Patent Publication Number: US-6901708-B1

Title: Building system

Description:
FIELD OF THE INVENTION 
   This invention relates to small buildings, such as garages, carports or canopies, storage sheds and the like. 
   More particularly, the present invention relates to easily assembled small buildings. 
   BACKGROUND OF THE INVENTION 
   At the present time small buildings placed about a person&#39;s property are very popular. Generally, it is preferred that these small buildings are free standing and situated at some distance from the main building or buildings. These small buildings may have a multitude of different purposes, such as completely or partially enclosed garages for single cars or other vehicles, carports or canopies, storage sheds and the like. 
   Some small buildings are presently available on the commercial market but they all have several drawbacks that severely limit their adaptability to different uses and situations. Generally, all available small buildings are constructed with a specific size (i.e., width, length, and height) and cannot be altered. Also, all commercially available small buildings are either constructed or assembled by the company that sells them or they are prefabricated in set pieces that are, in most instances, difficult for the purchaser to assemble. Further, if the small buildings are rugged they are relatively expensive and if they are inexpensive they do not last very well. These buildings cannot be altered at a later time to accommodate different or additional uses and any change or increase in size requires the purchase and assembly of a completely new building. 
   It would be highly advantageous, therefore, to remedy the foregoing and other deficiencies inherent in the prior art. 
   Accordingly, it is an object the present invention to provide a new and improved building system. 
   Another object of the present invention is to provide a new and improved building system that can be used to assemble small buildings for any of a large variety of purposes. 
   And another object of the present invention is to provide a new and improved building system which can be used to assemble small buildings that are easy and inexpensive to assemble, disassemble, alter in size, or otherwise modify. 
   Still another object of the present invention is to provide a new and improved building system which can be used to assemble small buildings that can easily be expanded or contracted in size for different uses and purposes. 
   Yet another object of the present invention is to provide a new and improved building system which can be used to assemble small buildings that are sturdy and can easily be assembled by the purchaser. 
   SUMMARY OF THE INVENTION 
   Briefly, to achieve the desired objects of the present invention in accordance with a preferred embodiment thereof, provided is a building system including an elongated sheet metal building element having a roof portion and two opposed sidewall portions extending longitudinally from opposite sides of the roof portion. The roof portion and sidewall portions of the building element are integrally formed and attached by bends in the sheet metal, and the roof portion and sidewall portions of the building element define a longitudinally and laterally extending flat surface between right-angle flanges extending along opposed edges of the roof portion and sidewall portions. The flanges are formed by bends in the sheet metal and include slots at the bends between the roof portion and sidewall portions. 
   The desired objects of the present invention are further realized in accordance with a preferred embodiment thereof wherein a building system is used that includes a plurality of elongated building elements each including a roof portion and two opposed sidewall portions extending longitudinally from opposite sides of the roof portion. The roof portion and sidewall portions of each building element are integrally formed and attached, and the roof portion and sidewall portions of each building element define a longitudinally and laterally extending flat surface between right-angle flanges extending along opposed edges of the roof portion and sidewall portions. Each of the plurality of elongated building elements is formed to be placed adjacent another of the plurality of elongated building elements with adjacent right-angle flanges abutting and fixedly engaged together at spaced apart points to form an extended roof and sidewalls. 
   In a more specific embodiment, a small building is assembled using a building system that includes a plurality of elongated building elements each having a roof portion and two opposed sidewall portions extending longitudinally from opposite sides of the roof portion. The roof portion and sidewall portions of each building element are integrally formed and attached, and the roof portion and sidewall portions of each building element define a longitudinally and laterally extending flat surface between right-angle flanges extending along opposed edges of the roof portion and sidewall portions. Each of the plurality of elongated building elements is placed adjacent another of the plurality of elongated building elements with adjacent right-angle flanges abutting and fixedly engaged together at spaced apart points to form an extended roof and sidewalls. 
