Note: Descriptions are shown in the official language in which they were submitted.
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ROOF TRUSS CHORD AND
APPARATUS AND PROCESS FOR FORMING SAME
FIE?~D OF THE TNVENTION
[0001] The present invention relates to a roof truss chord and to
an apparatus and process for forming same, and more particularly to
a high strength elongate roof truss chord and to an apparatus and
process for forming same.
BACKGROUND OF THE INVENTION
[0002] In the prior art, industrial roof trusses have been built
from heavy steel angle and re-bar steel (as shown in Figures 15 and
16). Such prior art industrial roof trusses have been quite costly
because of their usage of solid steel.
[0003] It is an object of the invention to provide a roof truss
chord.
[0004] It is a further object of the invention to provide an
apparatus and process for forming a roof truss chord.
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[OOOS] It is another object of the invention to provide an
apparatus and process for forming a roof truss chord wherein an
elongate sheet is passed through a series of tooling sets.
[0006] It is still another object of the invention to provide an
apparatus and process for forming a roof truss chord wherein an
elongate sheet is passed through a series of tooling sets, with each
of the tooling sets respectively comprised of a roll form assembly
and a mating channel portion.
[0007] It is another object of the invention to provide a process
and apparatus for the pre-fabrication of trusses using light-weight
steel materials.
[0008] It is a further object of the invention to provide tooling
necessary for the fabrication of light-weight steel trusses.
[0009] It is yet another object of the invention to provide a
high strength roof truss chord.
[0010] It is still another object of the present invention to
provide an elongate roof truss chord that is able to span a distance
between two bearing walls.
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[0011] It is a still further object of the present invention to
provide an elongate roof truss chord that is able to span a distance
in the order of approximately seventy-five feet between two bearing
walls.
[-0012] It is still yet another object of the present invention to
provide a roof truss chord that provides significant savings in
steel, concrete and labour costs.
SUt~IARY OF THE INVENTION
[0013] In accordance with the present invention, there is
disclosed a roof truss chord having a substantially "U"-shaped cross
section defined by a lower central base portion and two opposed
upper side edge portions. Each of the side edge portions has a top
portion with a respective upper lateral web portion extending
therefrom in a substantially outward direction. Each respective
upper lateral web portion has an outside portion with a respective
lip portion extending therefrom in a substantially downward
direction.
[0014] In accordance with another aspect of the invention, there
is disclosed a roof truss chord comprising a substantially "U"-
shaped cross-section portion defined by a central base portion, and
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two opposed outer side portions extending from the central base
portion, with each of the outer side portions having a base end
portion and a remote end portion. The roof truss chord further
comprises two lateral web portions, each respectively extending in a
substantially outward direction from a different one of the opposed
side portions adjacent its remote end portion, with each of the
lateral web portions having an inward end portion and an outward end
portion. Still further, the roof truss chord comprises two lip
portions, each respectively extending substantially perpendicularly
from a different one of the lateral web portions adjacent its
outward end portion.
[0015] In accordance with another aspect of the present
invention, there is disclosed an apparatus for forming a roof truss
chord comprising a series of tooling sets, each adapted for passing
an elongate sheet therethrough, with each of the tooling sets
respectively comprising a roll form assembly and a mating channel
portion.
[0016] In accordance with a still further aspect of the
invention, there is disclosed an apparatus for forming a roof truss
chord comprising a series of twelve tooling sets, each adapted for
passing an elongate sheet therethrough, and with each of the twelve
tooling sets respectively comprising a roll form assembly and a
mating channel portion.
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[0017] In accordance with another aspect of the invention, the
apparatus is particularly adapted such that passage of the elongate
sheet through each successive one of the tooling sets progressively
forms the roof truss chord.
[0018] In accordance with still another aspect of the invention,
there is disclosed a process for forming a roof truss chord
comprising the step of passing an elongate sheet through a first
tooling set comprising a first roll form assembly and a mating first
channel portion, wherein the elongate sheet is passed between the
first roll form assembly and the first channel portion. The process
further comprises the final step of passing the elongate sheet
through a last tooling set comprising a last roll form assembly and
a mating last channel portion, wherein the elongate sheet is passed
between the last roll form assembly and the last channel portion,
with the last roll form assembly and the last channel portion
defining a cross-sectional aperture therebetween. The cross-
sectional aperture has a substantially "U"-shaped cross-section
portion defined by a central base portion and two opposed outer side
portions extending from the central base portion, with each of the
outer side portions having a base end portion and a remote end
portion. The cross-sectional aperture also has two lateral web
portions, each respectively extending in a substantially outward
direction from a different one of the opposed side portions adjacent
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its remote end portion, with each of the lateral web portions having
an inward end portion and an outward end portion. The cross-
sectional aperture still further has two lip portions, each
respectively extending substantially perpendicularly from a
different one of the lateral web portions adjacent its outward end
portion. The roof truss chord is formed upon passage of the
elongate sheet through the last tooling set.
