Patent Publication Number: US-2013227906-A1

Title: Systems and methods for constructing a building structure

Description:
FIELD 
     This application relates generally to building systems. 
     BACKGROUND 
     Construction of a building structure generally involves a lengthy and complicated process, and requires multiple professionals in different fields to get involved. In existing process, an architect would design the building. Then the architect would provide the architectural plan to engineers (e.g., civil engineers, electrical engineers, mechanical engineers, etc.) to design the various components of the building. When a set of construction plans from the various professionals is completed, the plans are then provided to construction contractors, who then construct the building according to the construction plan. Applicant of the subject application determines that such process may be inefficient and not cost effective. 
     Also, before or during the construction of the building, if an owner of the building wishes to change the configuration of the building, the above process may need to be repeated, thereby involving multiple professionals, and causing a significant delay in the process. 
     In addition, after the building is constructed, if the owner wishes to change the configuration of the building, the above process may also need to be repeated, which may also be costly and inefficient. Also, changing the configuration of the building after it is constructed may require removal of some building components in a destructive manner. Thus, the removed components are not and cannot be re-used for later construction. Applicant of the subject application determines that it may be desirable to have a building system that would allow components of a building structure to be selectively removed in a non-destructive manner so that the components may be re-used if desired. 
     SUMMARY 
     In accordance with some embodiments, a system having a beam having a first end, a second end, and a longitudinal axis extending between the first end and the second end, wherein the first end is offset relative to the longitudinal axis in a first direction, and wherein the second end is offset relative to the longitudinal axis in a second direction that is opposite of the first direction. 
     In accordance with other embodiments, a building system includes a connector having a first plate having a first opening for connection to a first beam and a second opening for connection to a first column, and a second plate having a third opening for connection to a second beam and a fourth opening for connection to the first column, wherein the first plate is oriented relative to the second plate at 90°, wherein the first opening at the first plate and the third opening at the second plate are located at a first elevation with respect to the connector, wherein the second opening at the first plate is located at a second elevation with respect to the connector, wherein the fourth opening at the second plate is located at a third elevation with respect to the connector, and wherein the second plate does not include any opening at the second elevation. 
     Other and further aspects and features will be evident from reading the following detailed description of the embodiments, which are intended to illustrate, not limit, the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate the design and utility of embodiments, in which similar elements are referred to by common reference numerals. These drawings are not necessarily drawn to scale. In order to better appreciate how the above-recited and other advantages and objects are obtained, a more particular description of the embodiments will be rendered, which are illustrated in the accompanying drawings. These drawings depict only typical embodiments and are not therefore to be considered limiting of its scope. 
         FIG. 1  illustrates a building system in accordance with some embodiments; 
         FIG. 2A  illustrates an embodiment of a beam in accordance with some embodiments; 
         FIG. 2B  illustrates an embodiment of a beam in accordance with some embodiments; 
         FIG. 2C  illustrates an embodiment of a beam in accordance with some embodiments; 
         FIG. 3  illustrates components of a connector in accordance with some embodiments; 
         FIG. 4  illustrates a cross sectional view of the connector of  FIG. 1  in accordance with some embodiments; 
         FIG. 5  illustrates another cross sectional view of the connector of  FIG. 1  in accordance with some embodiments; 
         FIGS. 6A and 6B  illustrate another connector in accordance with other embodiments; 
         FIG. 7A  illustrates a column being detachably coupled to a beam in accordance with some embodiments; 
         FIG. 7B  illustrates a truss system being detachably coupled to a beam in accordance with some embodiments; and 
         FIG. 8  illustrates a building structure constructed using a building system in accordance with some embodiments. 
     
    
    
     DESCRIPTION OF THE EMBODIMENTS 
     Various embodiments are described hereinafter with reference to the figures. It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are represented by like reference numerals throughout the figures. It should also be noted that the figures are only intended to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention or as a limitation on the scope of the invention. In addition, an illustrated embodiment needs not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular embodiment is not necessarily limited to that embodiment and can be practiced in any other embodiments even if not so illustrated. 
