Extruded Aluminum Roof Truss Manufacturing System and Methods

Abstract

A method for manufacturing, transporting, and installing an extruded aluminum roof truss by manufacturing an extrusion that comprises a top chord extrusion, a bottom chord extrusion, a web brace extrusion, manufacturing standardized components such as a connector, a hinge, a bracket, and a fastener used to configure the extrusion into a truss configuration, pre-assembling the extrusion with an optionally pre-determined set of the standardized components required to either fully or partially assemble the truss prior to transport and installation at the building site, transporting the truss in either a fully or partially assembled compact configuration to the installation site, rotating the truss open by pivoting the web bracing into alignment with a matching connector hole on an extrusion at the installation site, and installing any required connectors or remaining standardized components to complete the truss.

Claims

1. An extruded roof truss, comprising: an extruded chord, comprising: a top chord; and a bottom chord removably coupled to the top chord; a web bracing removably coupled to the chord; a bracket removably coupled to the chord; and a connector removably coupled to the chord and the bracket, wherein the chord, the web bracing, the bracket, and the connector are configured as a truss and at least one of the chord and the web bracing are comprised of a substantially aluminum material.

2. The extruded roof truss of claim 1, wherein the truss has a truss configuration of at least one of the following: a fink truss, a howe truss, an attic truss, and a scissors truss.

3. The extruded roof truss of claim 1, wherein the bracket further comprises at least one of a gusset, a flat bracket, a pivot bracket, and a double bracket.

4. The extruded roof truss of claim 1, wherein the connector is pivotably coupled to the top chord and the bottom chord and further comprises a connecting pin and a lock ring.

5. The extruded roof truss of claim 1, wherein the connector is pivotably coupled to the chord and the web bracing and further comprises a connecting pin and a lock ring.

6. The extruded roof truss of claim 1, further comprising a fastener comprising at least one of the following: a screw, a bolt, a rivet, and a nut.

7. The extruded roof truss of claim 1, further comprising a hinge assembly comprising: a hinge left configured with a first pin boss, a first mounting hole, and a first hinge knuckle; and a hinge right configured with a second pin boss, a second mounting hole, and a second hinge knuckle.

8. The extruded roof truss of claim 1, wherein the first top cord comprises a first top chord extrusion and a second top chord extrusion and the truss further comprises a peak hinge assembly, the peak hinge assembly comprising: a hinge left coupled to the first top chord extrusion by a first fastener; and a hinge right coupled to the second top chord extrusion by a second fastener, wherein the hinge left is removably coupled to the hinge right by a connecting pin and a lock ring.

9. The extruded roof truss of claim 1, wherein the truss further comprises: a gusset further comprising a first end and a second end; a top chord extrusion coupled to the first end of the gusset by a connecting pin and a lock ring; and a bottom chord extrusion coupled to the second end of the gusset by a fastener.

10. The extruded roof truss of claim 1, wherein the truss further comprises an a-brace, comprising: a web brace extrusion further comprising a first end and a second end; a first pivot bracket coupled to the first end of the web brace extrusion by a first fastener; and a second pivot bracket coupled to the second end of the web brace extrusion by a second fastener.

11. The extruded roof truss of claim 1, wherein the truss further comprises a king post brace, comprising: a web brace extrusion further comprising a first end and a second end; a first double bracket coupled to the first end of the web brace extrusion by a first fastener; and a second double bracket coupled to the second end of the web brace extrusion by a second fastener.

12. The extruded roof truss of claim 1, wherein the truss further comprises a t-brace, comprising: a substantially vertical web brace extrusion having a first end and a second end; a double bracket coupled to the first end of the substantially vertical web brace extrusion by a first fastener; a first flat plate bracket further comprising a first side and a second side, wherein the first side of the first flat plate is coupled to the second end of the substantially vertical web brace extrusion by a second fastener; a substantially horizontal web brace extrusion further comprising a first side and a second side; and a second flat plate bracket; wherein the first side of the substantially horizontal web brace is coupled to the second side of the second side of the first flat plate and the second side of the substantially horizontal web brace extrusion is coupled to the second flat plate by a connecting bolt and a threaded nut.

13. The extruded roof truss of claim 1, wherein the truss further comprises a cross brace, comprising: a king post brace, comprising: a substantially vertical web brace extrusion, further configured with a first end, a second end, a first side, and a second side; a first double bracket coupled to the first end of the substantially vertical web brace extrusion by a first fastener; and a second double bracket coupled to the second end of the substantially vertical web brace extrusion by a second fastener; a first flat plate bracket coupled to a first substantially horizontal web brace extrusion by a third fastener; and a second flat plate bracket coupled a second substantially horizontal web brace extrusion by a fourth fastener; wherein the first flat plate is coupled to the first side of the substantially vertical web brace extrusion and the second flat plate is coupled to the second side of the substantially vertical web brace extrusion by a connecting bolt and a threaded nut.

14. The extruded roof truss of claim 1, wherein the truss further comprises a peak assembly, comprising: a king post brace, comprising: a double bracket further comprising a first end and a second end; and a web brace extrusion coupled to the double bracket; a first top chord extrusion coupled to the first end of the double bracket by a first connecting pin and a first lock ring; and a second top chord extrusion coupled to the second end of the double bracket by a second connecting pin and a second lock ring.

15. The extruded roof truss of claim 1, wherein the web bracing further comprises a web bracing configuration wherein the web bracing configuration comprises at least one of the following: a gusset, a pair of gussets, a gusset assembly, a peak hinge assembly, an a-brace, a king post brace, a t-brace, a cross brace, a peak assembly, and an a-brace assembly.

