US20110258943A1

US20110258943A1 - Modular building

Info

Publication number: US20110258943A1
Application number: US13/091,624
Authority: US
Inventors: Vic De Zen; Tony Curatolo; Rolf J. Ohrstrom
Original assignee: Vision Extrusions Ltd
Current assignee: Vision Extrusions Ltd
Priority date: 2010-04-21
Filing date: 2011-04-21
Publication date: 2011-10-27

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.

Description

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

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

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.
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

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.
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.
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.
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.
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.
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.
The load bearing central section may be integrally formed with the first and second roof panel connectors.
When viewed in cross section, the load bearing central section may define a cavity, and the cavity may be empty.
The load bearing central section and the connector upper walls and connector lower walls may be integral, unitary portions of a single extruded lineal.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
The first and second panel connectors may each comprise only a single hook.
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.
The hook of the first panel connector may be engageable with a hook of a second panel connector of the first adjacent panel.
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.
The first adjacent panel and second adjacent panel may be identical to the panel.
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.
The extruded lineal may be a metal. The metal may be aluminum.
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.
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.
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.
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.
The load bearing central section may be substantially rectangular in cross section.
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

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:

FIG. 1 is a perspective illustration of a shed comprising panels;

FIG. 2A is a perspective illustration of a panel of the shed of FIG. 1;

FIG. 2B is a perspective illustration of two of the panels of FIG. 2A, assembled together;

FIG. 3A is a cross section taken along line 3A-3A in FIG. 2A;

FIG. 3B is a cross section taken long line 3B-3B in FIG. 2B;

FIG. 4A is a cross section taken along line 3A-3A in FIG. 2A, showing an alternate panel connector;

FIG. 4B is a cross section taken long line 3B-3B in FIG. 2B, showing alternate panel connectors;

FIG. 5A is a cross section taken along line 3A-3A in FIG. 2A, showing an alternate panel connector;

FIG. 5B is a cross section taken long line 3B-3B in FIG. 2B, showing alternate panel connectors;

FIG. 5C shows the cross section of FIG. 5A, with a reinforcing bar inserted into the hook;

FIG. 5D is a cross section showing a corner piece usable with the panel of FIGS. 5A to 5C;

FIG. 6A is a cross section taken along line 3A-3A in FIG. 2A, showing an alternate panel connector;

FIG. 6B is a cross section taken long line 3B-3B in FIG. 2B, showing alternate panel connectors;

FIG. 7 is a cross section taken along line 7-7 in FIG. 1;

FIG. 8 is an enlarged view of the region shown in box 8 in FIG. 7;

FIG. 9A is a perspective illustration of a tie of the shed of FIG. 1;

FIG. 9B is another perspective illustration of the tie of the shed of FIG. 1;

FIG. 10 is a perspective illustration of a ridge beam of the shed of FIG. 1;

FIGS. 11A to 11C are schematic drawings showing the assembly of the roof of the shed of FIG. 1;

FIG. 12A is a perspective exploded illustration of an alternate ridge beam, and a cap usable with the alternate ridge beam; and

FIG. 12B is a perspective illustration of the ridge beam and cap of FIG. 12A, in an assembled configuration.