       FIG. 1  illustrates a building system  10  in accordance with some embodiments. The building system  10  includes a first beam  12   a,  a second beam  12   b,  a third beam  12   c,  and a fourth beam  12   d.  The building system  10  also includes a connector  14  to which the beams  12   a - 12   d  are detachably coupled. As shown in the figure, the building system  10  further includes a first column  16   a  and a second column  16   b  that are configured to detachably couple to the connector  14 . In other embodiments, the system  10  may include additional beams  12 , connectors  14 , and columns  16 . Also, in other embodiments, the beams  12 , connectors  14 , and/or columns  16  may come with different sizes (e.g., one column  16  may be longer than another, one beam  12  may be longer and/or deeper than another, etc.). 
       FIG. 2A  illustrates a beam  12  in accordance with some embodiments. The beam  12  may be any of the beams  12   a - 12   d  in  FIG. 1 . The beam  12  has a longitudinal axis  200 , a first end  202 , and a second end  204 . The first end  202  is offset from the longitudinal axis  200  in a first direction  206 , and the second end  204  is offset from the longitudinal axis  200  in a second direction  208  that is opposite of the first direction  206 . In the illustrated embodiments, the beam  12  is formed using a first beam portion  220  and a second beam portion  222 . Each of the portions  220 ,  222  may be a timber member, a steel member, or member made from other types of materials. In other embodiments, each of the portions  220 ,  222  may be a composite member. Also, instead of having a rectangular cross section shown, in other embodiments, each of the beam portions  220 ,  222  may have other cross sectional shapes, such as a L-shape, an I-shape, or other shapes. 
     As shown in the figure, the first beam portion  220  has the first end  202 , an opposite end (a first opposite end)  224 , and a body  226  extending between the ends  202 ,  224 . Similarly, the second beam portion  222  has the second end  204 , an opposite end (a second opposite end)  234 , and a body  236  extending between the ends  204 ,  234 . The first beam portion  220  and the second beam portion  222  are offset relative to each other in a direction of the longitudinal axis  200 , so that the first end  202  of the first beam portion  220  extends past the second opposite end  234  of the second beam portion  222 , and the second end  204  of the second beam portion  222  extends past the first opposite end  224  of the first beam portion  220 . 
     Also, as shown in the illustrated embodiments, the beam  12  includes a plate  250  sandwiched between the first and second beam portions  220 ,  222 . The plate  250  may be a plywood, a metal (e.g., steel, aluminum) plate, or otherwise made from a composite material. In other embodiments, instead of having a plate  250  that extends along the majority of the length of the beam  12 , the beam  12  may include a plurality of plates  250  that are placed along the length of the beam  12  to provide various spacing. 
     In the illustrated embodiments, the first beam portion  220 , the plate  250 , and the second beam portion  222  are detachably coupled to each other using fasteners  252 , which may be screws or bolts. In other embodiments, the first beam portion  220 , the plate  250 , and the second beam portion  222  may be non-detachably secured to each other (i.e., secured in a relatively more permanent manner so that separation of the components would require at least some destruction to occur), such as by using nails and/or adhesive. Also, in other embodiments, instead of having two rows of fasteners  252 , the beam  12  may include one row of fasteners  252 , or more than two rows of fasteners  252 . 
     Forming the beam  12  using two beam portions  220 ,  222  is advantageous because it allows the two beam portions  220 ,  222  to be individually detached from the rest of the building as one technique of removing the beam  12  from the rest of the building. In another technique, the beam  12  may be removed from the rest of the building without taking apart the two beam portions  220 ,  222  relative to each other. 
     In other embodiments, the beam  12  may not include a plate between the two beam portions  220 ,  222  ( FIG. 2B ). Instead, the beam portions  220 ,  222  may be directly secured to each other. Also, in further embodiments, instead of forming the beam  12  using the two beam portions  220 ,  222 , the beam  12  may be formed using a single member with parts of the ends removed to form the offset configuration shown at each of the ends  202 ,  204  of the beam  12  ( FIG. 2C ). 