16. An extruded roof truss, comprising: an extruded chord, comprising: a top chord, comprising: a top chord extrusion configured as a substantially aluminum material; and a bottom chord removably coupled to the top chord, comprising: a bottom chord extrusion configured as a substantially aluminum material; a web bracing removably coupled to the extruded chord, comprising: a web brace extrusion configured as a substantially aluminum material; and an a-brace removably coupled to the top chord extrusion and bottom chord extrusion, comprising: a web brace extrusion further comprising a first end and a second end; a first pivot bracket coupled to the first end of the web brace extrusion by a first fastener; and a second pivot bracket coupled to the second end of the web brace extrusion by a second fastener; a bracket removably coupled to the extruded chord, comprising: a gusset removably coupled to the top chord extrusion and the bottom chord extrusion; and a peak hinge assembly removably coupled to the top chord extrusion, comprising: a hinge left; and a hinge right; wherein the hinge left is pivotably coupled to a hinge right by a first connector further comprising a connecting pin and a lock ring; wherein the gusset is pivotably coupled to the top chord extrusion by a second connector further comprising a connecting pin and a lock ring and where the gusset is removably coupled to the bottom chord extrusion by a fastener further configured as a rivet, and wherein the chord, the web bracing, the bracket, and the connector are configured as a fink truss.

17. A method for manufacturing an extruded roof truss, comprising: extruding a top chord, a bottom chord, and a web bracing, the top chord, bottom chord, and web bracing comprised substantially of aluminum; pre-assembling the top chord, bottom chord, and web bracing with one or more brackets and fasteners; transporting the truss in either a fully or partially assembled compact configuration to an installation site; rotating the truss open by pivoting the web bracing into alignment with a matching connector hole on the at least one of the top chord, bottom chord, and web bracing at the installation site; and installing one or more fasteners to complete the truss assembly.

18. The method for manufacturing an extruded roof truss of clam 17, further comprising: connecting a peak hinge assembly to a truss by fastening a hinge left to a first top chord with four self-threading screws secured the mounting holes on the hinge left and the screw slots on the first top chord; fastening a hinge right to a second top chord with four self-threading screws secured the mounting holes on the hinge right and the screw slots on the second top chord; and removably connecting the hinge left and the hinge right with a connecting pin and lock ring.

19. The method for manufacturing an extruded roof truss of clam 17, further comprising: coupling a gusset to a truss by orienting a first gusset and a second gusset as pairs opposite each other; mechanically fastening each gusset with a blind rivet to the inside of each vertical face of the bottom chord; orienting a pivot hole the gusset with a top chord connector hole on a top chord; and securing each gusset pivot hole and the top chord connector hole with a connecting pin and a lock ring.

20. The method for manufacturing an extruded roof truss of clam 17, further comprising: coupling an a-brace to a truss by securing a first pivot bracket to a first end of a first web brace extrusion with four self-threading screws fastened between a web brace screw slot and the pivot bracket mounting holes; and securing a second pivot bracket to a second end of the first web brace extrusion with four self-threading screws fastened between a web brace screw slot and the pivot bracket mounting holes.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0034] A more complete understanding of the present invention may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the figures, like reference numbers refer to like elements or acts throughout the figures.

[0035] FIG. 1 representatively illustrates an orthographic of an embodiment of an extrusion shown as a top chord extrusion, a bottom chord extrusion, and a web brace extrusion, a connector shown as a connecting pin and a lock ring, a hinge shown as a hinge left and a hinge right, and three brackets shown as a flat plate bracket, a pivot bracket, and a double bracket.

[0036] FIG. 2 representatively illustrates an embodiment of a peak hinge assembly depicted in an assembled state and an exploded view and configured with a first top chord secured to a hinge left by four screws, a second top cord secured to a hinge right by four screws, and the hinge left secured to the hinge right by a connecting ping and lock ring.

[0037] FIG. 3 representatively illustrates an embodiment of a pair of gussets secured to a top chord by a connecting pin and lock ring and the pair of gussets secured to a bottom chord by rivets depicted as a section of the fully assembled view, a partially assembled view showing only the bottom chord with an installed pair of gussets, and an exploded view without the top chord.

[0038] FIG. 4 representatively illustrates an embodiment of an a-brace configured with two pivot brackets each secured by screws to a different end of a web brace extrusion and depicted in both an exploded view and an assembled view.

[0039] FIG. 5 representatively illustrates an embodiment of a king post brace configured with two double brackets each secured by screws to a different end of a web brace extrusion and depicted in both an exploded view and an assembled view.

[0040] FIG. 6 representatively illustrates an embodiment of a t-brace configured with a double bracket secured by screws to a first web brace extrusion, a first flat plate secured by screws to the first web brace extrusion, a second flat plate secured by screws to a second web brace extrusion, and the second web brace extrusion secured to the first flat plate by a connecting bolt and threaded nut and depicted in both an exploded view and an assembled view.

[0041] FIG. 7 representatively illustrates an embodiment of a cross brace configured with two flat plate brackets each secured by screws to a different section of a horizontal web brace extrusion such as two horizontal split braces and each flat plate on each horizontal web brace extrusion secured to a vertical king post brace by a connecting bolt and threaded nut and depicted in both an exploded view and an assembled view.

[0042] FIG. 8A representatively illustrates an exploded view of a section of an embodiment of a peak assembly depicting a configuration of two top chords secured to a double bracket on a king post brace with a configuration of connecting pins and lock rings.

[0043] FIG. 8B representatively illustrates an exploded view of a section of an embodiment of a-brace assembly secured to a bottom chord by a configuration of connecting pins and lock rings.

[0044] FIG. 9A representatively illustrates an orthographic view of an embodiment of the extruded aluminum truss manufacturing system configured as a fink truss depicted in a state as fully assembled and a state in a compact mode state such as when delivered to a jobsite.

[0045] FIG. 9B representatively illustrates an orthographic view of an embodiment of the extruded aluminum truss manufacturing system configured as an howe truss depicted in a state as fully assembled and a state in a compact mode state such as when delivered to a jobsite.

[0046] FIG. 9C representatively illustrates an orthographic view of an embodiment of the extruded aluminum truss manufacturing system configured as an attic truss depicted in a state as fully assembled and a state in a compact mode state such as when delivered to a jobsite.

[0047] FIG. 9D representatively illustrates an orthographic view of an embodiment of the extruded aluminum truss manufacturing system configured as a scissors truss depicted in a state as fully assembled and a state in a compact mode state such as when delivered to a jobsite.