   By changing the number of the plurality of elongated building elements used, the length of the building can be changed to any desired length. Further, additional building elements can be added or subtracted at any time during the life of the building. Also, by changing the length of the sidewall portions of the building elements, or the angle of the roof portion, the width and height of the building can be changed to any desired size. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing and further and more specific objects and advantages of the invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof, taken in conjunction with the drawings in which: 
       FIG. 1  is a side view of a small building, being used as a garage, in accordance with the present invention; 
       FIG. 2  is a partially exploded and enlarged overhead perspective view of the small building of  FIG. 1 , illustrating some of the assembly steps; 
       FIG. 3  is an enlarged view in cross-section of a sidewall of the small building of  FIG. 1 , portions thereof broken away; 
       FIG. 4  is a greatly enlarged perspective, interior view of a sidewall of the small building of  FIG. 1 , portions thereof broken away and, shown in section; 
       FIG. 5  is an overhead view in perspective of a garage with an end wall and over-head garage door in accordance with the present invention; 
       FIG. 6  is an overhead view in perspective of a carport or canopy type building in accordance with the present invention; 
       FIG. 7  is a side view of the carport or canopy type building of  FIG. 6  illustrating expansion possibilities; 
       FIG. 8  is an enlarged exterior perspective view of a corner of a small building in accordance with the present invention, illustrating some assembly steps; 
       FIG. 9  is an overhead view in perspective of another embodiment of a small building with an end wall and over-head door in accordance with the present invention; 
       FIG. 10  is an enlarged sectional view of a portion of a wall of the structure of  FIG. 9 , adjacent a lower end; 
       FIG. 11  is a side view of the upper end of a building element for a wall during manufacture; 
       FIG. 12  is a side view of the upper end of the building element illustrated in  FIG. 11  after a final manufacturing step; 
       FIG. 13  is a view in perspective of the upper end of the building element illustrated in  FIG. 9  with the step of  FIG. 12  illustrated in broken lines; 
       FIG. 14  is a sectional view of the upper end of the building element illustrated in  FIG. 12  attached to a building element used in the roof; 
       FIG. 15  is a cross-section of adjacent building elements forming a portion of a sidewall of the small building of  FIG. 9 ; 
       FIG. 16  is an enlarged sectional view of adjacent sides of building elements; 
       FIG. 17  is an enlarged view in perspective of an upper corner of the small building of  FIG. 9 , portions thereof broken away and shown in section; 
       FIG. 18  is a sectional view of a corner building element adjacent the bottom end; and 
       FIG. 19  is a sectional view of another corner building element adjacent the bottom end. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is directed to  FIG. 1 , which illustrates a small building, in this specific example a garage  10 , constructed in accordance with the present invention. Garage  10  is assembled using a building system including a plurality of elongated building elements  12  each including an elongated roof portion  14  and two opposed elongated sidewall portions  15  and  16  extending longitudinally from opposite ends of roof portion  14 . Roof portion  14  and sidewall portions  15  and  16  are integrally formed and attached, in this preferred embodiment from a single piece of sheet metal. In a preferred embodiment the sheet metal used is a thin gauge sheet steel but other materials, such as aluminum could be used if desired. 
   Flanges  20  and  21  extend along opposed edges of roof portion  14  and sidewall portions  15  and  16  of elongated sheet metal building element  12 . Flanges  20  and  21  are formed by right angle bends in the sheet metal and include slots  24  at the bends, for example, between roof portion  14  and sidewall portions  15  and  16 . Roof portion  14  and sidewall portions  15  and  16  define a laterally extending flat surface between flanges  20  and  21 . Flanges  20  and  21  operate as the studs in a standard wooden building and may have, for example, a width substantially equal to a wooden stud (e.g., approximately three and one-half inches). Also, in a preferred embodiment the distance between flanges  20  and  21 , or the lateral extent of the flat surface, is approximately equal to a standard building distance between studs (i.e., a distance in a range of eighteen inches to twenty-one inches). By making the width and spacing of flanges  20  and  21  approximately equal to the width and spacing of studs in a wooden building, garage  10  can be easily adapted to standard items used in the building industry. 
