U.S. patent application number 13/091624 was filed with the patent office on 2011-10-27 for modular building.
Invention is credited to Tony Curatolo, Vic De Zen, Rolf J. Ohrstrom.
Application Number | 20110258943 13/091624 |
Document ID | / |
Family ID | 44814585 |
Filed Date | 2011-10-27 |
United States Patent
Application |
20110258943 |
Kind Code |
A1 |
De Zen; Vic ; et
al. |
October 27, 2011 |
MODULAR BUILDING
Abstract
A roof for a modular building comprises a ridge beam extending
along a ridge beam axis. The ridge beam includes, when viewed in
cross section, a load bearing central section, and first and second
roof panel connectors on opposed first and second sides of the
central section. The roof further comprises at least a first and a
second roof panel extending transversely to the ridge beam axis and
downwardly and outwardly from the ridge beam. Each roof panel
comprises an inner end portion and an outer end portion. The inner
end portion of the first roof panel is engaged by the first roof
panel connector, and the inner end portion of the second roof panel
is engaged by the second roof panel connector. The roof further
comprises a first tie for the outer end portion of the first roof
panel, and a second tie for the outer end portion of the second
roof panel. Each tie extends parallel to the ridge beam axis and
comprises a top portion and a bottom portion. The top portion
comprises a roof panel outer end channel in which the outer end of
one of the first roof panel and second roof panel is received, and
the bottom portion comprises a wall channel in which a wall of the
modular building is received.
Inventors: |
De Zen; Vic; (Woodbridge,
CA) ; Curatolo; Tony; (Woodbridge, CA) ;
Ohrstrom; Rolf J.; (Richmond Hill, CA) |
Family ID: |
44814585 |
Appl. No.: |
13/091624 |
Filed: |
April 21, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61326419 |
Apr 21, 2010 |
|
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|
Current U.S.
Class: |
52/43 ; 52/79.1;
52/90.1 |
Current CPC
Class: |
E04D 3/40 20130101; E04B
1/34321 20130101; E04B 1/6179 20130101; E04B 7/20 20130101 |
Class at
Publication: |
52/43 ; 52/90.1;
52/79.1 |
International
Class: |
E04B 7/02 20060101
E04B007/02; E04H 1/00 20060101 E04H001/00; E04B 7/08 20060101
E04B007/08 |
Claims
1. A roof for a modular building, the roof comprising; a) a ridge
beam extending along a ridge beam axis and comprising, when viewed
in cross section, a load bearing central section, and first and
second roof panel connectors on opposed first and second sides of
the central section; b) at least a first and a second roof panel
extending transversely to the ridge beam axis and downwardly and
outwardly from the ridge beam, each roof panel comprising an inner
end portion and an outer end portion, the inner end portion of the
first roof panel engaged by the first roof panel connector, and the
inner end portion of the second roof panel engaged by the second
roof panel connector; c) a first tie for the outer end portion of
the first roof panel, and a second tie for the outer end portion of
the second roof panel, each tie extending parallel to the ridge
beam axis and comprising a top portion and a bottom portion, the
top portion comprising a roof panel outer end channel in which the
outer end of one of the first roof panel and second roof panel is
received, and the bottom portion comprising a wall channel in which
a wall of the modular building is received.
2. The roof of claim 1, wherein the inner end portion of the first
roof panel is spaced from the first side of the load bearing
central section, and the inner end portion of the second roof panel
is spaced from the second side of the load bearing central
section.
3. The roof of claim 1, wherein the roof panel outer end channel is
defined by a tie lower wall, a tie upper wall spaced above the tie
lower wall, and a tie end wall extending between the tie lower wall
and tie upper wall at an outer end of the top portion.
4. The roof of claim 3 further comprising a first panel spacing
extending orthogonally between the first side of the central
section and the end wall of the first tie, the first roof panel
having a first panel length that is less than the first panel
spacing.
5. The roof of claim 4 further comprising a second panel spacing
extending orthogonally between the second side of the central
section and the end wall of the second tie, the second roof panel
having a second panel length that is less than the second panel
spacing.
6. The roof of claim 5, wherein the first panel spacing and second
panel spacing are substantially the same.
7. The roof of claim 4, wherein the tie upper wall has a tie upper
wall width extending perpendicular to the ridge beam axis, the
first panel length is less than the first panel spacing by a
distance defining a first insertion gap, and the first insertion
gap is greater than the tie upper wall width.
8. The roof of claim 1, wherein the first and second roof panel
connectors each comprise a respective connector upper wall
extending outwardly and downwardly from the load bearing central
section adjacent a top thereof, and a respective connector lower
wall extending outwardly and downwardly from the load bearing
central section below the connector upper wall, the upper wall and
lower wall defining opposed roof panel inner end channels in which
the respective inner ends of the first roof panel and second roof
panel are received.
9. The roof of claim 1, wherein the load bearing central section is
integrally formed with the first and second roof panel
connectors.
10. The roof of claim 9, wherein, when viewed in cross section, the
load bearing central section defines a cavity, and the cavity is
empty.
11. The roof of claim 8, wherein the load bearing central section
and the connector upper walls and connector lower walls are
integral, unitary portions of a single extruded lineal.
12. The roof of claim 1, wherein the first and second roof panel
connectors each comprise a respective connector lower wall
extending outwardly and downwardly from the load bearing central
section, the lower walls defining respective seating surfaces on
which the respective inner ends of the first roof panel and second
roof panel rest.
13. The roof of claim 12, wherein the load bearing central section
and the connector lower walls are integral, unitary portions of a
single extruded lineal.
14. The roof of claim 12, further comprising a cap securable to the
ridge beam over the respective inner ends and comprising a first
cap wall for covering the first inner end and a second cap wall for
covering the second inner end.
