Patent Publication Number: US-2022235549-A1

Title: Wall roof truss building system

Description:
This application claims the benefit of U.S. Provisional Patent Application No. 63/140,345, filed on Jan. 22, 2021, the contents of which are herein incorporated by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     Embodiments related to the present disclosure are related to general building construction. More specifically, the present disclosure relates to structural elements and building components. 
     BACKGROUND 
     Residential buildings are typically built by hand-framing lumber to make vertical exterior walls. After construction of the vertical exterior walls, roof trusses are set to bear on top to the exterior walls. The lumber chosen for this typical building method also determines the thickness of the walls. Normally, the lumber chosen for the exterior walls is 2×6 nominal inches, resulting in an exterior wall thickness of anywhere between, 8 and 12 nominal inches depending on exterior siding. Residential insulation materials are often engineered to account for this; because heat transfer is inversely related to the thickness of the wall, materials with lower thermal conductivity is often used to control for large temperature gradients between the exterior and interior of the residential unit. Lower thermal conductivity materials light enough for construction are often expensive and come from non-renewable sources. The vertical nature of the walls also often calls for the use of gutters; without gutters, in some instances water from rain or melting snow adheres to the vertical walls due to surface tension, and water travels down the walls concentrating at, and damaging, the foundation and/or cellar. 
     Hand-framing the vertical exterior walls often involves skilled on-site construction teams. Typically, the nominal lumber is transported to the site, cut to specification, connected together by use of a pneumatic nail gun, and erected. Because materials are relatively inexpensive, speed becomes a primary objective on the job site, thus creating waste at the jobsite in some cases. 
     Alternative methods of residential construction have been implemented, such as metal and concrete. Metal, and metal-concrete construction techniques are typically used in commercial or apartment buildings, but they remain cost inhibitive for most single-family dwellings due to materials and highly skilled labor requirements; these methods can also significantly add to carbon dioxide emissions. Environmentally friendlier options such as poured-earth, geodesic domes, log cabins, or cobb homes are often not scalable in construction and can limit architectural freedom in some cases. 
     BRIEF SUMMARY 
     Some embodiments of the present disclosure are related to a wooden frame truss that can be used in a modular fashion to quickly, and easily assemble a residential dwelling unit. Specifically, some embodiments relate to a four-sided frame truss wherein each wall and the roof is a truss, the trusses each having non-parallel chords, where in the outer chords of the wall trusses are arranged to create an overhang. As used herein the term chords is meant to encompass beams or other building elements that are used to construct a wall truss, truss, or other housing structure. In some cases, chords can include dimensional lumber, other wood beams such as I-beams, logs, or joists. Chords can also include beams or other building components made from other materials such as aluminum, steel or other suitable metal, plastic, composites, or other suitable material such as concrete, or combinations thereof. These embodiments solve the issue of water adhesion and allow the use of renewable, higher-thermal conductivity insulation materials. One embodiment of the wall roof truss building system described herein has walls arrange to create a roof pitch capable projecting water far from the structure. In some embodiments, the thickness of the wall allows for more insulate material, giving the possibility that the wall truss can be insulated with high thermal conductivity material and retain a substantially similar heat transfer coefficient to that of a traditionally built structure with low-thermal conductivity insulation material. Additionally, these embodiments sequester carbon due to their wood construction, and maintain a reduced cost. 
     Some embodiments of the present disclosure relate to a symmetrical residential dwelling unit, where each of the walls is substantially the same size, and connects to a roof element in a substantially similar fashion. Some embodiments of the present disclosure are related to a frame truss that is not symmetrical with respect to a vertical axis, where each of the two walls are different sizes and can attach to a roof element at different angles. Some embodiments of the present disclosure have a roof element that is made of a single beam; other embodiments include a roof element that is a truss. Some embodiments also include a hinge, or plurality of hinges, to allow the frame truss to be folded and transported to the build site. 