       FIG. 3  illustrates components of the connector  14  of  FIG. 1  in accordance with some embodiments. As shown in  FIG. 1 , the connector  14  has a cross shape cross section. In some embodiments, the connector  14  may be formed from a first plate  300  and a second plate  302  ( FIG. 3 ). The first plate  300  includes a slot  310  extending from a side  312  of the first plate  300 , a first plate portion  314  on one side of the slot  310 , and a second plate portion  316  on the other side of the slot  310 . Similarly, the second plate  302  includes a slot  320  extending from a side  322  of the second plate  322 , a first plate portion  324  on one side of the slot  320 , and a second plate portion  326  on the other side of the slot  320 . In the illustrated embodiments, the first plate  300  and the second plate  302  are secured to each other using the slots  310 ,  320 , and the securing is achieved without using any weld or fasteners. 
     In other embodiments, the first and second plates  300 ,  302  may be secured to each other using weld and/or fasteners. Also, in other embodiments, either one or both of the plates  300 ,  302  may be formed using two plate elements. For example, the first plate  300  and the second plate  302  may not include the slots  310 ,  320 , and the second plate  302  may include two separate plate elements that are secured (e.g., by weld) to opposite surfaces of the first plate  300 . 
     Also, as shown in the figure, the first plate portion  314  at the connector  14  has openings  420   a,    420   b  configured (e.g., sized and/or shaped) for allowing the first beam  12   a  to be detachably coupled thereto, and the second plate portion  316  has openings  420   c,    420   d  configured for allowing the second beam  12   b  to be detachably coupled thereto. Similarly, the first plate portion  324  at the connector  14  has openings  420   e,    420   f  configured for allowing the third beam  12   c  to be detachably coupled thereto, and the second plate portion  326  has openings  420   g,    420   h  configured for allowing the fourth beam  12   d  to be detachably coupled thereto. 
     In the illustrated embodiments, the first beam  12   a  is detachably coupled to the first plate portion  314  of the first plate  300 , the second beam  12   b  is detachably coupled to the second plate portion  316  of the first plate  300 , the third beam  12   c  is detachably coupled to the first plate portion  324  of the second plate  322 , and the fourth beam  12   d  is detachably coupled to the second plate portion  326  of the second plate  322 . Also, the first column  16   a  is detachably coupled to a bottom of the connector  14 , and the second column  16   b  is detachably coupled to a top of the connector  14 . 
     As shown in  FIGS. 1 and 4 , the first end  202  of the beam  12   a  has two openings  400   a,    400   b  for accommodating respective fasteners  402   a,    402   b.  The fasteners  402   a,    402   b  are for detachably coupling the beam  12   a  to the connector  14 . The system  10  also includes additional fasteners  402  (not shown) for detachably coupling the beams  12   c - 12   d  to the connector  14  in a similar manner as that of beam  12   a.  The fasteners  402   a,    402   b  may be bolts, screws, or other types of connection devices. Each of the openings  400   a,    400   b  has an axis  410  extending therethrough, wherein the axis  410  forms an acute angle  412  with the longitudinal axis  200  of the beam  12   a.  The acute angle  412  may be any value that is between 30° and 80°, and more preferably between 45° and 75° (such as) 60°. Each of the openings  420   a,    420   b  at the first plate portion  314  has an axis  422  extending therethrough, wherein the axis  422  forms an acute angle  424  (which has the same value as the acute angle  412 ) with the first plate portion  314 . The other plate portions  316 ,  324 ,  326  have openings  324  with similar configuration as that of the openings  324  at the first plate portion  314 . 
     As shown in  FIG. 4 , the openings  420   a,    420   b  at the connector  14  correspond with the respective openings  400   a,    400   b  at the beam  12   a,  so that the fasteners  402   a,    402   b  can extend through the respective openings  400   a,    400   b  at the beam  12   a  to reach the respective openings  420   a,    420   b  at the connector  14 . Each fastener  402  may have threads at the distal end for mating with threads at the opening  420  at any of the plate portions  314 ,  316 ,  324 ,  326 . The skewed openings  420   a,    420   b  at the connector  14  and the skewed openings  400   a,    400   b  at the beam  12   a  allows the fasteners  402   a,    402   b  to be installed at an acute angle. Such configuration is advantageous because when all four beams  12   a - 12   d  are installed, their respective fasteners are exposed and are accessible so that any of the beams  12   a - 12   d  may be selectively removed in a non-destructive manner when desired. 