15. A ridge beam for a modular building comprising: an extruded
lineal comprising, when viewed in cross section, i) a load bearing
central section, and ii) first and second roof panel connectors on
opposed first and second sides of the central section, wherein the
load bearing central section is integrally formed with the first
and second roof panel connectors.
16. The ridge beam of claim 15, wherein each roof panel connector
defines a roof panel inner end channel for receiving an inner end
of a roof panel of the modular building.
17. The ridge beam of claim 16, wherein the first and second roof
panel connectors each comprise a connector upper wall extending
outwardly and downwardly from the load bearing central section, and
a connector lower wall extending outwardly and downwardly from the
load bearing central section, the upper wall and lower wall of the
first roof panel connector defining the channel of the first roof
panel connector, and the upper wall and lower wall of the second
roof panel connector defining the channel of the second roof panel
connector.
18. The ridge beam of claim 17, further comprising a first bracing
wall extending between the connector lower wall of the first roof
panel connector and the first side of the central section, and a
second bracing wall extending between the connector lower wall of
the second roof panel connector and the second side of the central
section.
19. The ridge beam of claim 18, wherein the first and second roof
panel connectors each comprise a respective connector lower wall
extending outwardly and downwardly from the load bearing central
section, the lower walls defining respective seating surfaces on
which the respective inner ends of the first roof panel and second
roof panel rest.
20. A kit of parts for a modular building, comprising: a) a ridge
beam comprising: an extruded lineal comprising, when viewed in
cross section, i) a load bearing central section, and ii) first and
second roof panel connectors on opposed first and second sides of
the central section, wherein the load bearing central section is
integrally formed with the first and second roof panel connectors;
b) a tie comprising: an extruded lineal comprising, when viewed in
cross section, (i) a top portion comprising a roof panel outer end
connection surface for attachment to an outer end portion of a roof
panel of the modular building; and (ii) a bottom portion comprising
a wall channel for receiving an upper end of a wall of the modular
building and attaching the roof panel to the wall; and c) a
plurality of panels each comprising: an extruded lineal extending
along an extrusion axis and comprising, when viewed in cross
section, i) a front wall, and an opposed rear wall, ii) a first
side wall and an opposed second side wall, each side wall extending
between the front wall and rear wall, and iii) a first panel
connector extending from the first side wall for connecting the
panel to a first adjacent panel, and a second panel connector
extending from the second side wall for connecting the panel to a
second adjacent panel; wherein the panel has a front width and a
rear width, each extending perpendicular to the axis, and the front
width and rear width are substantially equal and offset from each
other in a direction perpendicular to the axis.
Description
[0001] This application claims the benefit of Provisional Patent
Application No. 61/326,419, filed Apr. 21, 2010, which is hereby
incorporated herein by reference.
FIELD
[0002] The disclosure relates to modular buildings, such as storage
sheds, and to parts and methods of assembling the parts to from a
modular building.
BACKGROUND
[0003] The following is not an admission that anything discussed
below is prior art or part of the common general knowledge of
persons skilled in the art.
[0004] U.S. Pat. No. 6,889,475 (De Zen) discloses a plastic shed
having side walls, end walls which slope up to a central ridge
line, and a roof all formed of interlocking panels. The roof panels
are supported at their upper ends by a ridge beam assembly
comprising a metal beam extending between and supported by the end
walls and a plastic sleeve encasing the metal beam. The sleeve has
on each side integral downwardly sloping shelves on which the upper
ends of the roof panels rest. The shed side walls have caps
provided with upwardly sloping support platforms on which the lower
ends of the roof panels rest and the shed end walls have caps
provided with interlocking formations with which the roof panels
interlockingly engage.
SUMMARY
[0005] The following summary is intended to introduce the reader to
this specification but not to define any invention. In general,
this specification discusses one or more methods or apparatuses for
a roof for a modular building which comprises a ridge beam
extending along a ridge beam axis and comprising, when viewed in
cross section, a load bearing central section, and first and second
roof panel connectors on opposed first and second sides of the
central section. The roof further comprises at least a first and a
second roof panel extending transversely to the ridge beam axis and
downwardly and outwardly from the ridge beam. Each roof panel
comprises an inner end portion and an outer end portion. The inner
end portion of the first roof panel is engaged by the first roof
panel connector, and the inner end portion of the second roof panel
is engaged by the second roof panel connector. The roof further
comprises a first tie for the outer end portion of the first roof
panel, and a second tie for the outer end portion of the second
roof panel. Each tie extends parallel to the ridge beam axis and
comprises a top portion and a bottom portion. The top portion
comprises a roof panel outer end channel in which the outer end of
one of the first roof panel and second roof panel is received, and
the bottom portion comprises a wall channel in which a wall of the
modular building is received.
[0006] The inner end portion of the first roof panel may be spaced
from the first side of the load bearing central section, and the
inner end portion of the second roof panel may be spaced from the
second side of the load bearing central section.
[0007] The roof panel outer end channel may be defined by a tie
lower wall, a tie upper wall spaced above the tie lower wall, and a
tie end wall extending between the tie lower wall and tie upper
wall at an outer end of the top portion.
[0008] The roof may further comprise a first panel spacing
extending orthogonally between the first side of the central
section and the end wall of the first tie. The first roof panel may
have a first panel length that is less than the first panel
spacing. A second panel spacing may extend orthogonally between the
second side of the central section and the end wall of the second
tie. The second roof panel may have a second panel length that is
less than the second panel spacing. The first panel spacing and
second panel spacing may be substantially the same.
[0009] The tie upper wall may have a tie upper wall width extending
perpendicular to the ridge beam axis. The first panel length may be
less than the first panel spacing by a first insertion gap, and the
first insertion gap may be greater than the tie upper wall
width.