     Another embodiment of the current disclosure is a system of building a structure using frame trusses fabricated off-site. The frame trusses can be shipped to the jobsite, erected, and connected using pre-made connector-pieces with friction fittings. In some embodiments the connector pieces can be used to connect multiple frame trusses together using only friction. The connector piece can be a sheet good, girt, purlin, or beam. In some embodiments the connector-piece is a box, allowing a window or doorway to be framed in between the frame trusses. The building method may include different sized frame trusses for various wings of the residential structure, and can be constructed simply using the connector pieces. The off-site fabrication and ease of assembly reduce build time and costs, according to some embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a front elevation view of a wall roof truss building system, according to embodiments of the present disclosure. 
         FIG. 2  illustrates a front elevation view of a wall roof truss building system, according to embodiments of the present disclosure. 
         FIG. 3  illustrates a side perspective view of a template plate groove, according to embodiments of the present disclosure 
         FIG. 4A  illustrates a front elevation view of a wall roof truss building system incorporating a hinge, according to embodiments of the present disclosure. 
         FIG. 4B  illustrates a side perspective of the hinge of  FIG. 4A , according to embodiments of the present disclosure. 
         FIG. 5  illustrates a front elevation view of a wall roof truss building system incorporating a hinge, according to embodiments of the present disclosure. 
         FIG. 6  illustrates a perspective view of a wall roof truss building system with a perpendicular blocking element, according to embodiments of the present disclosure. 
         FIG. 7  illustrates a perspective view of a wall roof truss building system with a diagonal blocking element, according to embodiments of the present disclosure. 
         FIG. 8  illustrates a perspective view of the perpendicular blocking element, according to embodiments of the present disclosure. 
         FIG. 9  illustrates a perspective view of the diagonal blocking element, according to embodiments of the present disclosure. 
         FIG. 10  illustrates a side view of a wall roof truss building system incorporating a diagonal blocking element, according to embodiments of the present disclosure. 
         FIG. 11  illustrates a top view of a wall roof truss building system incorporating a diagonal blocking element and a perpendicular blocking element, according to embodiments of the present disclosure. 
         FIG. 12  illustrates a side view of a wall roof truss building system incorporating a perpendicular blocking element, according to embodiments of the present disclosure. 
         FIG. 13  illustrates a perspective view of a connector piece, according to embodiments of the present disclosure. 
         FIG. 14  illustrates a perspective view of a connector piece, according to embodiments of the present disclosure. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. While the disclosure is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the disclosure to the particular embodiments described. On the contrary, the disclosure is intended to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure as defined by the appended claims. 
     DETAILED DESCRIPTION 
     Embodiments of the present disclosure include wall roof frame trusses where the walls of the frame are trusses, such that the exterior or outer part of the wall creates an overhang. 
     As shown in  FIG. 1 , in one embodiment, a wall roof truss building system (“WRTBS”)  100  includes a first wall  101 , and a second wall  102 , and a roof element  103 . The roof element  103  includes several roof chords  112 ,  113 ,  114 ,  115 ,  116 , and  117 . The first wall  101  includes an inner chord  104 , an outer chord  105 , and a template plate  106 . The inner chord  104  and outer chord  105  are configured to attach to the template plate  106 . The inner chord  104  and outer chord  105  of the first wall  101  are also configured to attach to the roof element  103 . The inner chord  104  and the outer chord  105  of the first wall  101  are non-parallel. The angle of the outer chord  105  creates an overhang at the intersection between the outer chord  105  and the roof chord  117 . The second wall  102  includes an inner chord  107 , and outer chord  108 , and a template plate  109 . The inner chord  107  and outer chord  108  are configured to attach to the template plate  109 . The inner chord  107  and outer chord  108  of the second wall  102  are also configured to attach to the roof element  103 . The inner chord  107  and the outer chord  108  of the second wall  102  are non-parallel. The angle of the outer chord  108  creates an overhang at the intersection between the outer chord  108  and the roof chord  116 . The inner chord  104  of the first wall  101 , and the inner chord  107  of the second wall  102  can be substantially parallel. The distance  110  between the upper portions of the inner  104  and outer chord  105  of the first wall is greater than the distance  111  between the lower portions of the inner  104  and outer chord  105 . 