[0048] FIG. 10 depicts a general process diagram of an embodiment of an extruded aluminum roof truss manufacturing system that is configured to be transported in a compact configuration and rotated into an open configuration at the installation site to complete the truss.

[0049] FIG. 11 depicts a general process diagram of an embodiment of a peak hinge assembly as shown in FIG. 2.

[0050] FIG. 12 depicts a general process diagram of an embodiment of a gusset as shown in FIG. 3.

[0051] FIG. 13 depicts a general process diagram of an embodiment of an a-brace as shown in FIG. 4.

[0052] FIG. 14 depicts a general process diagram of an embodiment of a king post brace as shown in FIG. 5.

[0053] FIG. 15 depicts a general process diagram of an embodiment of a t-brace as shown in FIG. 6.

[0054] FIG. 16 depicts a general process diagram of an embodiment of a cross brace as shown in FIG. 7.

[0055] FIG. 17 depicts a general process diagram of an embodiment of a peak assembly as shown in FIG. 8A.

[0056] FIG. 18 depicts a general process diagram of an embodiment of an a-brace assembly as shown in FIG. 8B.

[0057] Elements and acts in the figures are illustrated for simplicity and have not necessarily been rendered according to any particular sequence or embodiment.

DETAILED DESCRIPTION

[0058] In the following description, and for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these specific details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed inventions may be applied. The full scope of the inventions is not limited to the examples that are described below.

[0059] In one embodiment, an extruded aluminum roof truss manufacturing system, may comprise an extrusion. In another embodiment, an extrusion may be configured as a top chord extrusion 010, a bottom chord extrusion 020, and a web brace extrusion 030 as shown in FIG. 1 through FIG. 9. In one embodiment, an extrusion may be configured to provide structure and support for a truss in an a-brace 034 configuration, a king post brace 036 configuration, a t-brace 038 configuration, a cross brace 040 configuration, a fink truss 100 configuration, a howe truss 200 configuration, an attic truss 300 configuration, an scissors truss 400 configuration, a king post truss configuration, a queen post truss configuration, a gable truss configuration, a lattice truss configuration, a space frame truss configuration, another standard truss configuration, and another custom designed truss configuration. In one embodiment, an extrusion may be configured with a single flange, more than one flange, a set of symmetric flanges, and a set of non-symmetric flanges. In another embodiment, an extrusion may be configured as a material that is lighter than wood, a metal material such as aluminum, a wood material, a wood composite material, a plastic material, and a combination of materials. In one embodiment, an extrusion may be configured as varying in both size, shape, length, cross-section, shape of section such as extrusion profile such as U-shaped, and contour. The extrusion, may however be configured in any suitable manner to secure a component of the extruded aluminum roof truss manufacturing system such as a chord, a web bracing, another extrusion, a connector, a hinge, a bracket, a fastener, or other component of a truss to another component of the truss and provide an alternative truss component to an existing wood-based truss component.

[0060] In one embodiment, a top chord extrusion 010 may be optionally configured with a top chord connector hole 014 optionally configured to mate with a gusset 046 pivot hole 048, a top chord flange 016, and a top chord screw slot 018 optionally configured to mate with a screw such as a self-threading screw 060. In another embodiment, a top chord extrusion 010 may be configured with a generally inverted U shape and four top chord screw slots 018 with one top chord screw slots 018 near each corner of the profile section, providing connection points into which self-threading screw 060 are installed parallel to the longitudinal axis of the top chord extrusion 010 as shown in FIG. 1. In another embodiment, a top chord extrusion 010 may be configured with opposing flanges 016 that extend outward from the base of the open end of the top chord extrusion 010 as structural reinforcement and a stop for rigid insulation board installed between adjacent trusses. In another embodiment, a top chord extrusion 010 maybe be configured with a top chord screw slot 018 and a flange 016 that are either or both homogeneously formed as integral components of the top chord extrusion 010. The top chord extrusion 010, may however be configured in any suitable manner to provide support and structure for a truss and provide an alternative truss component to an existing wood-based truss component.

[0061] In one embodiment, bottom chord extrusion 020 may be optionally configured with a bottom chord connector hole 026 optionally configured to mate with a gusset 046 pivot hole 048, a bottom chord flange 028, and a bottom chord screw slot optionally configured to mate with a screw such as a self-threading screw 060. In one embodiment, bottom chord extrusion 020 may be configured as generally U shaped with two opposing bottom chord flanges 028 at the top or open end of the U that are perpendicular to the vertical faces of the U-shaped extrusion facing outward providing structural reinforcement as shown in FIG. 1. The bottom chord extrusion 020, may however be configured in any suitable manner to provide support and structure for a truss and provide an alternative truss component to an existing wood-based truss component.

[0062] In one embodiment, a web brace extrusion 030 may be optionally configured with a web brace screw slot 032. In another embodiment, a web brace extrusion 030 may be configured as an interior component to be housed such as nested within the perimeter of a truss such as the U-shaped section of the top chord extrusion 010 and the bottom chord extrusion 020 and mate with a chord such as a top chord 012 and a bottom chord 022 as shown in FIG. 1 and FIG. 8B through 9D. In another embodiment, a web brace extrusion 030 may be configured with a cross section that is substantially hollow, a closed profile section, and generally rectangular in shape with four integral web brace screw slots 032 oriented near the four corners of the profile section as shown in FIG. 1. In one embodiment, a web brace extrusion 030 may be configured to provide structure and support for a truss in an a-brace 034 configuration, a king post brace 036 configuration, a t-brace 038 configuration, and a cross brace 040 configuration as shown in FIG. 4 through FIG. 7. The web brace extrusion 030, may however be configured in any suitable manner to provide support and structure for a truss and provide an alternative truss component to an existing wood-based truss component.