   In this specific embodiment, roof portion  14  is constructed to define a peak with two sloping sides  26  and  27  extending longitudinally from the peak to opposed sidewall portions  15  and  16 . Also, a slot  24  is formed in each of the flanges  20  and  21  at the bend between sloping sides  26  and  27 . It should be understood, however, that roof portion  14  could be designed to form a single sloping or flat side and a single sidewall portion (e.g., sidewall portion  15  or  16 ) could extend from either end. Also, the height of garage  10  can be changed by changing the angle of the bends at the junctures of roof portion  14  and sidewall portions  15  and  16  and/or the bend at the peak of roof portion  14 . Further, the height of garage  10  can be changed by altering the length of sidewall portions  15  and  16 . 
   To construct garage  10  a plurality of building elements  12  are provided. Also, in the preferred embodiment, two elongated channel elements  30  and  31  are provided. Each channel element  30  and  31  defines a channel with a width slightly larger than the width of right-angel flanges  20  and  21 . Channel elements  30  and  31  are positioned on a mounting surface, such as a cement footing or the ground, with the channels opening upwardly, as illustrated in  FIG. 2 . A first building element  12  is selected and the lower end of sidewall  15  is positioned in the channel of channel element  30  and the lower end of sidewall  16  is positioned in the channel of channel element  31 . By drilling holes (if not provided) and inserting self-tapping sheet metal screws the lower ends of the opposed sidewall portions  15  and  16  are fixedly engaged in the channels of channel elements  30  and  31 . Generally, appropriate assembly holes will be provided in building elements  12  by the manufacturer. 
   A second building element  12  is selected and positioned with the lower ends of sidewall portions  15  and  16  in the channels of channel elements  30  and  31 , respectively. The second building element  12  is moved so that flange  21  of the second building element  12  buts against flange  20  of the first building element. Holes can then be drilled (if not provided) and self-tapping sheet metal screws are used to fixedly engage the second building element  12  to the first building element  12 , as best illustrated in  FIGS. 3 and 4 , and in the channels of channel elements  30  and  31 . Additional building elements  12  are added in a similar fashion to extend garage  10  the desired length. In this fashion roof portions  14  form an extended roof and sidewall portions  15  and  16  form extended sidewalls. 
   As can best be seen in  FIG. 1 , decorative roof materials, such as tiles  35  can be affixed to an upper surface of the extended roof and in a similar fashion decorative siding materials can be affixed to the extended sidewalls if desired. 
   End-walls, as best seen in  FIG. 5 , can be formed in garage  10  if desired by providing a plurality of end-wall portions  35 . Each end-wall portion  35  defines a longitudinally and laterally extending flat surface between right-angle flanges extending along opposed edges, similar to sidewall portions  15  or  16 . The upper end of each end-wall portion  35  is cut at an angle to match the angle of roof portion  14  and the length varies according to the position in the end wall. End-wall portions  35  are assembled as described in conjunction with building elements  12  and a channel element (e.g., similar to channel elements  30  or  31 ) can be used at the lower end if desired. It will of course be understood that the length and angle of end-wall portions  35  depends upon the height of garage  10  and the type or shape of roof formed. For example, if a flat roof is formed end-wall portions  35  will all be rectangular and have the same length. 
   The outer-most end-wall portions  35  on each side of the end-wall are attached to flanges  20  and  21  of sidewall portions  15  and  16 , respectively, either by butting the outer-most flange of end-wall portions  35  against the inner flat surface of a selected sidewall portion  15  and  16  or by butting the outer-most flange against flanges  20  and  21  of sidewall portions  15  and  16 . In either case self-tapping metal screws are used to hold the end-wall fixedly in place. 
   If desired one or more openings can be provided in the end-wall and a door and/or windows can be mounted in the opening or openings using standard building techniques. As illustrated in  FIG. 5 , an opening is provided and an overhead garage door is affixed in the opening. 