     According to some embodiments, the elements  101 - 117  of the WRTBS  100  can be made of wood, metal, composite, polymers, or any combination thereof. The WRTBS elements  101 - 117  can be connected using plates made of metal, composite wraps, composite fittings, glue, or adhesive, or other connection mechanisms. 
     In some embodiments, as illustrated in  FIG. 2 , the WRTBS  100  includes a photovoltaic panel  203  lying flat on the roof chord  117  of the roof element  103 , where angle  204  of the roof chord  117  allows for an efficient incident angle with respect to sunlight exposure  250 . According to some embodiments, the outer chord  105  is arranged at an angle  206  optimized to reduce solar radiative heat transfer. Specifically, the outer chord  105  forms an acute angle  206  with respect to a ground surface outside of the dwelling, which can reduce direct sunlight exposure to first wall  101 . Angle  206  is formed between a horizontal surface (e.g., such as a flat underlying surface, or a ground surface) and outer chord  105 . According to some embodiments, the connection  207  between the roof chord  116  and the outer chord  108  facilitates flow of precipitation  251  off the roof element  103  at a trajectory that protects the siding and foundation of the WRTBS  100 . 
     In some embodiments, as illustrated in  FIG. 3 , the first and/or second template plate  106 ,  109  includes a base element  306 , and a groove  302  which may be formed in the base element  306 , to accommodate the inner chord  104 ,  107  and the outer chord  105 ,  108 . In some embodiments the inner chord  104 ,  107  and the outer chord  105 ,  108  are attached to the template plate  106 , 109  via a metal plate or bracket  305 . Groove  302  may be formed (e.g. by milling, carving, sawing, chiseling, or the like) directly into the base element  306 . Alternatively, groove  302  may be formed by or part of the bracket  305 , or formed by a combination of bracket  305  and base element  306 . Some embodiments include two brackets  305  on opposing sides of the chords  104 ,  107  and  105 ,  108 . Base element  306  in some embodiments is a footer, or an anchor, or otherwise coupled to or embedded within the ground, a foundation, or some other foundational or base element to which the WRTBS  100  is attached and/or stabilized. According to some embodiments, the chords  104  and  05  are rigidly or fixedly coupled to the base element  306 , for example via brackets  305 . 
     In some embodiments, as illustrated in the  FIG. 4A  and  FIG. 4B , the connection  401  between an inner chord  107  and the roof chord  116  includes a hinge  404 . The hinge includes a first hinge part  405  attached to the roof chord  116  and a second hinge part  407  attached to the inner chord  107 . The first hinge part  405  is rotatable with respect to the second hinge part  407 . This allows the second wall  102  to fold inward along  409  with respect to the roof element  103  when the outer chord  108  is disconnected from the roof chord  116  at connection point  207 . The dotted line in  FIG. 4A  shows a folded position  450  of the outer wall  102 , which facilitates ease of transportation of the WRTBS  100 . The hinge  404  may be made of metal or a composite. 
       FIG. 5  illustrates one embodiment in which a hinge  404  connects roof chord  112  to roof chord  114 , enabling the WRTBS  100  to be folded along direction  509 . The dotted line in  FIG. 5  shows a folded position of the left side of the WRTBS  100 . For example, the hinge  404  can be positioned at a mid-portion of the roof chord  112 , and an end portion of the roof chord  112  can detachably couple to the roof chord  116 . Accordingly, when the end portion of the roof chord  112  is detached from the roof chord  116 , the left portion of the WRTBS  100  can rotate inwards, facilitating ease of transportation. In some embodiments, the WRTBS  100  includes two hinges  404 ; one at the location shown in  FIG. 5 , and one at the location shown in  FIGS. 4A, 4B . In some embodiments, the WRTBS  100  includes additional hinges at other connection points to allow for additional folding. 