[0010] The first and second roof panel connectors may each comprise
a respective connector upper wall extending outwardly and
downwardly from the load bearing central section adjacent a top
thereof, and a respective connector lower wall extending outwardly
and downwardly from the load bearing central section below the
connector upper wall. The upper wall and lower wall may define
opposed roof panel inner end channels in which the respective inner
ends of the first roof panel and second roof panel are
received.
[0011] The load bearing central section may be integrally formed
with the first and second roof panel connectors.
[0012] When viewed in cross section, the load bearing central
section may define a cavity, and the cavity may be empty.
[0013] The load bearing central section and the connector upper
walls and connector lower walls may be integral, unitary portions
of a single extruded lineal.
[0014] The first and second roof panel connectors may each comprise
a respective connector lower wall extending outwardly and
downwardly from the load bearing central section. The lower walls
may define respective seating surfaces on which the respective
inner ends of the first roof panel and second roof panel may rest.
The load bearing central section and the connector lower walls may
be integral, unitary portions of a single extruded lineal. The roof
may further comprise a cap securable to the ridge beam over the
respective inner ends and comprising a first cap wall for covering
the first inner end and a second cap wall for covering the second
inner end.
[0015] According to another aspect, a tie for a roof panel of a
modular building comprises an extruded lineal. When viewed in
cross-section, the extruded lineal comprises a top portion
comprising a roof panel outer end channel for receiving an outer
end portion of the roof panel, and a bottom portion comprising a
wall channel for receiving an upper end of a wall of the building
and attaching the roof panel to the wall.
[0016] The roof panel outer end channel may be defined by a tie
lower wall, a tie upper wall spaced above the tie lower wall, and a
tie end wall extending between the tie lower wall and tie upper
wall at an outer end of the top portion.
[0017] The tie upper wall may have a tie upper wall width extending
perpendicular to an extrusion axis of the tie, the tie lower wall
may have a tie lower wall width extending perpendicular to the
extrusion axis of the tie, and the tie lower wall width may be
greater than the tie upper wall width.
[0018] The wall channel may be defined by a tie inner wall
extending downwardly from the tie lower wall, and a laterally
spaced tie outer wall extending downwardly from the tie lower
wall.
[0019] The tie lower wall may be at an angle with respect to the
tie inner wall and tie outer wall, and the wall channel may be
further defined by a tie central wall extending between and
perpendicular to the tie inner wall and tie outer wall.
[0020] The tie end wall may be spaced laterally from the tie inner
wall and tie outer wall. The tie end wall may be at an angle with
respect to the tie inner wall and tie outer wall.
[0021] According to another aspect, a panel for a modular building
comprises an extruded lineal extending along an extrusion axis. The
extruded lineal comprises, when viewed in cross section, a front
wall, an opposed rear wall, a first side wall and an opposed second
side wall. Each side wall extends between the front wall and rear
wall. The extruded lineal further comprises a first panel connector
extending from the first side wall for connecting the panel to a
first adjacent panel, and a second panel connector extending from
the second side wall for connecting the panel to a second adjacent
panel. The panel has a front width and a rear width, each extending
perpendicular to the axis, and the front width and rear width are
substantially equal and offset from each other in a direction
perpendicular to the axis.
[0022] The first and second panel connectors may each comprise a
hook. The hook of the first panel connector may comprise a first
base extending generally parallel to the front wall, and a first
tongue extending generally perpendicular to the first base. The
first tongue, the first base, and the first side wall may define a
first channel.
[0023] The hook of the first panel connector may have a hook width,
and the front width and rear width may be offset from each other by
an offset distance equal to the hook width.
[0024] The hook of the second panel connector may comprise a second
base extending generally parallel to the rear wall, and a second
tongue extending generally perpendicular to the second base. The
second tongue, the second base, and the second side wall may define
a second channel.
[0025] The first tongue may comprise a first tongue inner wall
adjacent the first channel, the second tongue may comprise a second
tongue inner wall adjacent the second channel, and the first tongue
inner wall and second tongue inner wall may each comprise a catch
for engaging with one of the first adjacent panel and second
adjacent panel, respectively.
[0026] The first catch and second catch may be substantially
identical. The first catch may comprise a first protrusion
extending towards the first side wall, and the second catch may
comprise a second protrusion extending towards the second side
wall. The first protrusion may be engageable with a second
protrusion of the first adjacent panel, and the second protrusion
may be engageable with a first protrusion of the first adjacent
panel.
[0027] Alternately, the first catch and second catch may be of a
different configuration. The first catch may comprise a protrusion
extending towards the first side wall, and the second catch may
comprise a recess. The protrusion may be receivable in a recess of
the first adjacent panel, and the recess may receive a protrusion
of the second adjacent panel.
[0028] The first channel may have a first depth extending parallel
to the first side wall, and second channel may have a second depth
extending parallel to the second side wall, and the first depth and
second depth may be equal. Alternately, the first depth may be
greater than the second depth.
[0029] The panel may be connectable to the first adjacent panel by
sliding engagement in both a direction parallel to the axis, and
perpendicular to the axis.
[0030] The first and second panel connectors may each comprise only
a single hook.
[0031] The front wall may define a front plane, and the rear wall
may define a rear plane, and the hook of the first panel connector
may define a first channel having a first opening facing towards
the rear plane, and the hook of the second panel connector may
define a second channel having a second opening facing towards the
front plane.
[0032] The hook of the first panel connector may be engageable with
a hook of a second panel connector of the first adjacent panel.
[0033] The hook of the first panel connector may comprise a first
base outer wall that is coplanar with the front wall. The first
base outer wall and the front wall may define the front width. The
hook of the second panel connector may comprise a second base outer
wall that is coplanar with the rear wall. The second base outer
wall and the rear wall may define the rear width.
[0034] The first adjacent panel and second adjacent panel may be
identical to the panel.