   Turning now to  FIGS. 6 and 7 , a carport or canopy  50  is illustrated, which is constructed in accordance with the present invention. Canopy  50  is assembled using a building system including a plurality of elongated building elements  52  each including an elongated roof portion  54  and two opposed elongated sidewall portions  55  and  56  extending longitudinally from opposite ends of roof portion  54 . Roof portion  54  and sidewall portions  55  and  56  are integrally formed and attached, in this preferred embodiment from a single piece of sheet metal. 
   Right-angle flanges  60  and  61  extend along opposed edges of roof portion  54  and sidewall portions  55  and  56  of elongated sheet metal building element  52 . Flanges  60  and  61  are formed by bends in the sheet metal and include slots  64  at the bends, for example, between roof portion  54  and sidewall portions  55  and  56 . Roof portion  54  and sidewall portions  55  and  56  define a laterally extending flat surface between flanges  60  and  61 . In this specific embodiment, roof portion  54  is constructed to define a peak with two sloping sides  66  and  67  extending longitudinally from the peak to opposed sidewall portions  55  and  56 . Also, a slot  64  is formed in each of the flanges  60  and  61  at the bend between sloping sides  66  and  67 . It should be understood, however, that roof portion  54  could be designed to form a single sloping or flat side and a single sidewall portion (e.g., sidewall portion  55  or  56 ) could extend from either end. 
   In a preferred embodiment, the lower ends of sidewall portions  55  and  56  are fixed in a channel element  70  and  71 , respectively. Channel elements  70  and  71  are similar to channel elements  30  and  31 , described above, and the manner of fixing the lower ends of sidewall portions  55  and  56  in the channels is similar. Channel elements  70  and  71  are then positioned at a desired height above the ground, or other supporting or mounting surface, by means of posts  75 . Generally, canopy  50  will have at least a post  75  supporting each corner and, depending upon the length, may have additional intermediate posts  75  positioned along the sides. Posts  75  are generally supported on feet  76  which may be positioned directly on the ground or on cement footings or the like. As portrayed in  FIG. 7 , the length of canopy  50  is determined by the number of building elements  52  used and can be altered at any time simply by adding or subtracting building elements  52 . 
   Referring additionally to  FIG. 8 , the over-all strength or rigidity of the small building (e.g., garage  10  or canopy  50 ) can be increased, if desired, by providing and attaching angled flat elements  80  thereto. Element  80  is formed to be affixed in abutting engagement with one of the flanges (flanges  20  and/or  21  of element  12  and flanges  60  and/or  61  of element  52 ) and to extend across the slot ( 24  or  64 ) between the roof portion and the sidewall portion for providing additional support. Generally, angled flat elements  80  can be conveniently formed from a thin sheet of rigid metal, such as steel or the like, and can be approximately the same width as the associated flange. Also, the angle of angled flat elements  80  can be approximately the same as the angle between the portions being bridged. Further, angled flat elements  80  can be used to bridge all of the slots in the small building if that amount of rigidity is desired or they can be used to bridge only specific slots, such as those in the outer-most single flanges (see  FIG. 8 ). 
   Turning now to  FIG. 9 , another embodiment of a small building  100 , such as a garage or the like, is illustrated. In this embodiment, elongated building elements  112  are used to form a roof  114  and two opposed sidewalls  115  and  116  extending downwardly from adjacent opposite ends of roof  114 . Referring additionally to  FIG. 10 , it can be seen that in this embodiment each of the building elements  112  include flanges  120  and  121  extending along opposed edges of elongated sheet metal building elements  112 . Flanges  120  and  121  each include a first right angle bend and a second right angle bend to form an end of the flange parallel and spaced from the main body of the building element. Each of the building elements  112  defines a laterally extending flat surface between flanges  120  and  121 . 