[0063] In one embodiment, a connector may comprise a connecting pin 042 and a lock ring 044 as shown in FIG. 1, FIG. 2, FIG. 3, FIG. 8A through FIG. 9D. In another embodiment, a connector may be configured as a separate connecting pin 042 and a lock ring 044 and an integrated connecting pin and lock ring. In another embodiment, the lock ring 044 may be shaped as a pin, screw, bolt, or combination of shapes configured to secure the connecting pin 042. In another embodiment, a connector may be configured to secure a web brace tween a top chord 012 and a bottom chord 022. In another embodiment, a connector may be configured to secure a hinge assembly, a chord to another chord such as a top chord to a bottom chord, and a chord to a web bracing. In another embodiment, a connector may be configured to be installed at manufacturing such as pre-assembled and at the installation location such as a job site post-assembled. In another embodiment, a connector may be configured as a metal material such as aluminum, a wood material, a plastic material, and a combination of materials. In one embodiment, a connector may be configured as varying in both size, shape, length, and contour. The connector, may however be configured in any suitable manner to secure a component of the extruded aluminum roof truss manufacturing system such as a chord, a web bracing, an extrusion, another connector, a hinge, a bracket, a fastener, or other component of a truss to another component of the truss and provide an alternative truss component to an existing wood-based truss component.

[0064] In one embodiment, a hinge assembly may comprise a hinge left 068 and a hinge right 070 as shown in FIG. 1, FIG. 2, and FIG. 9A. In another embodiment, a hinge assembly may comprise a hinge left 068 optionally configured with a hinge left pin boss 086, a hinge left mounting hole 072, and a hinge left knuckle. In another embodiment, a hinge assembly may comprise hinge right 070 optionally configured with a hinge right pin boss, a hinge right mounting hole, and a hinge knuckle 074. In another embodiment, a hinge assembly may comprise a hinge left 068 and a hinge right 070 configured to mate with a connecting pin 042 and a lock ring 044. In another embodiment, a hinge assembly may comprise a hinge left 068 and a hinge right 070 configured to mate with a top chord screw slot 018, a bottom chord screw slot, and a web brace screw slot 032. In another embodiment, a hinge assembly may comprise a hinge left 068 and a hinge right 070 configured to mate with a chord. In another embodiment, a hinge left 068 and a hinge right 070 may be configured to have the same extrusion profile cross section with a flat base plate that is the mating surface between the bracket and the end of a top chord 012 section and a standoff that is a triangular section situated away from the base supported by two inclined legs that form a triangular shape with the base of the bracket at the bottom and a circular tubular pin boss such as a hinge left pin boss 086 and a hinge right pin boss at the apex of the triangle with each of the inclined legs tangent to the circular tubular hinge pin boss such as a hinge left pin boss 086 and a hinge right pin boss at the apex. In one embodiment, a pin boss such as a hinge left pin boss 086 and a hinge right pin boss may be configured such having an apex that is parallel to the short dimension of the base of the bracket with an inside diameter sized to mate with a connecting pin 042. In another embodiment, a hinge left 068 and a hinge right 070 may be configured with an extended mating base of the hinge brackets both hinge left 068 and a hinge right 070 to provide clearance for mounting holes such as four hinge left mounting holes 072 and four hinge right mouthing holes that align with a screw slot on a chord such as top chord screw slot 018 integral to the top chord extrusion 010 as shown in FIG. 1. In another embodiment, a hinge left 068 and a hinge right 070 may be configured with a round bushing at the apex of the stand-off, after notches are machined to form a hinge knuckle such as a left hinge knuckle, and a right hinge knuckle 074 through which a hinge pin such as a connecting pin 042 may be positioned and secured with a lock ring 044 such as when assembling a peak hinge assembly 066 as shown in as shown in FIG. 1 and FIG. 2. In another embodiment, a hinge assembly may be configured with a mounting hole, a notch, a stop, and a leave such as integrated leaves. In another embodiment, a hinge assembly may be configured as a metal material such as aluminum, a wood material, a plastic material, and a combination of materials. In one embodiment, a hinge assembly may be configured as varying in both size, shape, length, cut length, pre-manufactured length, contour, and degree of rotation. In one embodiment, a hinge assembly may be configured as a removable hinge, a partially removable hinge such as one side of the hinge removeable and one side of the hinge permanent, a temporary removable hinge such as a hinge secured by a screw, and a bolt, and a non-removable permanent hinge such as a hinge secured by a weld and a glue. In another embodiment, a hinge assembly may be configured to attach to the ends of and situate between two chord components and connect the two chords allowing the chords of a truss to be manufactured, handled, and shipped in a linear configuration and rotating open at the job site where the final truss assembly takes place. The hinge assembly, may however be configured in any suitable manner to secure a component of the extruded aluminum roof truss manufacturing system such as a chord, a web bracing, an extrusion, a connector, another hinge, a bracket, a fastener, or other component of a truss to another component of the truss and provide an alternative truss component to an existing wood-based truss component.

[0065] In one embodiment, a bracket may be configured as a gusset 046, a flat plate bracket 050, a pivot bracket 052, and a double bracket 054 as shown in FIG. 1 through FIG. 9. In one embodiment, gusset 046 may be configured with a pivot hole 048 as shown in FIG. 3. In another embodiment, a bracket may be configured to fasten to the ends of a web brace and form the web brace within a truss. The bracket, may however be configured in any suitable manner to secure a component of the extruded aluminum roof truss manufacturing system such as a chord, a web bracing, an extrusion, a connector, a hinge, another bracket, a fastener, or other component of a truss to another component of the truss and provide an alternative truss component to an existing wood-based truss component.

