also provide chase ways for mechanicals up to 4 units×3 units in size/diameter. The holes are strategically placed to allow rafters to be joined together in similar fashion as the twin studs (FIGS. 20A through 20D). Additionally, they can be used to thread a cable through, thus tying the rafter array together, resulting in a more storm resistant roof framing assembly. The additional holes are aligned with holes on the roof sub panel clips (FIGS. 5, 10, 17) to provide securing points where panels are pinned to rafters. This rafter component like all other components is designed and shaped specifically to be interdependent on its associated parts. The overall sizes and dimensions can change as long as the proportions remain. If a greater amount of change can be accepted, the proportions can be changed as well. This design feature creates a true assembly system that provides built-in controls to prevent against improper placement of most components. As shown in FIG. 1, the shed rafters can also be doubled by assembling two of them with spacers between them, analogous to the kits and finished configuration of the studs 17-21 described below.
Another aspect disclosed is a cantilever support (14), also discussed in this specification as an outrigger. The cantilever support has a pair of major faces (120, 122). The cantilever support is adapted for being installed in spaced oblong cut outs (86 and 88) of first and second building supports (e.g. 13) running generally perpendicular to the cantilever support. The oblong cut outs have a major (largest) dimension and a minor (smaller) dimension. The cantilever support comprises a first portion and a second portion. The first portion (124) is configured to define a cantilever when installed. The second portion (126) comprises a first pair of opposed notches (128, 130) configured for engaging an oblong cut out of the first building support. The second portion (126) comprises a second pair of opposed notches (132, 134) for engaging an oblong cut out of the second building support.
The notches of each pair of opposed notches are separated from each other by a portion (136) of the cantilever support no larger than the minor dimension of the corresponding oblong cut out. At least part of the major face of the second portion of the cantilever support is wider than the minor dimension of the corresponding cut out. Its configuration is such that the cantilever support can be inserted through the cut outs with its major faces generally parallel to the long dimension of the oblong cut out. The notches and cut outs are lined up, then the cantilever support is rotated a quarter turn to engage the oblong cut outs with the corresponding notches and put the cantilever support in its intended final orientation.
FIGS. 16A through 16D illustrate a shed rafter outrigger shown with a length of 48 units by a maximum depth of 9 units and a 1.125 unit thickness. The outrigger is a single component designed to be dependent on the rafter (FIGS. 15A through 15D) in order to extend the surface area that roof sub panels (FIGS. 5, 10 & 17) can be placed without support directly underneath (i.e. providing an overhang). This cantilever design creates overhangs along the horizontal axis and sloped ends that are useful for proper concealment of many building envelope types. The outrigger is shaped in a manner that enables the component to be threaded through the primary rafter cut outs and then rotated 90 degrees to lock in to its proper resting position.
FIGS. 17A through 17H illustrate a starter roof sub panel shown as 24 units in width by 24 units in height by 0.5 units in thickness. It has two clips on each end that serve to hook into place in a parallel manner to the rafters (FIGS. 15A through 15D). The starter roof panel is unique from other roof sub panels due to its size and its two integral horizontal ridges located on the panel's underside. The component is designed to be the first roof sub-panel placed when running roof sub-panel courses. It is to be inserted first with the horizontal ridges acting as cleats that infill the pre-designed notch profile located at the upper edge of the lower rafter end. The sub panel is secured in place via pinning through aligning holes coinciding rafter holes. Once all starter panels are secured to rafters the placement of field sub panels (FIGS. 10A through 10G) can occur. The panel features 2 integral clip/hook configurations located on the panel sides, which face down toward the primary roof plane. This shape can act as a guide, spacer and joining mechanism for associated components. The top surface of the sub panel features keyhole-shaped voids, spaced to occur repetitively every eight units horizontally and every 12 units vertically, to facilitate connection of various roof-finishing systems. The sub-panel also has a unique edge profile that when placed side by side form additional larger key hole shaped openings that both allow for penetration of wiring from solar panels as well as connection points for additional surface fixtures and or treatments.
FIGS. 18A through 18D illustrate a wall brace shown at 48 units in length by 4 units in depth by 0.75 units in thickness. The wall brace is designed to be located typically between a series of wall studs (FIGS. 20A through 20D) to provide lateral reinforcement when needed. Additionally, the wall brace forms an integral part of the sill (FIGS. 14A through 14D), as they interlock by engaging tabs and slots to form a T section, typically after the wall brace is installed. The wall brace is designed to be inserted through the primary stud cut outs, and like all other components is self-aligning and self-squaring when fully seated.