     As shown in the figure, each opening  400  is countersunk so that the fastener  402  does not protrude above the surface of the beam  12 . In other embodiments, each opening  400  may not be countersunk, and the fastener  402  may protrude above the surface of the beam  12 . 
     Although the end  202  of beam  12   a  is illustrated as having two openings  400  for accommodating two fasteners  402 , in other embodiments, the end of the beam  12  may have only one opening  400  for accommodating one fastener  402 , or more than two openings  400  for accommodating more than two fasteners  402 . 
     It should be noted that the beams  12   b - 12   d  are coupled to the respective plate portions at the connector  14  in the same manner as the beam  12   a  discussed herein. Also, any of the beams  12   b - 12   d  may have the same configuration as any of the embodiments of beam  12   a  described herein. 
     Returning back to  FIG. 1 , the column  16   a  includes an opening  500  at one end  502  of the column  16   a,  wherein the opening  500  has a size and shape that correspond with the cross sectional shape of the connector  14 . The column  16   a  also includes openings  504   a - 504   d  for accommodating fasteners  510   a - 510   d,  respectively. During use, the lower end of the connector  14  may be placed inside the opening  500 , and the fasteners  510   a - 510   d  may be used to detachably couple the column  16   a  to the connector  14 . The connector  14  has openings  360   a - 360   d  ( FIG. 3 ) for receiving the respective fasteners  510   a - 510   d  that have been inserted through the respective openings  504   a - 504   d  at the column  16   a.    FIG. 5  illustrates a cross section of the connector  14  at the location where the column  16   a  is coupled to the connector  14 . As shown in the figure, each fastener  510  extends through the column  16   a  from one side and exits at another side. A nut is placed at the exit end of the fastener  510  to anchor the fastener  510  so that the fastener  510  is prevented from sliding off the column  16   a.  In some embodiments, each fastener  510  may be a bolt, a screw, or another type of connection device. 
     As shown in the figure, each opening  504  at the column  16  is countersunk so that the fastener  510  does not protrude above the surface of the column  16 . In other embodiments, each opening  504  may not be countersunk, and the fastener  510  may protrude above the surface of the column  16 . 
     Referring again to  FIGS. 1 and 3 , the connector  14  also includes four openings  360   e - 360   h  at the top end of the connector  14  for allowing the top column  16   b  to detachably couple to the connector  14  in a similar manner as that of column  16   a.    
     In the illustrated embodiments of  FIG. 3 , the openings  420   a - 420   h  at the middle portion of the connector  14  for connection to the beams  12   a - 12   d  have the same spacing  480  (e.g., ¾ inch) from the side edge of the connector  14 . Such configuration is advantageous because it allows any of the beams  12   a - 12   d  to interchangeably be coupled to different sides of the connector  14 . In other embodiments, the spacing may be different from the example shown. For example, in other embodiments, the spacing may be more than ¾ inch or less than ¾ in. 
     Also, the openings  360   a - 360   d  at the bottom end of the connector  14  for connection to the column  16   a,  and the openings  360   e - 360   h  at the top end of the connector  14  for connection to the column  16   b,  have the same spacing  482  (e.g., 2 inches) from the side edge of the connector  14 . Thus, the spacing  482  for the column attachment is different from the spacing  480  for the beam attachment. Such configuration is advantageous because it will prevent any of the beams  12  from being accidentally installed at the bottom end or the top end of the connector  14 . In other embodiments, the spacing  482  may be the same as the spacing  480 . Also, in other embodiments, the spacing  482  may be less than 2 inches or more than 2 inches. 