[0035] According to another aspect, a ridge beam for a modular
building comprises an extruded lineal. The extruded lineal
comprises, when viewed in cross section, a load bearing central
section, and first and second roof panel connectors on opposed
first and second sides of the central section. The load bearing
central section is integrally formed with the first and second roof
panel connectors.
[0036] The extruded lineal may be a metal. The metal may be
aluminum.
[0037] Each roof panel connector may define a roof panel inner end
channel for receiving an inner end of a roof panel of the modular
building.
[0038] The first and second roof panel connectors may each comprise
a connector upper wall extending outwardly and downwardly from the
load bearing central section adjacent the top of the load bearing
central section, and a connector lower wall extending outwardly and
downwardly from the load bearing central section below the upper
wall. The upper wall and lower wall of the first roof panel
connector may define the channel of the first roof panel connector,
and the upper wall and lower wall of the second roof panel
connector may define the channel of the second roof panel
connector.
[0039] The ridge beam may further comprise a first bracing wall
extending between the connector lower wall of the first roof panel
connector and the first side of the central section, and a second
bracing wall extending between the connector lower wall of the
second roof panel connector and the second side of the central
section. The connector lower walls may each comprise a first
section adjacent the load bearing central section having a first
wall thickness, and a second section extending from the first
section and having a second wall thickness. The first wall
thickness may be greater than the second wall thickness. The first
bracing wall may extend from the first section of the first roof
panel connector, and the second bracing wall may extend from the
first section of the second roof panel connector.
[0040] The first and second roof panel connectors may each comprise
a respective connector lower wall extending outwardly and
downwardly from the load bearing central section. The lower walls
define respective seating surfaces on which the respective inner
ends of the first roof panel and second roof panel may rest.
[0041] The load bearing central section may be substantially
rectangular in cross section.
[0042] According to another aspect, a kit of parts for a modular
building comprises a ridge beam, at least one tie, and at least one
panel. The ridge beam comprises an extruded lineal comprising, when
viewed in cross section, a load bearing central section, and first
and second roof panel connectors on opposed first and second sides
of the central section. The load bearing central section is
integrally formed with the first and second roof panel connectors.
The tie comprises an extruded lineal comprising, when viewed in
cross section, a top portion comprising a roof panel outer end
channel for receiving an outer end portion of a roof panel of the
modular building, and a bottom portion comprising a wall channel
for receiving an upper end of a wall of the modular building and
attaching the roof panel to the wall. The panel comprises an
extruded lineal extending along an extrusion axis and comprising,
when viewed in cross section, a front wall, an opposed rear wall, a
first side wall, and an opposed second side wall. Each side wall
extends between the front wall and rear wall. A first panel
connector extends from the first side wall for connecting the panel
to a first adjacent panel, and a second panel connector extends
from the second side wall for connecting the panel to a second
adjacent panel. The panel has a front width and a rear width, each
extending perpendicular to the axis, and the front width and rear
width are substantially equal and offset from each other in a
direction perpendicular to the axis.
DRAWINGS
[0043] The drawings included herewith are for illustrating various
examples of articles, methods, and apparatuses of the present
specification and are not intended to limit the scope of what is
taught in any way. In the drawings:
[0044] FIG. 1 is a perspective illustration of a shed comprising
panels;
[0045] FIG. 2A is a perspective illustration of a panel of the shed
of FIG. 1;
[0046] FIG. 2B is a perspective illustration of two of the panels
of FIG. 2A, assembled together;
[0047] FIG. 3A is a cross section taken along line 3A-3A in FIG.
2A;
[0048] FIG. 3B is a cross section taken long line 3B-3B in FIG.
2B;
[0049] FIG. 4A is a cross section taken along line 3A-3A in FIG.
2A, showing an alternate panel connector;
[0050] FIG. 4B is a cross section taken long line 3B-3B in FIG. 2B,
showing alternate panel connectors;
[0051] FIG. 5A is a cross section taken along line 3A-3A in FIG.
2A, showing an alternate panel connector;
[0052] FIG. 5B is a cross section taken long line 3B-3B in FIG. 2B,
showing alternate panel connectors;
[0053] FIG. 5C shows the cross section of FIG. 5A, with a
reinforcing bar inserted into the hook;
[0054] FIG. 5D is a cross section showing a corner piece usable
with the panel of FIGS. 5A to 5C;
[0055] FIG. 6A is a cross section taken along line 3A-3A in FIG.
2A, showing an alternate panel connector;
[0056] FIG. 6B is a cross section taken long line 3B-3B in FIG. 2B,
showing alternate panel connectors;
[0057] FIG. 7 is a cross section taken along line 7-7 in FIG.
1;
[0058] FIG. 8 is an enlarged view of the region shown in box 8 in
FIG. 7;
[0059] FIG. 9A is a perspective illustration of a tie of the shed
of FIG. 1;
[0060] FIG. 9B is another perspective illustration of the tie of
the shed of FIG. 1;
[0061] FIG. 10 is a perspective illustration of a ridge beam of the
shed of FIG. 1;
[0062] FIGS. 11A to 11C are schematic drawings showing the assembly
of the roof of the shed of FIG. 1;
[0063] FIG. 12A is a perspective exploded illustration of an
alternate ridge beam, and a cap usable with the alternate ridge
beam; and
[0064] FIG. 12B is a perspective illustration of the ridge beam and
cap of FIG. 12A, in an assembled configuration.
DETAILED DESCRIPTION
[0065] Various apparatuses or processes will be described below to
provide an example of an embodiment of each claimed invention. No
embodiment described below limits any claimed invention and any
claimed invention may cover processes or apparatuses that differ
from those described below. The claimed inventions are not limited
to apparatuses or processes having all of the features of any one
apparatus or process described below or to features common to
multiple or all of the apparatuses described below. It is possible
that an apparatus or process described below is not an embodiment
of any claimed invention. Any invention disclosed in an apparatus
or process described below that is not claimed in this document may
be the subject matter of another protective instrument, for
example, a continuing patent application, and the applicants,
inventors or owners do not intend to abandon, disclaim or dedicate
to the public any such invention by its disclosure in this
document.