[0019] In accordance with another aspect of the invention, the
process also includes the step of successively passing the elongate
sheet through a series of ten intermediate tooling sets, each
comprising an intermediate roll form assembly and a mating
intermediate first channel portion, wherein the elongate sheet is
successively passed between each intermediate roll form assembly and
the mating intermediate channel portion.
[0020] In accordance with a further aspect of the present
invention, there is disclosed a roof truss chord which is suitable
for use as either a top or a bottom roof truss chord.
[0021] The use of the roof truss chord of the present invention
makes roof trusses much stronger. This strength provides us with
the opportunity to create a much longer span between two bearing
walls. With this chord method, a span in the order of approximately
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seventy-five feet may be created. Therefore, there are significant
savings in steel, concrete and labour costs.
[0022] Other advantages, features and characteristics of the
present invention, as well as methods of operation and functions of
the related elements of the structure, and the combination of parts
and economies of manufacture, will become more apparent upon
consideration of the following detailed description and the appended
claims with reference to the accompanying drawings, the latter of
which is briefly described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Figure 1 of the drawings appended hereto is a front
elevational view of a roof truss chord formed according to the
invention;
[0024] Figure 2 is a front elevational view of a first tooling
set of an apparatus formed according to the invention:
[0025] Figure 3 is a similar view of a second tooling set;
[0026] Figure 4 is a similar view of a third tooling set;
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[0027] Figure 5 is a similar view of a fourth tooling set;
[0028] Figure 6 is a similar view of a fifth tooling set;
[0029) Figure 7 is a similar view of a sixth tooling set;
[0030] Figure 8 is a similar view of a seventh tooling set;
[0031) Figure 9 is a similar view of an eighth tooling set;
[0032] Figure 10 is a similar view of a ninth tooling set;
[0033] Figure 11 is a similar view of a tenth tooling set;
[0034] Figure 12 is a similar view of an eleventh tooling set;
[0035] Figure 13 is a similar view of a last tooling set;
[0036] Figure 14 is a side elevational view of a roof truss
formed according to the invention;
[0037] Figure 15 is a front elevational view of a prior art roof
truss:
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[0038] Figure 16 is a side elevational view of the prior art roof
truss of Figure 15; and
[0039] Figure 17 is a bottom perspective view of a rigid
framework for roof formed according to the invention.
DETAILED DESCRIPTION OF A PREFERRED E1~ODIMENT
[0040] In the prior art, and as shown in Figures 15 and 16, roof
trusses 30 have heretofore been built from heavy steel angle 32 and
re-bar steel 34. Such prior art roof trusses 30 have been quite
costly, at least in part because of their usage of solid steel.
[0041] With reference now to Figure l, there is shown a roof
truss chord 20 that is formed according to the present invention.
As best seen in Figure l, the chord 20 has a substantially "U"-
shaped cross section defined by a lower central base portion 22 and
two opposed upper side edge portions 24. Each of the side edge
portions 24 has a top portion 24a with a respective upper lateral
web portion 26 extending therefrom in a substantially outward
direction (as indicated by arrows "A1" and "AZ" in Figure 1). Each
respective lateral web portion 26 has an outside portion 26a with a
respective lip portion 28 extending therefrom in a substantially
downward direction (as indicated by arrow "B" in Figure 1). The
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roof truss chord of the present invention is preferably formed from
galvanized steel sheets or strips.
[0042] At this point, it should perhaps be noted that the various
dimensions, orientations and materials specified the drawings are
exemplary of dimensions, orientations and materials which fall
within acceptable parameters, according to the invention, and it
will be appreciated by those skilled in the art that other
dimensions, orientations and materials may be used in the design and
manufacture of the roof truss chord and apparatus and process for
forming same according to the present invention without departing
from its spirit and scope. Hereinafter, the roof truss chord 20 may
alternately be referred to either as a truss channel profile (as
best seen in Figure 1), or simply as a chord.
[0043] As best seen in Figures 14 and 17, two roof truss chords
20 according to the invention, namely, a bottom chord 20a and a top
chord 20b, may be used with steel ribs 38 welded therebetween in a
criss-cross formation. In this manner, and as best seen in Figure
17, the steel ribs 38 may be assembled together with the roof truss
chords 20 so as to form a rigid framework 40 for a roof.
[0044] According to the invention, the roof truss chord 20 is
preferably formed by passing a galvanized steel elongate sheet 42 or
strip through a series of twelve tooling sets, 51 through 62.
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According to a preferred embodiment of the invention, first through
last tooling sets, 51 through 62, for forming the chord 20 are shown
in Figures 2 through 13.
[0045] The first tooling set 51 is shown in Figure 2 and includes
a first roll former assembly 51a and a mating first channel portion
51b. The elongate sheet 42 is first pressed between the first roll
former assembly 51a and the mating first channel portion 51b.
[0046] After being partially formed by the first tooling set 51,
the elongate sheet 42 is then further formed by a second tooling set
52 (shown in Figure 3). The second tooling set 52 includes a second
roll former assembly 52a and a mating second channel portion 52b.