DETAILED DESCRIPTION

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.
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 102 a, an opposed rear wall 102 b, a first side wall 102 c, and an opposed second side wall 102 d. The front wall 102 includes a door 104. The shed further includes a roof 106.
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.
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.
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.
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 108 a, 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).
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 130 a of the first adjacent panel 108 a, to connect the panel 108 to the first adjacent panel 108 a, 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).
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.
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.
With reference to FIGS. 3A and 3B, the first tongue 134 is receivable in a second channel (not shown) of the first adjacent panel 108 a, and the first channel 136 receives a second tongue 140 a of the first adjacent panel 108 a, to connect the first adjacent panel 108 a 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.
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 166 a of the first adjacent panel 108 a, to aid in securing the first tongue 134 in the second channel of the first adjacent panel 108 a. 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).
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 108 a, and the second protrusion is engageable a first protrusion of the second adjacent panel (not shown).
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.
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.
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 108 a, 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 114 a, 118 a of an adjacent panel 108 a connected thereto.
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 570 a of the second channel 542 a of the adjacent panel 508 a. 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, 508 a 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.
In the assembled panels 508, 508 a of FIG. 5B, the second tongue 540 a of the adjacent panel 508 does substantially fill the first channel 534 of the panel 508. The leading edge of the tongue 540 a generally abuts the base 532 of the connector 526 when the walls 114, 118 of one panel 108 are coplanar with the walls 114 a, 118 a 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.
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 608 a, the first tongue 640 does not substantially fill the second channel of the first adjacent panel 608 a, and the second tongue 640 a of the first adjacent panel 608 a does not substantially fill the first channel of the panel 608 (i.e. the tongues 640, 640 a 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.
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.
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).
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 102 a to 102 d, 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.
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, 108 a may be assembled by aligning the lower end of a first connector 126 with the upper end of a second connector 128 a of an adjacent panel 108 a, 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.
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 102 a and rear wall 102 b are gabled. A corner piece 176 may be used to connect two or more walls 102 together at a corner.
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.
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 102 c, 102 d. Further, the tie 900 may cover the upper end 103 c, 103 d, respectively, of the side walls 102 c, 102 d, and the outer ends of the panels 108 of the roof 106.
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.
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 102 c, 102 d. 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 102 c or 102 d can bear flush against the tie central wall 926 when received in the wall channel 920.
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.
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 102 a and rear 102 b walls of the shed 100.
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.
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.
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.
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.
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 102 a and rear 102 b walls (not shown in FIG. 11A) of the shed 100. For example, the front 102 a and rear 102 b 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 102 a and rear 102 b walls.
A first tie 900 a may be assembled to the first side wall 102 c, and a second tie 900 b may be assembled to the second side wall 102 d, so that the first 900 a and second 900 b ties extend parallel to the ridge beam axis 1002 (shown in FIG. 10). Specifically, the upper end 103 c of the first side wall 102 a may be inserted into a wall channel 920 (shown in FIGS. 9A and 913) of the first tie 900 a until the upper end 103 c of the first side wall 102 c abuts a tie central wall 926 of the wall channel 920, and the upper end 103 d of the second side wall 102 d may be inserted into the wall channel 920 (shown in FIGS. 9A and 9B) of the second tie 900 b until the upper end 103 d abuts a tie central wall 926 of the wall channel 920.
Referring still to FIG. 11A, a plurality of panels 108 may be assembled to the ridge beam 1000, first tie 900 a, and second tie 900 b. For simplicity, the following description relates to the assembly of two panels 108 to the ridge beam 1000, first tie 900 a, and second tie 900 b, 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 900 a, and second tie 900 b, 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 900 a, and second tie 900 b, 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 900 a as described below. Another five panels 108 may be assembled together, and then assembled to the ridge beam 1000 and second tie 900 b as described below.
As will be described in more detail below, a first panel 108 c may be assembled to the ridge beam 1000 such that (1) the first panel 108 c 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 105 c of the first panel 108 c is engaged by the first panel connector 1014, and (3) an outer end portion 107 c of the first panel 108 c is engaged by the roof panel outer end channel 906 a of the first tie 900 a. A second panel 108 d may be assembled to the ridge beam 1000 such that (1) the second panel 108 d extends transversely to the ridge beam axis 1002 and downwardly and outwardly from the ridge beam 1000, (2) an inner end portion 105 d of the second panel 108 d is engaged by the second panel connector 1016, and (3) an outer end portion 107 d of the second panel 108 d is engaged by the roof panel outer end channel 906 b of the second tie 900 b.
To assemble a first panel 108 c to the ridge beam 1000 and first tie 900 a, the first panel 108 c may be positioned on top of the first tie 900 a, and the inner end portion 105 c of the first panel 108 c 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 912 a. 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 900 a. Accordingly, referring to FIG. 11B, as the inner end portion 105 c is slid into the roof panel inner end channel 1018 (not labeled in FIG. 11B), the outer end 107 c of the first panel 108 c will slide over and past the tie upper wall 910 a. Referring to FIG. 11C, the outer end portion 107 c of the first panel 108 c may then be lowered such that it rests on the tie lower wall 918 a, and the first panel 108 c may be slid outwardly, such that the outer end portion 107 c is received in the roof panel outer end channel 906 (not labeled in FIG. 11C) of the first tie 900 a. When the outer end portion 107 c is received in the roof panel outer end channel 906, the inner end portion 105 c is spaced from the first side 1010 of the central section 1004.
The second panel 108 c may be assembled to the ridge beam 1000 and second tie 900 b in a similar manner.
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.
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 105 c, 105 d of the panels 108 c, 108 d (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.
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 105 c, 105 d of the panels 108 c, 108 d. The cap 1300 may comprise a first cap wall 1302 for covering inner end 105 c of the first panel 108 c, and a second cap wall 1304 for covering the inner end 105 d of the second panel 108 c. 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.
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.

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.