[0066] Referring to FIG. 1, an exemplary modular building is
illustrated in the form of a shed 100. In alternate examples, a
modular building may be another type of building, such as a garage,
a storage box, or a home. The shed 100 includes four walls 102,
including a front wall 102a, an opposed rear wall 102b, a first
side wall 102c, and an opposed second side wall 102d. The front
wall 102 includes a door 104. The shed further includes a roof
106.
[0067] In some examples, a shed may include an alternate number of
walls, an alternate configuration or number of doors, and may
optionally further include one or more windows.
[0068] Referring still to FIG. 1, each wall 102 includes a
plurality of panels 108, which are connected together to form the
walls 102. Further, the roof 106 includes a plurality of panels
108, which are connected together to form the roof 106.
[0069] Referring to FIG. 2A, the panels 108 of the walls 102 and
the panels 108 of the roof 106 are each extruded lineals, and
extend along an extrusion axis 110. The panels 108 may be extruded
from a plastic, such as vinyl. Referring to FIG. 3A, in the example
shown, the panels 108 of the walls 102 and the panels 108 of the
roof 106 all have a common extrusion profile 112. In some examples
the panels of the wall may have a different extrusion profile than
the panels of the roof. In some examples, the walls may be
assembled from wall panels, and the roof may be assembled from roof
panels that may be the same as, or distinct from, the wall
panels.
[0070] Each panel 108 (as viewed in cross section) includes a front
wall 114 which defines a front plane 116 of the panel 108, and an
opposed rear wall 118 which defines a rear plane 120 of the panel
108. A first side wall 122 and an opposed second side wall 124
extend between the front wall 114 and rear wall 118. A first panel
connector 126 extends from the first side wall 122 for connecting
the panel 108 to a first adjacent panel 108a, as shown in FIGS. 3A
and 3B. A second panel connector 128 extends from the second side
wall 124 for connecting the panel 108 to a second adjacent panel
(not shown).
[0071] Referring still to FIG. 3A the first 122 and second 124
panel connectors 126, 128 each comprise a hook 130. Particularly,
in the example shown, the first 126 and second 128 panel connectors
each comprise a single hook 130. The hook 130 of the first panel
connector 126 (also referred to herein as "the first hook 130") is
engageable with a hook 130a of the first adjacent panel 108a, to
connect the panel 108 to the first adjacent panel 108a, as shown in
FIG. 3B. Similarly, the hook 130 of the second panel connector 128
(also referred to herein as "the second hook 130") is engageable
with a hook of the second adjacent panel to connect the panel 108
to the second adjacent panel (not shown).
[0072] The first hook 130 includes a first base 132 extending from
the first side wall 122 and generally parallel to the front wall
114. The first base 132 includes a first base outer wall 144 that
is coplanar with the front wall 114, and an opposed first base
inner wall 146. The first hook 130 further includes a first tongue
134 extending generally perpendicular to the first base 132 and
spaced from the first side wall 122. The first tongue includes a
first tongue outer wall 148 extending from the first base outer
wall 144 towards the rear plane 120, and a first tongue inner wall
150 extending from the first base inner wall 146 towards the rear
plane 120. The first tongue 134, first base 132, and first side
wall 122 define a first channel 136, which has a first opening 152
facing towards the rear plane 120. The first channel has a first
depth 168, extending parallel to the first side wall 122.
[0073] Similarly, the second hook 130 includes a second base 138
extending from the second side wall 124 and generally parallel to
the rear wall 118. The second base 138 includes a second base outer
wall 154 that is coplanar with the rear wall 118, and an opposed
second base inner wall 156. The second hook 130 further includes a
second tongue 140 extending generally perpendicular to the second
base 138 and spaced from the second side wall 124. The second
tongue 140 includes a second tongue outer wall 158 extending from
the second base outer wall 146 towards the front plane 116, and a
second tongue inner wall 160 extending from the second base inner
wall 156 towards the front plane 116. The second tongue 140, second
base 138, and second side wall 124 define a second channel 142,
which has a second opening 162 facing towards the front plane 116.
The second channel has a second depth 170 extending parallel to the
second sidewall 124.
[0074] With reference to FIGS. 3A and 3B, the first tongue 134 is
receivable in a second channel (not shown) of the first adjacent
panel 108a, and the first channel 136 receives a second tongue 140a
of the first adjacent panel 108a, to connect the first adjacent
panel 108a to the panel 108. Similarly, the second tongue 140 is
receivable in a first channel of the second adjacent panel (not
shown), and the second channel 142 receives a first tongue of the
second adjacent panel (not shown), to connect the second adjacent
panel to the panel 108.
[0075] The first tongue inner wall 150 may comprise a first catch
164, and the second tongue inner wall may comprise a second catch
166. Referring to FIG. 3B, the first catch 164 is engageable with a
second catch 166a of the first adjacent panel 108a, to aid in
securing the first tongue 134 in the second channel of the first
adjacent panel 108a. The second catch 166 is engageable with a
first catch of the second adjacent panel (not shown), to facilitate
securing the second tongue 140 in the first channel of the second
adjacent panel (not shown).
[0076] In the example shown, the first catch 164 and second catch
166 are substantially identical. The first catch 164 includes a
first protrusion extending towards the first sidewall 122, and the
second catch 166 includes a second protrusion extending towards the
second sidewall 124. Referring to FIG. 3B, the first protrusion is
engageable with a second protrusion of the first adjacent panel
108a, and the second protrusion is engageable a first protrusion of
the second adjacent panel (not shown).