   Flanges  120  and  121  operate as the studs in a standard wooden building and may have, for example, a width substantially equal to a wooden stud (e.g., approximately three and one-half inches). Also, in a preferred embodiment the distance between flanges  120  and  121 , or the lateral extent of the flat surface, is approximately equal to a standard building distance between studs (i.e., a distance in a range of eighteen inches to twenty-one inches). By making the width and spacing of flanges  120  and  121  approximately equal to the width and spacing of studs in a wooden building, small building  100  can be easily adapted to standard items used in the building industry. 
   To construct garage  100  a plurality of building elements  112  are provided for roof  114  and sidewalls  115  and  116 . Also, in the preferred embodiment, two elongated channel elements  130  and  131  are provided. Each channel element  130  and  131  defines a channel with a width slightly larger than the width of flanges  120  and  121 . Channel elements  130  and  131  are positioned on a mounting surface, such as a building floor  125 , a cement footing, or the ground, with the channels opening upwardly, as illustrated in  FIG. 10 . Here it should be noted that floor  125  can be formed of building elements  112  also, if desired. 
   A first building element  112  is selected and the lower end is positioned in the channel of channel element  130 . A second building element  112  is selected and positioned with the lower end in the channel of channel element  30 . The second building element  112  is moved so that flange  120  of the second building element  112  buts against flange  121  of the first building element. Holes can then be drilled (if not provided) and self-tapping sheet metal screws are used to fixedly engage the second building element  112  to the first building element  112 , as best illustrated in  FIG. 10 , and in the channels of channel element  130 . Generally, appropriate assembly holes will be provided in building elements  112  by the manufacturer. Additional building elements  112  are added in a similar fashion to complete sidewall  115  and to extend small building  100  the desired length. In a similar fashion sidewall  116  is assembled in channel  131 . 
   In this specific embodiment, roof  114  is constructed of a plurality of building elements  112  formed to define a peak with two sloping sides  126  and  127  extending longitudinally from the peak to opposed sidewalls  115  and  116 . Also, a slot  124  is formed in each of the flanges  120  and  121  at the bend between sloping sides  126  and  127  of the building elements  112  forming roof  114 . It should be understood, however, that roof  114  could be designed to form a single sloping or flat side, if desired. Also, a single sidewall (e.g., sidewall  115  or  116 ) could extend from adjacent either end. Also, the height of garage  100  can be changed by changing the height of sidewalls  115  and  116  and/or the bend at the peak of roof  114 . 
   Roof  114  is attached to sidewalls  115  and  116  by performing some additional steps on the upper ends of the building elements  112  forming sidewalls  115  and  116 , as can be seen by referring additionally to  FIGS. 11 through 14 . In a preferred embodiment the sheet metal used in building elements  112  is a thin gauge sheet steel but other materials, such as aluminum could be used if desired. As seen in  FIGS. 11 and 13 , flanges  120  and  121  are removed from the upper edges of each building element  112  used in sidewalls  115  and  116  leaving a portion  128  of the laterally extending flat surface. Generally the length of flanges  120  and  121  removed will be such that the length of portion  128  is approximately equal to the amount of soffit desired for small building  100 , as can best be seen in  FIG. 14 . Portion  128  is then bent at an angle (see  FIG. 12 ) to the longitudinal axis of building element  112 . 
   Portion  128  mates with flanges  120  and  121  of an overlying building element  112  of roof  114 , as best seen in  FIG. 14 . Holes can then be drilled (if not provided) and self-tapping sheet metal screws are used to fixedly engage portion  128  of the building element  112  of sidewall  115  to flanges  120  and  121  of the overlying building element  112  of roof  114 . In a similar fashion the upper ends of building elements  112  forming sidewall  116  are formed and attached to the opposite ends of the building elements  112  of roof  114 . Thus, roof  114  is firmly attached to sidewalls  115  and  116  and the soffits are substantially enclosed. To finish roof  114  channel elements  129  are affixed over the ends of building elements  112  forming roof  114  to substantially completely enclose the ends of roof  114 . To affix channel elements  129 , holes can be drilled (if not provided) and self-tapping sheet metal screws are used to fixedly engage channel elements  129  to the flanges  120  and  121  and to the upper surface of the building elements  112  of roof  114 . 