     Furthermore, as shown in  FIGS. 1 and 3 , the openings  360   a,    360   b  at the first plate  300  are located at different elevation from the openings  360   c,    360   d  at the second plate  302 . Also, the first plate  300  does not have any openings that are at the same elevation as the openings  360   c,    360   d  at the second plate  302 , and the second plate  302  does not have any openings that are at the same elevation as the openings  360   a,    360   b  at the first plate  300 . Such configuration is advantageous because it allows the two fasteners  510   a,    510   b  to couple the column  16  to the connector  14  without interfering with the fasteners  510   c,    510   d.  Such configuration is also advantageous in that it reduces the number of openings at the column  16  that are required to be made (i.e., when compared to the configuration that has eight openings with four openings at the elevation of opening  360   a,  and the other four openings at the elevation of opening  360   c ) in order to secure the column  16  to the connector  14 . This in turn prevents the column  16  strength from being weakened too much due to high number of openings made at the column  16 . 
     It should be noted that the configuration of the connector  14  is not limited to the example shown, and that the connector  14  may have different configurations in different embodiments. For example, in other embodiments, the number of openings  420  for connection to a beam  12  at each side of the connector  14  may be less than two (e.g., one), or more than two. Also, in other embodiments, the number of openings  360  for connection to a column  16  at each side of the connector  14  may be more than one. In addition, in other embodiments, the spacing for the opening(s)  420  from the side edge of the connector  14  may be the same as that for the opening(s)  360  from the side edge of the connector  14 . In further embodiments, the slot  310  at the first plate  300  may be extended from the top edge  313  (instead of the bottom edge  312 ), and the slot  320  at the second plate  322  may be extended from the bottom edge  323  (instead of the top edge  322 ). In still further embodiments, the lengths of the slots  310 ,  320  may be different. 
     In the above embodiments, the connector  14  is configured to allow two columns  16  to be detachably coupled to the top and bottom ends of the connector  14 . In other embodiments, the connector  14  may be configured to allow one column  16  to be detachably coupled to the bottom end of the connector  14 . In such cases, the connector  14  may not include the top portion that is for detachably coupling to the column  16   b.    FIG. 6A  shows the connector  14  that is the same as the embodiments of  FIG. 1 , except that the connector  14  does not have any part for allowing a top column  16  to be detachably coupled thereto. As shown in the illustrated embodiments, the connector  14  has a cross shape cross section, with four plate portions  314 ,  316 ,  324 ,  326 . The four plate portions  314 ,  316 ,  324 ,  326  allow up to four beams  12  to be detachably coupled thereto. However, in other embodiments, there may be one, two, or three beams  12  connected to the connector  14 .  FIG. 6B  illustrates components of the connector  14  of  FIG. 6A . The embodiment of the connector  14  of  FIG. 6  may be used to connect beams  12  at the roof level, or at other location where there is no top column  16 . 
     As discussed, in some embodiments, the beam  12  may include one or more plates  250  between beam portions  202 ,  204  ( FIG. 2A ). In some cases, the plates  250  may be spaced along the length of the beam  12  so that they define one or more spacing  251  between them ( FIG. 7A ). Such configuration allows another building component  700  to be inserted into the spacing  251  between the adjacent plates  250  that are sandwiched between beam portions  202 ,  204 . In the illustrated embodiments, the component  700  is a connector plate for connecting a column  702  to a part of the beam  12  that is away from the ends of the beam  12 . In other embodiments, the spacing  251  between the beam portions  202 ,  204  may optionally allow truss connectors  710   a,    710   b  to be inserted therethrough, wherein each of the truss connectors  710   a,    710   b  is coupled to a column  16  at one end, and to a truss member  712   a / 712   b  at the other end ( FIG. 7B ). In further embodiments, the spacing  251  between the beam portions  202 ,  204  may allow other building component(s) (e.g., structural member(s), or architectural member(s) such as a panel, a window, a door, a flooring, etc.), to be coupled to the beam  12 . 
       FIG. 8  illustrates a building structure  800  that is constructed using the building system  10  of  FIG. 1  in accordance with some embodiments. As shown in the figure, the beams  12 , columns  16 , and connectors  14  are used to construct the frame for the building structure  800 . The building system  10  further includes foundation  802 , and foundation posts  803 . Each foundation  802  may include a concrete footing with a metal connector for allowing the foundation post  803  to detachably couple thereto. Each foundation post  803  includes a top end for detachably couple to a bottom end of the connector  14 . 