[0077] In alternate examples, a first catch and second catch may
not be identical, and may be of different configurations. For
example, a first catch may include a first protrusion extending
towards a first side wall, and a second catch may include a second
recess (not shown). The protrusion may be receivable in a recess of
the first adjacent panel, and the recess may receive a protrusion
of the second adjacent panel.
[0078] Referring to FIGS. 4A and 4B, in a further alternate
example, where like reference numerals are used to refer to like
features of FIG. 3A with the first digit incremented to 4, the
first 426 and second 428 panel connectors may not include a
catch.
[0079] Referring back to FIG. 3A, in the example shown, the first
depth 168 and the second depth 170 are substantially equal, and the
first tongue 134 is sized to substantially fill a second channel
(not shown) of the first adjacent panel 108a, and the second tongue
140 is sized to substantially fill a first channel of the second
adjacent panel (not shown). In other words, when assembled, the
leading edge of the tongue generally abuts the base of the
connector when the walls 114, 118 of one panel 108 are coplanar
with the walls 114a, 118a of an adjacent panel 108a connected
thereto.
[0080] In an alternate example, shown in FIGS. 5A and 5B where like
reference numerals are used to refer to like features of FIG. 3A
with the first digit incremented to 5, the second depth 570 is
greater than the first depth 568 of the connectors 528, 526 of the
panel 508. The first tongue 534 extends only partially along the
depth 570a of the second channel 542a of the adjacent panel 508a.
This can leave a gap 571 or drainage trough that can facilitate
draining away water that may work its way between the connectors of
adjacent panels. When used to make a roof (such as roof 106 shown
in FIG. 1), the panels 508, 508a can be oriented so that the
second, deeper channels 542 open upwards (as shown in FIGS. 5A and
5B). This can help to prevent water from collecting in the
connector portions (potentially leading to mold or other problems)
and/or from leaking through the roof into the shed interior.
[0081] In the assembled panels 508, 508a of FIG. 5B, the second
tongue 540a of the adjacent panel 508 does substantially fill the
first channel 534 of the panel 508. The leading edge of the tongue
540a generally abuts the base 532 of the connector 526 when the
walls 114, 118 of one panel 108 are coplanar with the walls 114a,
118a of an adjacent panel connected thereto. In this way, at each
joint between adjacent panels, an abutment surface is provided to
help align the adjacent panels in coplanar relationship when
assembled, and a drainage trough is provided to facilitate moisture
management.
[0082] In a further alternate example, shown in FIGS. 6A and 6B,
where like reference numerals are used to refer to like features of
FIG. 3A, with the first digit incremented to 6, the first depth 668
is substantially the same as the second depth 670, and is greater
than the depth of the tongues received therein. When the panel 608
is connected to the first adjacent panel 608a, the first tongue 640
does not substantially fill the second channel of the first
adjacent panel 608a, and the second tongue 640a of the first
adjacent panel 608a does not substantially fill the first channel
of the panel 608 (i.e. the tongues 640, 640a extend only partially
into the depths of the corresponding channels). Furthermore, the
second tongue 640 would not substantially fill a first channel of
the second adjacent panel (not shown), and the first tongue of the
second adjacent panel (not shown) would not substantially fill the
second channel 642 of the panel 608.
[0083] In some examples where a tongue does not substantially fill
a channel (i.e. where a gap such as gap 571 is provided between the
leading edge of a tongue and the bottom of the channel into which
the tongue is installed), a reinforcing bar (not shown) may
optionally be inserted into one or more gaps to provide
reinforcement to the respective joints. Alternately, a reinforcing
bar may be inserted into one of the first tongue and the second
tongue, to provide reinforcement to the joint. For example,
referring to FIG. 5C, a reinforcement bar 572 is inserted into the
second tongue 540.
[0084] Referring back to FIG. 3A, each panel 108 has a front width
180, and a rear width 182, each of which extends perpendicular to
the extrusion axis 110. The front width 180 is defined by the front
wall 114, and the first base outer wall 144. The rear width 182 is
defined by the rear wall 118 and the second base outer wall 154.
The front width 180 and rear width 182 are substantially equal, but
are offset from each other in a direction perpendicular to the
extrusion axis 110. The offset distance 184 is generally equal to a
width 186 of both the first hook 130, and the second hook 130 (also
referred to herein as a hook width 186).
[0085] When assembling the shed 100, a foundation may first be
poured, and a base 174 (shown in FIG. 1) may be secured to the
foundation. The base may include a plurality of aluminum tracks
arranged to align with the four walls 102a to 102d, the tracks
having an upwardly open recess to receive lower ends of the panels
108. The panels 108 may then be assembled to the base 174, and to
each other. In order to assemble the panels 108 to the base, the
panels may be lowered into the track recess.
[0086] The panels may be assembled to each other either by sliding
engagement in a direction parallel to the axis 110, or by sliding
engagement perpendicular to the axis. For example, two panels 108,
108a may be assembled by aligning the lower end of a first
connector 126 with the upper end of a second connector 128a of an
adjacent panel 108a, and then sliding the panels together in a
lengthwise direction. Alternatively, two panels may connected
together by aligning all or most of the length of the tongue of one
connecter with the opening of the channel in the connector of an
adjacent panel, and then sliding (or pushing) the tongue into the
channel. A combination of these two assembly techniques can be
used, for example, by pushing (in the perpendicular direction) a
portion of the tongue into the channel of an adjacent panel, and
then sliding the panels relative to each other in a lengthwise
direction to complete the assembly.
[0087] Referring to FIGS. 7 and 8, a plurality of panels 108 may be
connected together to form the walls 102. The panels may have
different heights, and may be assembled in a particular
configuration, so that the front wall 102a and rear wall 102b are
gabled. A corner piece 176 may be used to connect two or more walls
102 together at a corner.