       FIG. 6  illustrates a partial view of a series of WRTBS  100  arranged in parallel to form the frame of a dwelling unit.  FIG. 6  shows three WRTBS  100  by way of illustration, however, some embodiments include additional WRTBS  100 . Each WRTBS  100  is attached to the first template plate  106 , as illustrated in detail  FIG. 3 . A perpendicular blocking element  80  is coupled to the inner chord  104  of multiple WRTBS  100  to provide structural support. In some embodiments, the perpendicular blocking element  80  is coupled to each inner chord  104  via a friction fitting, without the use of nails, brackets or other hardware. This allows the perpendicular blocking element  80  to be coupled to the WRTBS  100  using a mallet, for example, facilitating ease of construction. It is noted that, while  FIG. 6  illustrates the first wall  101 , the second wall  102  may have a similar arrangement as shown in  FIG. 6 . 
       FIG. 8  shows an isolated view of the perpendicular blocking element  80 . The perpendicular blocking element  80  includes notches  85 , each of which engages with an inner chord  104 ,  107 , of a respective WRTBS  100  via a friction fitting. In some embodiments, the perpendicular blocking element  80  is made of a composite material. In other embodiments the perpendicular blocking element  80  is made from other materials such as wood, aluminum, steel or other suitable metal, plastic, concrete, or combinations thereof.  FIG. 12  shows a side view of the perpendicular blocking element  80  engaging with inner chords  104 ,  107 . 
       FIG. 7  illustrates another partial view of a series of WRTBS  100  arranged in parallel to form the frame of a house. A diagonal blocking element  90  is coupled to the inner chord  104  of one WRTBS  100  and the outer chord  105  of an adjacent WRTBS  100  to provide structural support. In some embodiments, the diagonal blocking element  90  is coupled to the inner chord  104  and outer chord  105  via a friction fitting, without the use of nails, brackets or other hardware. This allows the diagonal blocking element  90  to be coupled to the WRTBS  100  using a mallet, for example, facilitating ease of construction. It is noted that, while  FIG. 7  illustrates the first wall  101 , the second wall  102  may have a similar arrangement as shown in  FIG. 7 . 
       FIG. 9  shows an isolated view of the diagonal blocking element  90 . The diagonal blocking element  90  includes two notches  95 . One notch  95  engages with an inner chord  104 ,  107 , of a WRTBS  100 , and the other notch  95  engages with an outer chord  105 ,  108  of an adjacent WRTBS  100 . In some embodiments, the diagonal blocking element  90  is made of a composite material. In other embodiments the diagonal blocking element  90  is made from other materials such as wood, aluminum, steel or other suitable metal, plastic, concrete, or combinations thereof.  FIG. 10  shows a side view of the diagonal blocking element  90  engaging with an inner chord  104 ,  107  and an outer chord  105 ,  108 . 
       FIG. 11  shows a top down view of a perpendicular blocking element  80 , a diagonal blocking element  90 , inner chords  104 ,  107 , and outer chords  105 ,  108 . 
       FIG. 13  illustrates a connector piece  702  which can be used in addition to or in lieu of the blocking elements  80 ,  90 . The connector piece  702  may connect the inner chords  104 ,  107  of multiple WRTBS  100 . Although the connector piece  702  is shown connecting inner chords  104 ,  107 , it may also be used to connect outer chords  105 ,  108 . In one embodiment, the connector piece  702  is attached to the chords  104 ,  107  via a plate  701 . In other embodiments, the connector piece  702  may be attached to the chords  104 ,  107  using a tie, a strap, or any other suitable attachment mechanism. 
     Some embodiments, as illustrated in  FIG. 14 , include a box-shaped connector piece  901 . In some embodiments, the box-shaped connector piece  901  is attached to the inner chord  104 ,  107 , and the outer chord  105 ,  108  using a plate  904 . While half of the box-shaped connector piece  901  is shown in  FIG. 14 , the other half of the connector piece  904  may attach to an adjacent WRTBS  100  in substantially the same way. In some embodiments the box frame connector piece  901  can be used as a window frame or a door frame. 
     In some embodiments, the connector pieces  702 ,  901  and blocking elements  80 ,  90  are used to couple roof chords  112 ,  113 ,  114 ,  115 ,  116 ,  117  of adjacent WRTBS  100 . Various embodiments may include any combination of the connector pieces  702 ,  901  and blocking elements  80 ,  90  described above.