US-12623834-B2 - Methods of assembly of prefabricated truss construction modules

US12623834B2US 12623834 B2US12623834 B2US 12623834B2US-12623834-B2

Abstract

The disclosure provides a method that includes providing or assembling a rectangular horizontal member, joining a vertical member to the rectangular horizontal member such that the vertical member bisects a length of the horizontal member and forms a T-junction at the horizontal member, joining first and second sloped members to the rectangular horizontal member and vertical member such that the first and second sloped members span from a top of the vertical member to opposing ends of the horizontal member, and joining first and second support members such that the first and second support members span from the T-junction between the vertical member and horizontal member to work points on an underside of each of the first and second sloped members. The structure thus formed can be assembled from prefabricated units shipped together in parallel planar orientation in a shipping container to provide a roof truss unit.

Inventors

Kyle Tompane
Greg Otto

Assignees

Kyle Tompane
Greg Otto

Dates

Publication Date: 20260512
Application Date: 20240110

Claims (20)

1 . A method, comprising: providing or assembling a rectangular horizontal member; joining a vertical member to the rectangular horizontal member such that the vertical member bisects a length of the horizontal member and forms a T-junction at the horizontal member; joining first and second sloped members to the rectangular horizontal member and vertical member such that the first and second sloped members span from a top of the vertical member to opposing ends of the horizontal member, each first and second sloped member having a groove cut into an underside portion; and joining first and second support members such that the first and second support members span from first ends disposed on either side of the T-junction between the vertical member and horizontal member to opposing second ends which only make direct contact with work points on the underside portion of each of the first and second sloped members at each groove, wherein the second ends of the first and second support members are precision cut male ends which are mated with each groove; wherein no additional support members are joined such that each of the first and second sloped members has no more than one work point disposed on their respective underside portions between the top of the vertical member and each opposing end of the horizontal member.
2 . The method of claim 1 , wherein the rectangular horizontal member is a panel.
3 . The method of claim 1 , wherein the vertical member is a panel.
4 . The method of claim 1 , wherein the first and second sloped members are panels.
5 . The method of claim 1 , wherein first and second support members are planks.
6 . The method of claim 1 , wherein the rectangular horizontal member is a frame.
7 . The method of claim 1 , wherein the vertical member is a plank.
8 . The method of claim 1 , wherein the first and second sloped members are frames.
9 . The method of claim 1 , wherein the first and second support members are frames.
10 . The method of claim 1 , wherein the first and second support members are panels.
11 . The method of claim 1 , wherein the rectangular horizontal member, vertical member, first and second sloped members, and first and second support members are made of wood.
12 . The method of claim 1 , wherein when assembled together the rectangular horizontal member, vertical member, first and second sloped members, and first and second support members form a truss unit for manufacture of a roof structure.
13 . The method of claim 12 , further comprising joining a roof structure overlying the truss unit.
14 . The method of claim 13 , further comprising joining filler units representing ceiling panels or frames to flank on either side of the truss unit, wherein the roof structure is joined to overlie the truss unit and flanking filler units.
15 . The method of claim 13 , further comprising joining two truss units to flank a filler unit representing a ceiling panel or frame, wherein the roof structure is joined to overlie the filler unit and flanking truss units.
16 . The method of claim 14 , further comprising joining a plank spanning a top of the truss unit and a width of each of the flanking filler units, the plank forming a ridge to support the roof structure.
17 . The method of claim 15 , further comprising joining a plank spanning a top of the two truss units and a width of the filler unit therebetween, the plank forming a ridge to support the roof structure.
18 . The method of claim 13 , wherein the roof structure comprises panels overlying alternating truss units and filler units representing ceiling panels or frames.
19 . The method of claim 13 , wherein the roof structure comprises a frame, panels overlying the frame, and roofing material overlying the panels.
20 . The method of claim 19 , further comprising weaving a web of wiring to connect and compress members of the frame of the roof structure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present application is a continuation-in-part of U.S. Non-Provisional patent application Ser. No. 17/752,799 filed on May 24, 2022 and a continuation-in-part of U.S. Non-Provisional patent application Ser. No. 18/380,107 filed on Oct. 13, 2023, which was a continuation application of U.S. Non-Provisional Patent Application Ser. No. 18,116,756 filed on Mar. 2, 2023 now U.S. Pat. No. 11,801,990, which was a continuation application of U.S. Non-Provisional Patent Application Ser. No. 17,752,804 filed on May 24, 2022 now U.S. Pat. No. 11,603,260, all of which are incorporated by reference in their entireties. FIELD The present disclosure is directed to the field of construction. More particularly, the present disclosure relates to prefabricated construction modules designed for manufacturing roof trusses and methods of assembly and shipping. BACKGROUND Trusses are built with all members either in tension or compression. The members converge at nodes (referred to as work points). Examples of conventional trusses are shown in FIGS. 1-4. Planar trusses are not stable out of plane making them difficult to handle until braced. This presents significant safety risk to installers as work is done in elevated conditions. What is needed for maximum safety and efficiency is a prefabricated solution that can be built mostly on ground and is stable. SUMMARY In general, in a first aspect, the disclosure features an article of manufacture. The article of manufacture includes a rectangular horizontal member, a vertical member bisecting a length of the horizontal member and forming a T-junction at the horizontal member, first and second sloped members spanning from a top of the vertical member to opposing ends of the horizontal member, and first and second support members spanning from the T-junction between the vertical member and horizontal member to work points on an underside of each of the first and second sloped members. In general, in a second aspect, the disclosure features a method. The method includes providing or assembling a rectangular horizontal member, joining a vertical member to the rectangular horizontal member such that the vertical member bisects a length of the horizontal member and forms a T-junction at the horizontal member, joining first and second sloped members to the rectangular horizontal member and vertical member such that the first and second sloped members span from a top of the vertical member to opposing ends of the horizontal member, and joining first and second support members such that the first and second support members span from the T-junction between the vertical member and horizontal member to work points on an underside of each of the first and second sloped members. In general, in a third aspect, the disclosure features a shipping container, The shipping container has first, second, and third planar prefabricated modules capable of forming an article of manufacture of the disclosure as cargo in the interior of the shipping container, the prefabricated modules stacked vertically in parallel planar orientation, the shipping container having an open top capable of top loading and unloading. In general, in a fourth aspect, the disclosure features a method. The method includes loading a shipping container with first, second, and third planar prefabricated modules capable of forming an article of manufacture of the disclosure as cargo in the interior of the shipping container through an open top of the shipping container, the prefabricated modules stacked vertically in parallel planar orientation. Features of the articles of manufacture and methods can include the following. The horizontal members, vertical members, sloped members, support members, and combinations thereof can take the form of structures such as panels, frames, and planks or beams, and combinations thereof. Ends of the first and second support members can have a precision cut design to fit a corresponding groove at the work points on an underside of the first and second sloped members. The rectangular horizontal member, vertical member, first and second sloped members, and first and second support members can be made of wood and can form a truss unit for manufacture of a roof structure when assembled together. A roof structure can overlie the truss unit or can be joined to overly the truss unit. Filler units representing ceiling panels or frames can flank or can be joined to flank on either side of the truss unit, where the roof structure overlies the truss unit and flanking filler units. Two truss units can flank or can be joined to flank a filler unit representing a ceiling panel or frame, where the roof structure overlies the filler unit and flanking truss units. The truss unit can have a plank or can be joined with a plank that spans a top of the truss unit and a width of each of the flanking filler units, the plank forming a ridge to support the roof structure, or the truss u