     As shown in the illustrated embodiments, the building structure  800  further includes roof panels  804 , window frame(s)  810 , and wall panel(s)  820 . The wall panel  820  is illustrated as having two large window openings. In other embodiments, the wall panel  820  may have one window opening, or no window opening. Also, in further embodiments, the wall panel  820  may be secured to the outside face of the beams  12  and columns  16  so that the wall panel  820  may be used to completely cover up the framing formed by the beams  12  and columns  16 . The roof panels  804  are configured to detachably couple to the beams  12  of the building structure  800 . Also, the window frame(s)  810  and the wall panel(s)  820  are configured to detachably couple to the frame formed by the beams  12  and columns  16  of the building structure  800 . In further embodiments, the building system  10  may further includes other building components (such as interior wall panels, floor panels, ceiling panels, etc.) that are configured to detachably couple to the framing formed by the beams  12  and columns  16 . The detachably coupling of the components (e.g., components  802 ,  803 ,  804 ,  810 ,  820 , interior wall panels, floor panels, ceiling panels, etc.) to the building structure  800  may be accomplished using fasteners, such as screws, bolts, clips, or other types of connection devices. 
     As illustrated in the above embodiments, the building system  10  is advantageous because it allows the building structure  800  to be designed and constructed efficiently and cost effectively. Because the building structure  800  can be assembled easily using the building system  10 , the design and construction of the building structure  800  may not require multiple professionals to get involved, and an owner of the building may design and construct the building structure  800  himself/herself. Also, the building system  10  is advantageous because it allows any of the components (e.g., beam(s)  12 , connector(s)  14 , column(s)  16 , post(s)  803 , panel(s)  804 , window frame(s)  810 , wall panel(s)  820 , interior wall panel(s), floor panel(s), ceiling panel(s), etc.) of the building to be conveniently removed in a non-destructive manner from the rest of the building when desired. If example, if a user of the system  10  wishes to change the configuration of the building, the user may selectively remove some of the components from the building, and re-use at least some of the components to form a different configuration for the building  800 . Also, in some cases, the entire building  800  made from the building system  10  may be disassembled at one location, and be re-assembled in a different location. Furthermore, if a user of the building system  10  wishes to expand a building (such as adding a room  830 , as represented by the dashed line in the figure), the user may obtain additional components (e.g., beam(s), connector(s)  14 , column(s)  16 , etc.), and add those to the already formed building  800 . Thus, embodiments of the building system  10  allow scalability of the building to be accomplished in a cost effective and efficient manner. In other cases, the building  800  formed using the building system  10  may also be scaled down (downsized) by removing some of the components in a non-destructive manner. 
     Also, as illustrated in the above embodiments, the building system  10  is advantageous because it allows an owner of the building to selectively change the configuration at any time (e.g., before, during, and/or after the construction of the building). Because the owner can himself/herself decide how the configuration of the building is to be changed, purchase the building components, and assemble the building components himself/herself, the changing of the configuration of the building does not require multiple professionals to get involved. This in turn, allows the configuration of the building to be changed in a cost effective and efficient manner. 
     It should be noted that the various dimensions shown in some of the figures are exemplary dimensions, and that in other embodiments, the components may have different sizes from that illustrated in the figures. 
     Also, it should be noted that the term “first” (as in “first plate portion”, “first beam”, “first opening”, for examples), and the term “second” (as in “second plate portion”, “second beam”, “second opening”, for examples), are used to refer to different things, and do not necessarily refer to the order of things. 
     Although particular embodiments have been shown and described, it will be understood that they are not intended to limit the present inventions, and it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the present inventions. The specification and drawings are, accordingly, to be regarded in an illustrative rather than restrictive sense. The present inventions are intended to cover alternatives, modifications, and equivalents, which may be included within the spirit and scope of the present inventions as defined by the claims.