[0088] An alternate corner piece 576 is shown in FIG. 5D. The
corner piece 576 is usable with the panels 508 shown in FIGS. 5A to
5C.
[0089] Referring now to FIGS. 9A and 9B, a tie 900 is shown. As
will be described further below the tie 900 can facilitate
attaching a panel 108 of the roof 106 to one of the side walls
102c, 102d. Further, the tie 900 may cover the upper end 103c,
103d, respectively, of the side walls 102c, 102d, and the outer
ends of the panels 108 of the roof 106.
[0090] The tie 900 is, in the example illustrated, an extruded
lineal that extends along a tie extrusion axis 901. The tie 900 may
be extruded from a plastic, such as a vinyl, for example. In the
example illustrated, the tie 900 is formed of an aluminum
extrusion. The tie 900 includes a top portion 902 and a bottom
portion 904. The top portion 902 includes a roof panel outer end
channel 906 for receiving an outer end portion of a roof panel 108.
The roof panel outer end channel 906 is defined by a tie lower wall
908, a tie upper wall 910 spaced above the tie lower wall 908, and
a tie end wall 912 extending between the tie lower wall 908 and tie
upper wall at an outer end 914 of the top portion. The tie upper
wall 910 has a tie upper wall width 916 and tie lower wall 908 has
a tie lower wall width 918, and the tie lower wall width 918 is
greater than the tie upper wall width 916.
[0091] Referring still to FIGS. 9A and 9B, the bottom portion 904
of the tie 900 includes a wall channel 920 for receiving an upper
end of a side wall 102c, 102d. The wall channel 920 is defined by a
tie inner wall 922 extending downwardly from the tie lower wall
908, and a laterally spaced tie outer wall 924 extending downwardly
from the tie lower wall 908. The tie lower wall 908 is at an angle
with respect to the tie inner wall 922 and tie outer wall 924. In
the assembled shed 100, the tie inner wall 922 and tie outer wall
924 extend generally vertically, and the tie lower wall 908 is at
an angle with respect to the horizontal to match the angle (or
incline) of the roof. The wall channel 920 is further defined by a
tie central wall 926 extending between, and perpendicular to, the
tie inner wall 922 and tie outer wall 924. The upper end of the
wall 102c or 102d can bear flush against the tie central wall 926
when received in the wall channel 920.
[0092] Referring still to FIGS. 9A and 9B, the tie end wall 912 is
spaced laterally and outwardly from the tie inner wall 922 and tie
outer wall 924, and the tie end wall 912 is at an angle with
respect to the tie inner wall 922 and tie outer wall 924. In the
assembled shed 100, the tie end wall 912 is at an acute angle with
respect to the vertical.
[0093] Referring now to FIG. 10, a ridge beam 1000 is shown. As
will be described below, the ridge beam 1000 supports the inner
ends of the panels 108 of the roof 106 on the front 102a and rear
102b walls of the shed 100.
[0094] The ridge beam 1000 extends along a ridge beam axis 1002
(also referred to herein as a ridge beam extrusion axis 1002). The
ridge beam 1000 includes a central section 1004. The central
section 1004 bears a portion of the load of the roof 106 in the
assembled shed 100, and may also be referred to as a load bearing
central section 1004. The central section 1004 is generally
rectangular in cross section, and includes a top 1006, a bottom
1008, and first 1010 and second 1012 opposed sides. The top 1006,
bottom 1008, first side 1010 and second side 1012 may define a
cavity 1011.
[0095] Referring still to FIG. 10, the ridge beam 1000 further
includes first 1014 and second 1016 roof panel connectors on the
opposed first 1010 and second 1012 sides of the central section
1004, respectively. In the example shown, the first 1014 and second
1016 roof panel connectors each define a roof panel inner end seat
1018, 1020, respectively, for supporting an inner end of a panel
108 of a the 106 of the shed 100. Each connector 1014, 1016
comprises a connector lower wall 1026, 1028, respectively,
extending outwardly and downwardly from the central section 1004.
Each connector 1014, 1016 may further include a connector upper
wall 1022, 1024, respectively, extending outwardly and downwardly
from the central section 1004 adjacent the top 1006, and above the
lower walls 1026, 1028. The connector upper wall 1022 and connector
lower wall 1026 can define a roof panel inner end seat 1018 in the
form of a channel, and the connector upper wall 1024 and connector
lower wall 1028 can define a roof panel inner end seat 1020 in the
form of a channel.
[0096] The connector lower walls 1026, 1028 each comprise a first
section 1030, 1032, respectively, adjacent the central section
1004, and a second section 1034, 1036, respectively, extending from
the first section 1030 1032. The first sections 1030, 1032 each
have a first wall thickness (not shown), and the second sections
1034, 1036 each have a second wall thickness (not shown), and the
first wall thickness is greater than the second wall thickness. The
ridge beam 1000 further includes a first bracing wall 1038
extending between the first section 1030 of connector lower wall
1026 and the first side 1010 of the central section 1004, and a
second bracing wall 1040 extending between the first section 1032
of the connector lower wall 1028 and the second side 1012 of the
central section 1004.
[0097] Referring still to FIG. 10, the ridge beam 1000 may be an
extruded lineal, and the central section 1004 may be integrally
formed with the first 1014 and second 1016 roof panel connectors.
That is, the load bearing central section 1004 and the connector
upper walls 1022, 1024 and lower walls 1026, 1028 may be integral,
unitary portions of a single extruded lineal. The ridge beam 1000
may be a metal, such as aluminum.
[0098] Referring now to FIG. 11A, in order to assemble the roof 106
to the walls 102 of the shed, a ridge beam 1000 may be assembled to
the front 102a and rear 102b walls (not shown in FIG. 11A) of the
shed 100. For example, the front 102a and rear 102b walls may
include cutouts (not shown) in which the ends of the ridge beam
1000 are received so that the ridge beam 1000 is supported by the
front 102a and rear 102b walls.