FIGS. 19A through 19D shows the assembled components of a kit adapted for assembling a building support, which can also be used with the embodiments of FIG. 15, 20, 21, 22, or 23. The kit includes first and second building support plates (82, 84), each having a length greater than its width and depth. Spacers (e.g. 86 and 88) are adapted for insertion between the building support plates. The building supports configured to allow them to be joined in spaced parallel relation with the spacers between the first and second building support plates. In an alternative embodiment, the building supports could also be provided as a single plate or as an assembly of three or more plates.
Optionally, the spacers can be sized to allow a utility line to pass between the plates of the assembled building support, for example vertically if the building component is vertical in use.
FIGS. 19A through 19D illustrate a wall stud made of two plates with an overall height of 36 units by a width of 4.5 units by a thickness of 1.125 units. The stud set or “twin studs” provide a unique wall frame pattern exclusive to the system. The twin stud shown in (FIGS. 19A through 19D) consists of two studs 1.125 units×4.5 units×36 units. The identical studs are both pierced with repetitive cut outs that provide both connection points for wall braces and sill components as well as provide horizontal chase ways for pipes and wires up to 1.5 units in diameter. The twin studs are joined by a series of equally spaced cylinders functioning as spacers. These cylinders are integral and positioned horizontally between the wall studs sets. Studs are typically placed in pairs. The ends are specifically shaped with a triple profile notch as previously described to allow them to fit into the pre-spaced opposing notches on the floor joists. This pre-spacing insures for exact placement within the grid every time. The ends of the studs are secured by pinning through the perpendicular joists component, which they flank. This system insures the wall structure is tied to the floor at every stud. Additionally, the studs are shaped to allow for penetrations of various mechanical systems (i.e.: plumbing and electric). The spacing of the twin studs also provides for perpendicular connectors that strengthen the entire assembly while also providing connection points for wall sheathing assemblies. The wall system is created to offer endless variation within both a vertical (12 unit increments currently) grid and horizontal grid (currently 24 units×24 units). The wall studs are also designed to receive pre-made lateral re-enforcing braces as well as post tensioning cables if needed.
FIGS. 20A through 20D illustrate a wall stud 94 with an overall height of 94 units by a width of 4.5 units by 1.125 units thick. The stud set or “twin studs” provide a unique wall frame pattern exclusive to the system. The twin stud shown in (FIGS. 20A through 20D) consists of two studs 1.125 units×4.5 units×94 units. The identical studs are both pierced with repetitive cut outs that provide both connection points for wall braces and sill components as well as provide horizontal chase ways for pipes and wires up to 1.5 units in diameter. The twin studs are joined by a series of equally spaced cylinders. These cylinders are integral and positioned horizontally between the wall studs sets.
Studs are typically placed in pairs, as shown in FIGS. 19-23. The ends are specifically shaped with a triple profile notch to allow them to fit into the pre-spaced opposing notches on the floor joists. This pre-spacing insures for exact placement within the grid every time. The ends of the studs are secured by pinning through the perpendicular joists component that they flank. This system insures the wall structure is tied to the floor at every stud. Additionally the studs are shaped to allow for penetrations of various mechanical systems (i.e.: plumbing and electric). The spacing of the twin studs also provides for perpendicular connectors that strengthen the entire assembly while also providing connection points for wall sheathing assemblies. The wall system is created to offer endless variation within both a vertical (e.g. 12 unit increments) grid and horizontal grid (e.g. 24 units square). The wall studs are also designed to receive pre-made lateral re-enforcing braces as well as post tensioning cables if needed. The wall studs are designed to receive rim headers, which provide both identical spacing and reinforcement to the overall wall and superstructure. The illustrated rim header design is universal in nature and can be inverted to connect to itself in a perpendicular manner.
FIGS. 21A through 21D illustrate a gable wall stud shown with an overall height of 13.75 units by a width of 4.5 units by 1.125 units thick. The stud set or “twin studs” provide a unique wall frame pattern exclusive to the system. The twin stud shown in (FIGS. 21A through 21D) consists of two studs 1.125 units×4.5 units×13.75 units. The identical studs are both pierced with repetitive holes that provide both connection points for wall sub panels as shown in FIGS. 24A through 24F. The stud set is specifically designed to provide connection points for the gable rafters (FIGS. 11A through 11D) to the rim header while forming a wall frame similar to others shown within the system. The twin studs are joined by a series of equally spaced cylinders. These cylinders are integral and positioned horizontally between the wall studs sets. Studs are typically placed in pairs. The ends are specifically shaped with a triple profile notch to only allow them to fit into the pre-spaced opposing notches on the floor joists. This pre-spacing insures for exact placement within the grid every time.