[0066] In one embodiment, a flat plate bracket 050 may be configured with a bolt clearance hole 080 and a flat plate counter sunk mounting hole 082 as shown in FIG. 1. In another embodiment, a flat plate bracket 050 may be configured perpendicular to connections between vertical and horizontal web braces and secured with fasteners such as a bolt and a nut. In another embodiment, a flat plate bracket 050 may be configured as oblong in shape being the same width as the narrow dimension of the web brace extrusion 030 configured with mounting holes such as four flat plate countersunk mounting holes 082 as shown in FIG. 1 that are configured to align with the a mating web brace screw slots 032 integral to the web brace extrusion 030 and fastened to that web brace extrusion 030 with a fastener such as four self-threading flat-head screws 062 through the four countersunk mounting holes 082 and into the four web brace screw slots 032 as shown in FIG. 6 and FIG. 7. In another embodiment, a flat plate bracket 050 may be configured to extend past the wide width of the web brace extrusion 030 to provide for a bolt clearance hole 080 as shown in FIG. 1 where on each side of the web brace extrusion 030 aligning with a double bracket clearance hole 056 in the horizontal web brace extrusion 030 section through which a first fastener such as a connecting bolt 076 is configured to pass and be secured with a second fastener such as a threaded nut 078. In another embodiment, a flat plate bracket 050 may be a second flat plate bracket 052 configured to serve as a bearing plate on the lower face of a horizontal web brace extrusion 030 as shown in the detail in FIG. 6. The flat plate bracket 050, may however be configured in any suitable manner to provide an alternative truss component to an existing wood-based truss component.

[0067] In one embodiment, a pivot bracket 052 may be configured with a pivot bracket pin boss 088 and a pivot bracket mounting hole 090. In another embodiment, a pivot bracket 052 may be configured to attach to each end of a web brace to allow for vertical and inclined bracing between a top chord 012 and a bottom chord 022 within a truss being secured in place by a connector such as a connecting pin 042 through a clearance hole in chords such top chord connector hole 014 and a bottom chord connector hole 026 with a top that aligns with the pivot hole in the bracket and a connector such as a connecting pin 042 extending through the aligned holes in the chords where the the pivot bracket 052 is between the chords and secured with a connector such as lock ring 044. In another embodiment, a pivot bracket 052 may be comprise a material configured as an aluminum extrusion that may be extruded to the same width as the wide dimension of the end face of the web brace extrusion 030 and cut to a length that matches the narrow dimension of the end face of the web brace extrusion 030 establishing the base of the pivot bracket 052. In another embodiment, the base on the pivot bracket 052 may be configured as a flat face and provide a mating surface between the pivot bracket 052 and an end of the web brace extrusion 030. In another embodiment, a pivot bracket 052 may be configured with a round tubular shaped pivot bracket pin boss 088 configured with an inside dimension sized to accept a connector such as a connecting pin 042 and where the linear axis of the pivot bracket pin boss 088 is configured perpendicular to the linear axis of the brace extrusion 030, parallel to the narrow dimension of the brace extrusion 030, and set away from the base by two inclined legs that form a triangular shape with the mating base being the third leg of the triangle and the round tubular shaped boss at the apex of the triangle with the two inclined legs being tangent to the tubular shaped boss as shown in FIG. 1. In another embodiment, a pivot bracket 052 may be configured with a pivot bracket mounting hole 090 configured through the mating surface to align with a web brace screw slot 032 integral to the web brace extrusion 030 and through which a self-threading screw 060 is configured to pass through and a pivot bracket 052 secured to each end of the web brace extrusion 030 such as in completing an assembly of an a-brace 034 as shown in FIG. 4. The pivot bracket 052, may however be configured in any suitable manner to provide an alternative truss component to an existing wood-based truss component.

[0068] In one embodiment, a double bracket 054 may be configured with a double bracket clearance hole 056, a double bracket mounting hole 058, and a double bracket pin boss 092 as shown in FIG. 1. In another embodiment, a double bracket 054 may be configured as a double bracket 054 on each end of a we brace to allow for a vertical post centered on a seam between two chords such as a top chord 012 and extends such as downward to the bottom of the truss such as a king post brace 036 and fastened in place with a connector such as a connecting pin 042 and secured with a connector such as a lock ring 044. In one embodiment, a bracket may be configured as a combination of brackets configured to secure a connection between a top chord 012, a bottom chord 022, and a web bracing. In another embodiment, a double bracket 054 may be configured from a material manufactured from an aluminum extrusion and cut to a length that matches the narrow dimension of the end face of the web brace extrusion 030. The double bracket 054, may however be configured in any suitable manner to provide an alternative truss component to an existing wood-based truss component.

[0069] In one embodiment, a fastener may be configured as a screw, bolt, rivet, and a nut as shown in FIG. 2 through FIG. 9. In one embodiment, a fastener may be configured as a screw such as a self-threading screw 060, a self-threading flat-head screw 062, a non-threading screw, a self-tapping screw, a non-tapping screw. In one embodiment, a fastener may be configured as a rivet such as a blind rivet 064. In one embodiment, a fastener may be configured as a nut such as a threaded nut 078. In one embodiment, a fastener may be configured as a combination of fasteners such as a bolt and a nut and may optionally include additional components such as a washer, a locking washer, an insert, and a grommet. In one embodiment, a fastener may be configured as a metal material, a wood material, a plastic material, and a combination of materials. In one embodiment, a fastener may be configured as varying in both size, shape, length, diameter, thread type, thread count, and thread pitch. In one embodiment, a fastener may be configured as a removable fastener, temporary removable fastener, and a non-removable permanent fastener such as a fastener secured by a weld and a glue. In another embodiment, a fastener may be configured to be installed at manufacturing such as pre-assembled and at the installation location such as a job site post-assembled. The fastener, may however be configured in any suitable manner to secure a component of the extruded aluminum roof truss manufacturing system such as a chord, a web bracing, an extrusion, a connector, a hinge, a bracket, another fastener, or other component of a truss to another component of the truss and provide an alternative truss component to an existing wood-based truss component.

[0070] In one embodiment, a peak hinge assembly 066 may comprise a chord, a hinge, a connector, and a fastener. In another embodiment, a peak hinge assembly 066 may comprise a chord configured as a top cord 012, a hinge configured as a hinge left 068 and a hinge right 070, a connector configured as a connecting pin 042 and a lock ring 044, and a fastener configured as a self-threading screw 060 as shown in FIG. 2. In another embodiment, a peak hinge assembly 066 may comprise a top chord 012 comprising a first top chord extrusion 010 configured with a top first chord screw slot 018 and a first top chord connector hole 014, a hinge left 068 coupled to the first chord extrusion 010 by a first fastener such as a self-threading screw 060 configured with a hinge left mounting hole 072 and a hinge left pin boss 086, a second top chord extrusion 010 configured with a top second chord screw slot 018 and a second top chord connector hole 014, a hinge right 070 coupled to the second chord extrusion 010 by a second fastener such as a self-threading screw 060 configured with a hinge right mounting hole and a hinge right pin boss wherein the hinge left is removably coupled to the hinge right by a connector such as a connecting pin 042 and a lock ring 044 as shown in FIG. 2. The peak hinge assembly 066, may however be configured in any suitable manner to secure a chord to at least one other chord and provide an alternative truss component to an existing wood-based truss component.

[0071] In one application, a peak hinge assembly 066 may be used to secure a web bracing to a chord by fastening a hinge left to a first top chord with a fastener such as four self-threading screws secured the mounting holes on the hinge left and the screw slots on the first top chord 1110, fastening a hinge right to a second top chord with a fastener such as four self-threading screws secured the mounting holes on the hinge right and the screw slots on the second top chord 1120, and connecting the hinge left and the hinge right with a connector such as a connecting pin and lock ring 1130 as shown in FIG. 11.

[0072] In one embodiment, a gusset assembly may comprise a top chord 012, a bottom chord 022, a gusset 046, a connector, and a fastener. In another embodiment, a gusset assembly may comprise a top chord 012 comprising a top chord extrusion 010, a bottom chord 022 comprising a bottom chord extrusion 020, a gusset 046 configured as a pair of gussets, a connector, and a fastener. In one embodiment, a gusset 046 may comprise a top chord 012 comprising a top chord extrusion 010, a bottom chord 022 comprising a bottom chord extrusion 020, a gusset 046 configured as a pair of gussets such as a first gusset 046 and a second gusset 046, a connector such as a connecting pin 042 and a lock ring 044, and a fastener, such as a rivet such as a blind rivet 064 wherein the gusset 046 is coupled to the top chord 012 by a connector such as a connecting pin 042 and a lock ring 044 and the gusset 046 is coupled to the bottom chord 022 by the blind rivet 064 as shown in FIG. 3. In one embodiment, a gusset 046 may comprise a top chord 012 comprising a top chord extrusion 010 configured with a top chord connector hole 014 and a bottom chord 022 comprising a bottom chord extrusion 020 configured with bottom chord connector hole 026. The gusset 046, may however be configured in any suitable manner to secure a chord to another chord or a web bracing to a chord and provide an alternative truss component to an existing wood-based truss component.

[0073] In one application, a gusset 046 may be used to secure a first chord to a second chord by securing by orienting a first gusset and a second gusset as pairs opposite each other 1210, mechanically fastening each gusset with a fastener such as a blind rivet to the inside of each vertical face of the bottom chord 1220, orienting a pivot hole the gusset with a top chord connector hole on a top chord 1230, and securing each gusset's pivot hole and the top chord connector hole with a connecting pin and a lock ring 1240 as shown in FIG. 12.

[0074] In one embodiment, an a-brace 034 may comprise a web brace extrusion 030, a pivot bracket 052, and a fastener. In another embodiment, an a-brace 034 may comprise a web brace extrusion 030 comprising a first end configured with a first web brace screw slot 032 and a second end configured with a second web brace screw slot 032, a first pivot bracket 052 coupled to the first end of the web brace extrusion 030 by a first fastener such as a self-threading screw 060 and configured with a first pivot bracket pin boss 088, and a second pivot bracket 052 coupled to the second end of the web brace extrusion 030 by a second fastener such as a self-threading screw 060 and configured with a second pivot bracket pin boss 088 as shown in FIG. 4. In another embodiment, an a-brace 034 may be configured with an a-brace mounting hole 090 as shown in FIG. 4. In another embodiment, an a-brace 034 may be configured to combine a section of web brace extrusion 030 with a pivot bracket 052 secured at each end of the web brace extrusion 030 section by a fastener such as four self-threading screw 060 on each end. In another embodiment, an a-brace 034 may be configured to connect between pivot brackets 052 integral to the a-brace 034 and a section of bottom chord 022 with connections between the a-brace 034 and the top chord 012 accomplished in like manner. In another embodiment, an a-brace 034 may be configured with the end of the a-brace 034 with the integral pivot bracket 052 positioned between the vertical faces of the bottom chord 022 and the pivot bracket pin boss 088 aligned with the bottom chord connector hole 026 through the vertical faces of the bottom chord 022 into which a connector such as a connecting pin 042 may be assembled and secured with a connector such as a lock ring 044 establishing the connection between the a-brace 034. The a-brace 034, may however be configured in any suitable manner to secure a web bracing to a chord and provide an alternative truss component to an existing wood-based truss component.

[0075] In one application, an a-brace 034 may be used to secure a web bracing to a chord by securing a first pivot bracket to a first end of a first web brace extrusion with a fastener such as a four self-threading screws fastened between a web brace screw slot and the pivot bracket mounting holes 1310, and securing a second pivot bracket to a second end of the first web brace extrusion with a fastener such as four self-threading screws fastened between a web brace screw slot and the pivot bracket mounting holes 1320 as shown in FIG. 13.

[0076] In one embodiment, a king post brace 036 may comprise a web brace extrusion 030, a double bracket 054, and a fastener. In another embodiment, a king post brace 036 may comprise a web brace extrusion 030 comprising a first end configured with a first web brace screw slot 032 and a second end configured with a second web brace screw slot 032, a first double bracket 065 coupled to the first end of the web brace extrusion 030 by a first fastener such as a self-threading screw 060 and configured with a first double bracket clearance hole 056, a second double bracket 054 coupled to the second end of the web brace extrusion 030 by a second fastener such as a self-threading screw 060 and configured with a second double bracket clearance hole 056 as shown in FIG. 5. In another embodiment, a king post brace 036 may comprise a double bracket 054 configured with a double bracket mounting hole 058 and a double bracket pin boss 092 as shown in FIG. 5.

[0077] In another embodiment, a king post brace 036 may be configured to combine a section of web brace extrusion 030 with two double brackets 054 where one double bracket 054 is secured on each end of the web brace extrusion 030 section by a fastener such as four self-threading screws 060. In another embodiment, a king post brace 036 may be configured with a profile section of the a double bracket 054 that shows a flat face at the base that may be the mating surface of the bracket with the web brace extrusion 030 section and another parallel face that is offset from the mating face of similar size and with two opposing tubular shaped double bracket pin boss 092 each positioned to the right and left where both the mating face and the offset face tangent to the two double bracket pin boss 092 each with an inside diameter sized to accept a connector such as a connecting pin 042 and where the linear axis of each boss parallel to the other, perpendicular to the linear axis of the web brace extrusion 030, and parallel to the narrow dimension of the web brace extrusion 030 as shown in FIG. 1. In another embodiment, a king post brace 036 may be configured with clearance holes on the double bracket 054 such as a double bracket clearance hole 056 configured in the offset face and sized to allow the heads of the self-threading screws 060 to pass through without engagement and in alignment with a double bracket mounting hole 058 on the mating face that aligns with the a web brace screw slot 032 integral to the web brace extrusion 030 profile. In another embodiment, a king post brace 036 may be configured to allow four self-threading screws 060 to pass through four mating double bracket clearance hole 056 and into the mating double bracket mounting hole 058 to fasten the double bracket 054 securely to the mating web brace screw slot 032 with the head of the -threading screws 060 seating on the inside surface of the base as shown in FIG. 5. The king post brace 036, may however be configured in any suitable manner to secure a web bracing to a chord and to provide a vertical support for a truss.

[0078] In one application, a king post brace 036 may be used to secure a web bracing to a chord by securing a first double bracket to a first end of a web brace extrusion with a fastener such as a four self-threading screws fastened between mounting holes on the first double bracket and screw slots on the first end of the web brace extrusion through clearance holes on the first double bracket 1410, and securing a second double bracket to a second end of a web brace extrusion with a fastener such as a four self-threading screws fastened between mounting holes on the second double bracket and screw slots on the second end of the web brace extrusion through clearance holes on the second double bracket 1420 as shown in FIG. 14.

[0079] In one embodiment, a t-brace 038 may comprise a web brace extrusion 030, a double bracket 054, a flat plate bracket 050, and a fastener. In another embodiment, a t-brace 038 may comprise a first web brace extrusion 030 configured with a first web brace screw slot 032, a second web brace screw slot 032, and a first bolt clearance hole 080, a double bracket 054 coupled to a first end of the first web brace extrusion 030 by a fastener such as a first self-threading screw 060 and configured with a double bracket clearance hole 056, a flat plate bracket 050 comprising a first side and a second side, wherein the first side of the flat plate bracket 050 is coupled to a second end of the first web brace extrusion 030 by a fastener such as a second self-threading flat head screw 062 and configured with a flat plate counter sunk mounting hole 082, a second web brace extrusion 030 coupled to the second side of the flat plate bracket 050 by a connector such as a connecting bolt 076 and a threaded nut 078 and configured with a second bolt clearance hole 080 as shown in FIG. 6. In another embodiment, a t-brace 038 may be configured as king post brace 036 and an intersecting horizontal section of a web brace extrusion 030 connected by a flat plate bracket 050, with a connector such as a connecting bolt 076 and a threaded nut 078 to form an inverted “T” shape such as in an Attic Truss 300 shown on FIG. 9C. The t-brace 038, may however be configured in any suitable manner to secure a web bracing to a chord and to provide a connection between a vertically aligned web brace extrusion 030 and a horizontally aligned web brace extrusion 030.

[0080] In one application, a t-brace 038 may be used to secure a web bracing to a chord by securing a double bracket to a first end of a first web brace extrusion with a fastener such as four self-threading screws fastened between mounting holes on the double bracket and screw slots on the first end of the web brace extrusion through clearance holes on the double bracket 1510, securing a first flat plate to a second end of the first web brace extrusion with a fastener such as a four self-threading flat-head screws fastened between the countersunk mounting holes on the first flat plate and the screw slots on the second end of the first web brace 1520, and securing a second flat plate and a second web brace extrusion to the first web brace extrusion with a connector such as two connecting bolts and two threaded nuts fastened between the second flat plate and the first web extrusion through the second web brace extrusion and clearance holes on the first flat plate 1530 as shown in FIG. 15.

[0081] In one embodiment, a cross brace 040 may comprise a king post brace 036, a flat plate bracket 050, a fastener, a connector, and a horizontal split brace 084. In another embodiment, a cross brace 040 may comprise a king post brace 036, further comprising a first web brace extrusion 030 configured with a web brace screw slot 032 and a bolt clearance hole 080, a flat plate bracket 050 coupled to the first web brace extrusion 030 by a fastener such as self-threading flat-head screw 062 and configured with a flat plate counter sunk mounting hole 082 and a second web brace extrusion 030 coupled to the flat plate bracket 050 by a connecting bolt 076 and a threaded nut 078 and configured as a horizontal split brace 084 with a web brace screw slot 032 as shown in FIG. 7. In another embodiment, a cross brace 040 may be configured as a king post brace 036 and two horizontal split braces 084 that intersect the vertical element of the king post brace 036, a section of web brace extrusion 030 where the two horizontal split braces 084 are configured with a section of web brace extrusion 030 and a flat plate bracket 050 attached to one end of each horizontal split braces 084 where the two horizontal split braces 084 sections are secured, perpendicularly, to the vertical king post brace 036 with a horizontal connector such as a connecting bolt 076 and a threaded nut 078 that are fastened through a mating bolt clearance hole 080 on the each flat plate bracket 050 and where a mating double bracket clearance hole 056 is centered on the narrow face of the vertical upright section of the king post brace 036. In another embodiment, a cross brace 040 may be configured with the opposite end of the horizontal split brace 084 and with a pivot brackets 052 attached to the end opposite the horizontal split braces 084 such as in a Scissors Truss 400 shown in FIG. 9D. The cross brace 040, may however be configured in any suitable manner to secure a web bracing to a chord.

[0082] In one application, a cross brace 040 may be used to secure a web bracing to a chord by securing a first double bracket to a first end of a web brace extrusion with a fastener such as four self-threading screws fastened between mounting holes on the first double bracket and screw slots on the first end of the web brace extrusion through clearance holes on the first double bracket 1610, securing a second double bracket to a second end of a web brace extrusion with a fastener such as four self-threading screws fastened between mounting holes on the second double bracket and screw slots on the second end of the web brace extrusion through clearance holes on the second double bracket 1620, securing a first horizontal split brace to a first flat plate with a fastener such as a four self-threading flat-head screws fastened between mounting holes such as countersunk mounting holes on the first flat plate and screw slots on a first end of the first horizontal split brace 1630, securing a second horizontal split brace to a second flat plate with a fastener such as four self-threading flat-head screws fastened between countersunk mounting holes on the second flat plate and screw slots on a first end of the second horizontal split brace 1640, and securing the first flat plate to a first side of the web brace extrusion and the second flat plate to a second side of the web brace extrusion with a connector such as connecting bolts and threaded nuts fastened between the first flat plate and the second flat plate through the web brace extrusion flat plate clearance holes 1650 as shown in FIG. 16.

[0083] In one embodiment, a peak assembly may comprise a top chord extrusion 010, a king post brace 036, and a connector. In another embodiment, a peak assembly may comprise a top chord extrusion 010 configured with a top chord connector hole 014, a king post brace 036 configured with a double bracket 054, a connector configured as a connecting pin 042, and a lock ring 044 as shown in FIG. 8A. The peak assembly, may however be configured in any suitable manner to secure a web bracing to a chord.

[0084] In one application, an peak assembly may be used to secure a web bracing to a chord by securing a double bracket to a first end of a web brace extrusion with fastener such as four self-threading screws fastened between mounting holes on the first double bracket and screw slots on the first end of the web brace extrusion through clearance holes on the double bracket 1710, securing a first top chord to a first side of the double bracket with a first connector such as a first connecting pin and a first locking ring 1720, and securing a second top chord to a second side of the double bracket with a second connector such as a second connecting pin and a second locking ring 1730 as shown in FIG. 17.

[0085] In one embodiment, an a-brace assembly may comprise a bottom chord 022, an a-brace 034, and a connector. In another embodiment, an a-brace assembly may comprise a bottom chord 022, an a-brace 034, and a connector configured as a connecting pin 042; and a lock ring 044 as shown in FIG. 8B. The a-brace assembly, may however be configured in any suitable manner to secure a web bracing to a chord.

[0086] In one application, an a-brace assembly may be used to secure a web bracing to a chord by connecting a first end of a first a-brace assembly to a bottom chord with a first connector such as a first connecting pin and a first lock ring 1810, connecting a first end of a second a-brace assembly to the bottom chord with a second connector such as a second connecting pin and a second lock ring 1820, and optionally connecting a second end of the first a-brace assembly to a top chord with a third connector such as a third connecting pin and a third lock ring 1830 as shown in FIG. 18.

[0087] In one application, an extruded aluminum roof truss manufacturing system, may be used to secure a web bracing to a chord using a truss configuration where in the truss configuration such as a fink truss 100, a howe truss 200, an attic truss 300, a scissors truss 400, a king post truss configuration, a queen post truss configuration, a gable truss configuration, a lattice truss configuration, a space frame truss configuration, another standard truss configuration, and another custom designed truss configuration. In one embodiment, an extruded aluminum roof truss manufacturing system, may comprise a chord such as a top chord 012 and bottom chord 022, a web bracing, a bracket, and a connector configured as a truss. In one embodiment, a fink truss 100 may comprise a top chord 012, a bottom chord 022, a gusset 046, a web brace extrusion 030, a peak hinge assembly 066, and an a-brace 034, wherein the truss is configured as a fink truss as shown in FIG. 9A. In one embodiment, a howe truss 200 may comprise a top chord 012, a bottom chord 022, a gusset 046, a web brace extrusion 030, a peak assembly, an a-brace 034, and a king post brace 036, wherein the truss is configured as a howe truss FIG. 9B. In one embodiment, an attic truss 300 may comprise a top chord 012, a bottom chord 022, a gusset 046, a web brace extrusion 030, a peak assembly, an a-brace 034, a king post brace 036, and a t-brace 038, wherein the truss is configured as an attic truss FIG. 9C. In one embodiment, a scissors truss 300 may comprise a top chord 012, a bottom chord 022, a gusset 046, a web brace extrusion 030, a peak assembly, a king post brace 036, and a cross brace 040 wherein the truss is configured as a scissors truss FIG. 9D. The extruded aluminum roof truss manufacturing system, may however be configured in any suitable manner to secure a web bracing to a chord and provide support and connection for a structure such as a roof on a building.

[0088] In one application, an extruded aluminum roof truss manufacturing system may provide an assembled truss configuration by manufacturing aluminum extrusions that form primary structural members of a truss such as a top chord, a bottom chord, and a web bracing 1010, manufacturing standardized truss related components such as a connector, a hinge, a bracket, and a fastener used to configure the primary structural members of the truss into a truss configuration 1020, pre-assembling the top chord, the bottom chord, and the web bracing with a pre-determined set of standardized components required to either fully or partially assemble the truss prior to transport and installation at the building site 1030, transporting the truss in either a fully or partially assembled compact configuration, such as a linear configuration to the installation site 1040, rotating the truss open by pivoting the web bracing into alignment with the matching connector holes on the primary structural members such as the top chord, the bottom chord, and the web bracing at the installation site 1050, and installing any required connectors such as connecting pins and lock rings or remaining standardized components to complete the truss 1060 as shown in FIG. 10.

[0089] In places where the description above refers to particular implementations of systems and methods for extruded aluminum roof trusses, it should be readily apparent that a number of modifications may be made without departing from the spirit thereof and that these implementations may be applied to other to systems and methods for extruded aluminum roof trusses.