The elongate sheet 42 is further pressed between the second roll
former assembly 52a and the mating second channel portion 52b.
[0047] Next, the elongate sheet 42 is still further formed by
passing through a third tooling set 53 (shown in Figure 4). The
elongate sheet 42 is pressed between a third roll former assembly
53a and a mating third channel portion 53b of the third tooling set
53.
[0048] After being formed as aforesaid by the third tooling set
53, the elongate sheet 42 is passed through a fourth tooling set 54
(shown in Figure 5). The fourth tooling set 54 includes a fourth
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roll former assembly 54a and a mating fourth channel portion 54b.
The elongate sheet 42 is pressed between the fourth roll former
assembly 54a and the mating fourth channel portion 54b.
[0049] Next, the elongate sheet 42 passes through a fifth tooling
set 55 (shown in Figure 6), which includes a fifth roll former
assembly 55a and a mating fifth channel portion 55b. As with the
other tooling sets, the elongate sheet 42 is pressed between the
fifth roll former assembly 55a and the mating fifth channel portion
55b.
[0050] The elongate sheet 42 is then moved from the fifth tooling
set 55 to a sixth tooling set 56 (shown in Figure 7), which includes
a sixth roll former assembly 56a and a mating sixth channel portion
56b. The elongate sheet 42 is then pressed between the sixth roll
former assembly 56a and the mating sixth channel portion 56b.
[0051] Thereafter, the elongate sheet 42 passes through a seventh
tooling set 57 (shown in Figure 8), which includes a seventh roll
former assembly 57a and a mating seventh channel portion 57b. As
with the other tooling sets, the elongate sheet 42 is pressed
between the seventh roll former assembly 57a and the mating seventh
channel portion 57b.
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[0052] After passing as aforesaid through the seventh tooling set
57, the elongate sheet 42 is still further formed by an eighth
tooling set 58 (shown in Figure 9). The eighth tooling set 58
includes an eighth roll former assembly 58a and a mating eighth
channel portion 58b. The elongate sheet 42 is pressed between the
eighth roll former assembly 58a and the mating eighth channel
portion 58b.
[0053] Next, the elongate sheet 42 passes through a ninth tooling
set 59 (shown in Figure 10), which includes a ninth roll former
assembly 59a and a mating ninth channel portion 59b. As with the
other tooling sets, the elongate sheet 42 is pressed between the
ninth roll former assembly 59a and the mating ninth channel portion
59b.
[0054] The elongate sheet 42 is then moved from the ninth tooling
set 59 to a tenth tooling set 60 (shown in Figure 11), which
includes a tenth roll former assembly 60a and a mating tenth channel
portion 60b. The elongate sheet 42 is then pressed between the
tenth roll former assembly 60a and the mating tenth channel portion
60b.
[0055] Thereafter, the elongate sheet 42 passes through an
eleventh tooling set 61 (shown in Figure 12), which includes an
eleventh roll former assembly 61a and a mating eleventh channel
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portion 61b. As with the other tooling sets, the elongate sheet 42
is pressed between the eleventh roll former assembly 61a and the
mating eleventh channel portion 61b.
[0056] Lastly, the elongate sheet 42 is finally passed between
the last tooling set 62 (shown in Figure 13), which includes a last
roll former assembly 62a and a mating last channel portion 62b.
After being pressed between the last roll former assembly 62a and
the mating last channel portion 62b, a cross-sectional profile of
the elongate sheet 42 is identical to that of the roof truss chord
20. The process for forming the roof truss chord 20 according to
the invention is substantially complete once the entire sheet 42 has
passed between last tooling set 62.
[0057] As such, the apparatus and process for forming the roof
truss chord 20 according to the present invention will be seen to
include the passage of an elongate sheet 42 through a series of
tooling sets, each of tooling sets respectively comprised of a roll
former assembly and a mating channel portion.
[0058] The process and apparatus for forming the roof truss chord
20, according to the present invention, is capable of forming a high
strength elongate roof truss chord of the type shown in the drawings
(as best seen in Figures 1, 14 and 17), and provides for the pre-
fabrication of roof truss chords 20 and roof trusses using light-
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weight steel materials. The process and apparatus disclosed hereby
provide the tooling necessary for the fabrication of light-weight
steel roof truss chords and roof trusses.
[0059] According to the invention, the process and apparatus
disclosed hereby are capable of producing roof truss chords 20 that
span a distance in the order of approximately seventy-five feet
between two bearing walls (not shown). The roof truss chord 20
formed according to the present invention provides significant
savings in steel, concrete and labour costs.
[0060] The use of the roof truss chord 20 of the present
invention makes roof trusses 40 much stronger. This strength
provides the opportunity to create a much longer span between two
bearing walls - in the order of approximately seventy-five feet -
with significant savings in steel, concrete and labour costs.
[0061] Various other modifications and alterations may be used in
the design and manufacture of the roof truss chord 20 and the
apparatus and process for forming same, according to the present
invention, without departing from the spirit and scope of the
invention, which is limited only by the accompanying claims.
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