FIGS. 22A through 22D illustrate a gable wall stud, shown with overall height of 21.75 units by a width of 4.5 units by 1.125 units thick per plate. The stud set or “twin studs” provide a unique wall frame pattern exclusive to the system. The twin stud shown in (FIGS. 22A through 22D) as shown is assembled from two studs 1.125 units×4.5 units×21.75 units. The identical stud plates are both pierced with repetitive holes that provide connection points for wall sub panels (FIGS. 24A through 24F). The stud set is also specifically designed to provide connection points for the gable rafters (FIG. 11) to the rim header while forming a wall frame similar to others shown within the system. The twin studs are joined by a series of equally spaced cylinders. These cylinders are integral and positioned horizontally between the wall studs sets. Stud plates are typically placed in pairs. The ends are specifically shaped with a triple profile notch to allow them to fit into the pre-spaced opposing notches on the floor joists. This pre-spacing insures for exact placement within the grid every time.
FIGS. 23A through 23D illustrate a gable wall stud with an overall height of 29.75 units by a width of 4.5 units by 1.125 units thick per plate. The stud plate set or “twin studs” provide a unique wall frame pattern exclusive to the system. The identical studs are both pierced with repetitive cut outs that provide both connection points for wall braces and sill components as well as provide horizontal chase ways for pipes and wires up to 1.5 units in diameter. The twin studs are joined by a series of equally spaced cylinders. These cylinders are integral and positioned horizontally between the wall studs sets. Stud plates again are typically placed in pairs. The ends are specifically shaped with a triple profile notch to only allow them to fit into the pre-spaced opposing notches on the upper and lower rim headers (FIGS. 13A through 13D). This pre-spacing insures for exact placement within the grid every time. The ends of the studs are secured by pinning through the perpendicular joists or interior soffit beam component, which they flank. This system insures the wall structure is tied to the floor at every stud. Additionally the studs are shaped to allow for penetrations of various mechanical systems (i.e.: plumbing and electric). The spacing of the twin studs also provides for perpendicular connectors, which strengthen the entire assembly while also providing connection points for wall sheathing assemblies. The wall system is created to offer endless variation within both a vertical (for example in 12 unit increments) grid and horizontal grid (for example in 24 units×24 unit increments). The wall studs are also designed to receive pre-made lateral re-enforcing braces as well as post tensioning cables if needed.
FIGS. 24A through 24F illustrate a wall sub panel shown as 24 units in width by 12 units in height by 0.5 units in thickness. It has two clips on each end that serve to hook into place in a parallel manner to the wall studs (FIGS. 20A through 20D). The component is designed to be a universal style wall panel, placed first running along the wall/floor base and then being stacked above. It is secured in place via placing in between twin studs and hooking over horizontal rods and sliding downward until firmly seated. The panel features 2 integral clip/hook configurations located on the panel sides that face down toward the primary roof plane. This shape acts as a guide, spacer and joining mechanism for associated components. The top surface of the sub panel features key hole shaped voids spaced to occur repetitively ever 12 units horizontally and every 6 units vertically to facilitate connection of various wall-finishing systems. The sub-panel also has a unique edge profile that when placed side by side form additional larger key hole shaped openings that both allow for penetration of wiring from exterior fixtures as well as connection points for additional surface panels and or treatments.
FIGS. 32A through 32E and 33A through 33B show several views of a ring truss assembly 170 including upper chords 172, lower chords 174, a center truss ring 176, flanking truss rings 178, saddles 180, and in the case of FIGS. 32A through 32F showing a more complex design horizontal tension members 182 and a vertical tension member 184.
The overall size of the ring truss 170 is dependent on the decided pitch of the roof and span. The truss system is unique because unlike many trusses it is specifically designed for onsite assembly and placement by two people. There are four primary components that work together to form the illustrated adjustable ring truss: an adjustable truss saddle, two bottom chords, two upper chords, and truss rings.
The saddle is the first component placed with a notch identical to the floor joist notch. This will fit flush and square into a modified rim header with joist type notches. The saddle is shown with an overall width of 36 units. This shape in addition to providing key connection points also forms the exterior overhang in the interior soffit line. The truss top chords are also designed with a profile that allows them to mix and match with the rafter design and roof panel system. Another feature is the small size of each component that allows the system to be flat packed and transported in small, manageable pieces.
The upper and lower chords are attached at the saddle or node using a pin system. There are two sets of holes at the hinge end of the lower chords. The hinge end of the lower chord is lifted to the saddle. The exterior or outside holes are pinned. The process is repeated with the second lower chord. The truss ring is pinned to the opposite ends or interior ends of the chords, forming the desired pitch. The lower chords are lifted into the horizontal position and braced in the horizontal position. The second pin is inserted into the lower chord. The interior holes on the hinge end of the lower chords are pinned. The upper chords are lifted into place. The interior side of the upper chords are pinned to the truss ring while the exterior sides rest in the truss saddle. The exterior holes on the upper chord are pinned to the corresponding holes on the truss saddle. To complete the process, a second adjustable truss system is built on the opposite side. The two systems meet at the center. In the figure shown it will create a 288-unit clear span.