   Also in another embodiment, the flanges formed in the building elements can be slightly indented, as illustrated in  FIGS. 15 and 16 , to provide a more secure fit. In this embodiment similar components are designated with a similar number and a prime is added to indicate the different embodiment. To form each building element  112 ′ flanges  120 ′ and  121 ′ are formed along each edge, respectively, as described above. Also, an elongated wrinkle or crease  132 ′ is formed adjacent one side so as to extend the length of building element  112 . Similarly, a second wrinkle or crease  133 ′ is formed adjacent the opposite side so as to extend the length of building element  112 . Creases  132 ′ and  133 ′ are formed to project outwardly (form a ridge) from one surface and to project inwardly (form a groove) in the opposite surface. Further, creases  132 ′ and  133 ′ are positioned approximately centrally in the side portion of flanges  132 ′ and  133 ′ and are formed in the material so as to be directed in opposite directions. Generally, for convenience in manufacture, creases  132 ′ and  133 ′ will be formed prior to the formation of flanges  120 ′ and  121 ′. 
   Thus, as illustrated best in  FIG. 16 , when two building elements  112 ′ are positioned side-by-side in abutting engagement, crease  132 ′ of one building element  112 ′ is nestled into crease  133 ′ of the adjacent building element  112 ′. The nestling of the oppositely directed creases between adjacent building elements effectively closes any passage for the movement of dirt or other foreign materials into the building. 
   Turning now to  FIGS. 17 ,  18  and  19 , some additional elements for forming openings, such as door or window casings, are illustrated. One such element is a tubular element  140  having a substantially square cross-section and sized to be nestingly positioned within one of the flanges  120  or  121  of a building element  112 . In  FIG. 18 , for example, element  140  is positioned within flange  121  so that flange  121  extends around and in abutting engagement with sides of element  140 . To affix element  140  to building element  112 , holes can be drilled (if not provided) and self-tapping sheet metal screws are used to fixedly engage element  140  to flange  121 . Thus, element  140  forms a very ridged corner or side for the addition of a door or window or just for additional support of the building. 
   Referring to  FIG. 19 , an element  142  is constructed with flanges  143  and  144  substantially similar to building elements  112  but may have a narrower transverse direction than building elements  112 . Element  142  is positioned generally perpendicular to a building element  112  in a side wall so that one side of flange  144  buts against the inside surface of building element  112 . In this embodiment, to add additional strength to the structure, a small tubular element  145 , with a generally rectangular cross-section, is nested in flange  120  of building element  112  and element  142  is positioned in abutting engagement with the exposed surface of element  145 . To affix element  142  to building element  112  and element  145 , holes can be drilled (if not provided) and self-tapping sheet metal screws are used to affix one surface of flange  144  of element  142  to the inner surface of building element  112  and to affix the outer surface of element  142  to the exposed surface of element  145 . Thus, the opening between flanges  143  and  144  of element  142  is used as a track for a sliding door, for example. 
   In the embodiments illustrated in  FIGS. 9 through 19 , one standardized building element can be used to form side walls, roof, floor doors, etc. The standardized building elements can be modified, either by the factory or by an individual, to be positioned in the roof or to form the side walls. Also, the standardized elements can be cut to different lengths to form different portions of a building or to form different sized buildings. 
   Thus, a new and improved building system is disclosed that can be used to assemble small buildings for any of a large variety of purposes, such as completely or partially enclosed garages for single cars or other vehicles, carports or canopies, storage sheds and the like. The new and improved building system can be used to assemble small buildings that are easy and inexpensive to assemble, disassemble, alter in size, or otherwise modify. Also, the new and improved building system can be used to assemble small buildings that can easily be expanded or contracted in size for different uses and purposes and that are sturdy and can easily be assembled by the purchaser. 
   Various changes and modifications to the embodiments herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims. 
   Having fully described the invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is: