Modular wall and roof pocket system

Abstract

A modular pre-fabricated wall panel has a plurality of stud sets. The stud sets each have a pocket, the pocket having a floor for supporting a roof truss. The wall panel has a sheathing attached to an exterior surface of the plurality of stud sets. The wall panel also has an air/vapor barrier on an interior surface of the plurality of stud sets. The wall panel also has a plurality of pocket liners sealably connected to the air/vapor barrier lining, each of the plurality of pocket liners lining a pocket of the plurality of stud sets and forming a barrier to air/vapor. A modular roof system has a plurality of trusses, hinged to roof sheathing. The hinges allow the trusses to lie flat against the sheathing during storage or transportation and to orient into a perpendicular orientation for installation.

We claim: 
     
         1 . A modular pre-fabricated wall panel comprising:
 a plurality of stud sets, the stud sets each comprising a pocket, the pocket having a floor for supporting a roof truss;   a sheathing attached to an exterior surface of the plurality of stud sets;   an air/vapor barrier on an interior surface of the plurality of stud sets;   a plurality of pocket liners sealably connected to the air/vapor barrier lining, each of the plurality of pocket liners lining a pocket of the plurality of stud sets and forming a barrier to air/vapor; and   a top board located between each of the plurality of stud sets and aligned with a top surface of the roof truss, the top board wrapped in air/vapor barrier, the wrapped air/vapor barrier sealably connected to the air/vapor barrier, the wrapped air/vapor barrier forming an attachment point for an air vapor barrier of the trusses.   
     
     
         2 . The wall panel of  claim 1 , further comprising a plurality of pocket sleeves, the pocket sleeves lining the plurality of pocket liners, the pocket sleeves protecting the pocket liners from the trusses. 
     
     
         3 . A modular roof system comprising:
 substantially planar roof sheathing having a bottom surface; and   a plurality of trusses, the trusses having a depth and a thickness, each truss affixed to the roof sheathing by one or more hinges, the hinges permitting the trusses to pivot from a collapsed state where the depth of the trusses are substantially parallel with the roof sheathing, and a deployed state, where the depth of the trusses are substantially perpendicular to the roof sheathing.   
     
     
         4 . The modular roof system of  claim 3 , wherein a pivot point of the one or more hinges of the plurality of trusses are movable from a first position proximate to the roof sheathing to a second position a distance from the roof sheathing, where the distance is substantially a multiple of the truss depth. 
     
     
         5 . The modular roof system of  claim 4 , wherein the one or more hinges of the plurality of trusses comprises a bar passing through a flange constrained by a stopper at a first end, with the pivot point at the second end of the bar, the flange affixed to the roof sheathing. 
     
     
         6 . The modular roof system of  claim 3  further comprising one or more lifting points. 
     
     
         7 . A method of installing a modular roof system on a structure comprising:
 transporting a modular roof system, the modular roof system comprising:
 substantially planar roof sheathing having a bottom surface; and 
 a plurality of trusses, the trusses having a depth and a thickness, each truss affixed to the roof sheathing by one or more hinges, the hinges permitting the trusses to pivot from a collapsed state where the depth of the trusses are substantially parallel with the roof sheathing, and a deployed state, where the depth of the trusses are substantially perpendicular to the roof sheathing; 
 wherein the plurality of trusses are in a collapsed state during transporting; 
   lifting the modular roof system and hinging the plurality of trusses from the collapsed state to a deployed state;   affixing the trusses to one or more walls of the structure; and   affixing the roof sheathing to the plurality of trusses.