The upper chord is shown as a single component comprised of two identical plates that are 168 units in length by 6 units in depth by 1.125 units in thickness. The upper chord is an integral part of the adjustable ring truss. It is designed with two sets of attachment holes at either end of the piece. These attachment holes coincide with attachment holes in the truss saddle. The attachment holes are located at the topside of the chord approximately 6 units from the end and a main attachment point in the vertical center of the chord approximately 6 units from the end of the chord. The opposite end of the upper chord is also designed with a series of holes and cut outs. The cut outs are shaped to provide a simple method for securing the truss ring to the upper chord. The additional holes are aligned with holes on the roof sub panel clips (FIGS. 5, 10, 17) to provide securing points where panels are pinned to rafters. This upper chord component like all other components is designed and shaped specifically to be interdependent on its associated parts. The overall sizes and dimensions can change as long as the proportions remain. This design feature creates a true assembly system that provides built-in controls to prevent against improper placement of most components.
The lower chord is shown as a single component that is 142.8 units in length by 6 units in depth by 1.125 units in thickness. The lower chord is an integral part of the adjustable ring truss. It is designed with two sets of attachment holes. These attachment holes coincide with attachment holes in the truss saddle. The attachment holes are located at the topside of the rafter approximately 6 units from the end and a main attachment point in the vertical center of the chord approximately 6 units from the end of the chord. The opposite end of the upper chord is also designed with a series of holes and cut outs. The cut outs are shaped to provide a simple method for securing the ring to the upper chord. This lower chord component like all other CERAS components is designed and shaped specifically to be interdependent on its associated parts. The overall sizes and dimensions can change as long as the proportions remain. This design feature creates a true assembly system that provides built-in controls to prevent against improper placement of most components.
The adjustable ring truss saddle is shown as 36 units wide by 18 units in height. The assembly is constructed with three 0.75-unit flat pieces. The saddle features unique three-dimensional underside cut-outs that allow for insertion perpendicularly to the modified rim header creating the node or truss saddle. The saddle is the attaching point and guide for the lower and upper chords of the adjustable ring truss.
The primary function of the assembly is to provide a base and elevation guides for the adjustable ring truss system. The saddle is designed with a series of pre-made holes to assist in proper placement of upper and lower chords.
FIGS. 33A and 33B shows a simpler ring truss
The assemblies of plates in the various figures optionally can include various additional features, for example the following.
For example, as previously explained, the first and second major faces of the plates can be congruent and registered.
A variety of different types of fasteners can be used for joining the plates at their major faces (e.g. bolts and nuts like 142, 144). Optionally, as illustrated, the fasteners (e.g. 142, 144) can be hollow, providing an aperture through the plates when they are assembled with the fasteners.
As mentioned, in any embodiment of crossing parts a crossing notch (146-150), also known as a field notch in this specification, can be provided in a major face of one of the plates for receiving a corresponding field notch of a perpendicular plate or building component assembled from plates. In one embodiment, a field notch of a plate can extend one half of the height of the plate. As illustrated, the field notches, or any of them, can be centered between a pair of butting notches in the same major face of a plate. This allows the studs to be supported at the strongest point in the joist system, where two joists cross.
Optionally, at least some of the notches and tongues can be butting notches and tongues for receiving corresponding butting tongues and notches on an end of a perpendicular part.
Optionally, the plates of joists and beams can have notches on a lower portion at each end to engage a vertical web of a foundation chair.
Optionally gable rafters (FIGS. 11A through 11D) can be adapted by extension of the center plate to define one or more tabs (152 or 154) projecting laterally for securing the plate to an adjacent structural member (e.g. 11).
The present technology allows for economical manufacturing. Parts can be manufactured at minimal cost and under control and high quality. The components would currently by cut from 4×8 foot (1.2 by 2.4 meter) sheets that would feed into a CNC router or laser cutter. These machines can cut up to 400 inches (about 10 meters) per minute and within 1000th inch (25 microns) accuracy. There are many types of materials available in these 4×8 foot (1.2 by 2.4 meter) sheets which allows the use of different strengths and types of material, for example 23/32-inch (1.8 cm.) thick Advantech® wood structural panel material. The triple plate or ply system illustrated in this disclosure also offers the ability to mix and match materials and makes reducing weight or increasing member strength more viable.
Another benefit gained from the compound or three-ply or three plate method is that it is much easier to create male/female type connections for extending a beam or joist. Even evolving the system to make site built trusses is logical with an inner profile and two outer profiles.
While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art and practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.