[0099] A first tie 900a may be assembled to the first side wall
102c, and a second tie 900b may be assembled to the second side
wall 102d, so that the first 900a and second 900b ties extend
parallel to the ridge beam axis 1002 (shown in FIG. 10).
Specifically, the upper end 103c of the first side wall 102a may be
inserted into a wall channel 920 (shown in FIGS. 9A and 913) of the
first tie 900a until the upper end 103c of the first side wall 102c
abuts a tie central wall 926 of the wall channel 920, and the upper
end 103d of the second side wall 102d may be inserted into the wall
channel 920 (shown in FIGS. 9A and 9B) of the second tie 900b until
the upper end 103d abuts a tie central wall 926 of the wall channel
920.
[0100] Referring still to FIG. 11A, a plurality of panels 108 may
be assembled to the ridge beam 1000, first tie 900a, and second tie
900b. For simplicity, the following description relates to the
assembly of two panels 108 to the ridge beam 1000, first tie 900a,
and second tie 900b, so that one panel 108 is on each side of the
ridge beam 1000. However, if more than two panels 108 are to be
assembled to the ridge beam 1000, first tie 900a, and second tie
900b, the panels 108 may first be assembled together, as described
above with respect to FIGS. 2A to 3B, and the assembled panels 108
may be assembled to the ride beam 1000, first tie 900a, and second
tie 900b, in the same manner as will be described below. For
example, five panels 108 may be assembled together, and then
assembled to the ridge beam 1000 and first tie 900a as described
below. Another five panels 108 may be assembled together, and then
assembled to the ridge beam 1000 and second tie 900b as described
below.
[0101] As will be described in more detail below, a first panel
108c may be assembled to the ridge beam 1000 such that (1) the
first panel 108c extends transversely to the ridge beam axis 1002
(shown in FIG. 10) and downwardly and outwardly from the ridge beam
1000, (2) an inner end portion 105c of the first panel 108c is
engaged by the first panel connector 1014, and (3) an outer end
portion 107c of the first panel 108c is engaged by the roof panel
outer end channel 906a of the first tie 900a. A second panel 108d
may be assembled to the ridge beam 1000 such that (1) the second
panel 108d extends transversely to the ridge beam axis 1002 and
downwardly and outwardly from the ridge beam 1000, (2) an inner end
portion 105d of the second panel 108d is engaged by the second
panel connector 1016, and (3) an outer end portion 107d of the
second panel 108d is engaged by the roof panel outer end channel
906b of the second tie 900b.
[0102] To assemble a first panel 108c to the ridge beam 1000 and
first tie 900a, the first panel 108c may be positioned on top of
the first tie 900a, and the inner end portion 105c of the first
panel 108c may be slid towards and into the roof panel inner end
channel 1018. The roof panel has a first panel length 109 (shown in
FIGS. 2A and 11C), and a first panel spacing 111 (shown in FIG.
11C) extends orthogonally between the first side 1010 of the
central section 1004 of the ridge beam and the tie end wall 912a.
The first panel length 109 is less than the first panel spacing
111. Specifically, the first panel length is less than the first
panel spacing 111 by an insertion gap 113 that is greater than the
tie upper wall width 916 (shown in FIG. 9A) of the first tie 900a.
Accordingly, referring to FIG. 11B, as the inner end portion 105c
is slid into the roof panel inner end channel 1018 (not labeled in
FIG. 11B), the outer end 107c of the first panel 108c will slide
over and past the tie upper wall 910a. Referring to FIG. 11C, the
outer end portion 107c of the first panel 108c may then be lowered
such that it rests on the tie lower wall 918a, and the first panel
108c may be slid outwardly, such that the outer end portion 107c is
received in the roof panel outer end channel 906 (not labeled in
FIG. 11C) of the first tie 900a. When the outer end portion 107c is
received in the roof panel outer end channel 906, the inner end
portion 105c is spaced from the first side 1010 of the central
section 1004.
[0103] The second panel 108c may be assembled to the ridge beam
1000 and second tie 900b in a similar manner.
[0104] Referring still to FIG. 11C, in the assembled roof 106, the
cavity 1011 (shown in FIG. 10) of the ridge beam 1000 may be
substantially empty, and ridge beam 1000 may not necessarily
require any further support, such as by the insertion of a separate
beam.
[0105] Referring now to FIG. 12A, in which like reference numerals
are used as in FIG. 10, with the first digit incremented to 12, an
alternate ridge beam 1200 is shown. In the ridge beam 1200, the
first 1214 and second 1216 roof panel connectors each comprise a
connector lower wall 1226, 1228, respectively, extending outwardly
and downwardly from the central section 1204. The connector lower
walls 1226, 1228 each define a seating surface on which the
respective inner ends 105c, 105d of the panels 108c, 108d (shown in
FIG. 11) may rest. Similarly to the ridge beam 1000, the central
section 1204 and connector lower walls 1226, 1226 may be integral,
unitary portions of a single extruded lineal.
[0106] Referring to FIGS. 12A and 12B, a roof assembled with the
ridge beam 1200 may further include a cap 1300 securable to the
ridge beam 1200 over the inner ends 105c, 105d of the panels 108c,
108d. The cap 1300 may comprise a first cap wall 1302 for covering
inner end 105c of the first panel 108c, and a second cap wall 1304
for covering the inner end 105d of the second panel 108c. The cap
1300 may be slidably receivable on the top 1006 of the central
section 1004, and may be snapingly secured thereto. The cap 1300
may be an extruded lineal, and may be a plastic such as a
vinyl.
[0107] While the above description provides examples of one or more
processes or apparatuses, it will be appreciated that other
processes or apparatuses may be within the scope of the
accompanying claims.
* * * * *