U.S. patent application number 11/027248 was filed with the patent office on 2005-06-02 for cast log structure.
Invention is credited to Morgenstern, Richard.
Application Number | 20050115177 11/027248 |
Document ID | / |
Family ID | 25494386 |
Filed Date | 2005-06-02 |
United States Patent
Application |
20050115177 |
Kind Code |
A1 |
Morgenstern, Richard |
June 2, 2005 |
Cast log structure
Abstract
A structural system includes a plurality of structural elements.
Each of the elements includes an interior layer, an exterior layer,
and an insulating layer lies between the interior layer and the
exterior layer. The structural elements are stacked adjacent one
another to form a wall. A respective cushion is placed between
adjacent structural elements. The cushions create airspaces such
that there is no direct surface contact between adjacent structural
elements. The exterior layers of the structural elements can be
fabricated from cast concrete material, and can be provided with
simulative exterior surfaces, for example, with exterior surfaces
simulating the appearance of structural logs.
Inventors: |
Morgenstern, Richard;
(Frenchtown, MT) |
Correspondence
Address: |
JEAN KYLE
P. O. BOX 2274
HAMILTON
MT
59840-4274
US
|
Family ID: |
25494386 |
Appl. No.: |
11/027248 |
Filed: |
December 30, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11027248 |
Dec 30, 2004 |
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09953678 |
Sep 15, 2001 |
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6851233 |
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Current U.S.
Class: |
52/233 |
Current CPC
Class: |
Y10T 428/4935 20150401;
E04B 1/20 20130101 |
Class at
Publication: |
052/233 |
International
Class: |
E04B 001/10 |
Claims
1. A pre-cast simulated log comprising: an interior layer cast from
a cementitious material; an exterior layer cast from a cementitious
material; and an insulating layer between the interior layer and
the exterior layer, the insulating layer substantially completely
isolating the interior layer from the exterior layer.
2. The pre-cast simulated log claim 1, wherein said exterior layer
is provided with simulative exterior surfaces.
3. The pre-cast simulated log of claim 2, wherein said exterior
layer is provided with exterior surfaces simulating the appearance
of a structural log.
4. The pre-cast simulated log of claim 1, further comprising at
least one connector rod, the connector rod securing said interior
layer to said exterior layer.
5. A method of preparing a pre-cast simulated log, the method
comprising the steps of: casting an exterior layer from a
cementitious material; providing an insulating layer; and casting
an interior layer from a cementitious material; wherein the
insulating layer is between the exterior layer and the interior
layer and substantially completely isolates the exterior layer from
the interior layer.
6. The method claim 5, wherein said exterior layer is provided with
simulative exterior surfaces.
7. The method of claim 6, wherein said exterior layer is provided
with exterior surfaces simulating the appearance of a structural
log.
8. The method of claim 5, further comprising the step of inserting
at least one connector rod in said pre-cast simulated log to secure
said interior layer to said exterior layer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending application
Ser. No. 09/953,678, filed Sep. 15, 2001. The disclosure of this
application is hereby incorporated by reference in its entirety,
including all figures, tables, and drawings.
FIELD OF THE INVENTION
[0002] The invention relates generally to structures composed of
log elements. Specifically, the invention relates to structures
composed of cast log elements that provide enhanced appearance,
structural integrity, insulative properties, and ease of
assembly.
BACKGROUND OF THE INVENTION
[0003] Log structures have been instrumental in the history of many
cultures. As a result, such structures have become symbolic in many
places, going beyond mere shelter and into the realm of cultural
icon. Log structures, specifically log homes, have therefore become
desirable due not only to their natural beauty, but because of
their historical and cultural feel as well.
[0004] Unfortunately, log construction is not particularly well
adapted to modern building standards. Log structures are often dark
and closed-in by modern standards, and have a tendency to "settle"
as the logs age. Furthermore, log construction fails to provide the
insulation values available in standard modem construction
methods.
[0005] It can thus be expected that the improvement of log
structures, and the emulation of certain aspects of log structures
using alternative materials, has been the subject of inventive
activity. For example, U.S. Pat. No. 4,503,648 to Mahaffey is
directed to a lightweight composite building module capable of
being readily attached to other correspondingly shaped modules for
providing a wall of a building. The module includes a pair of
spaced elongated wooden side boards joined by a wooden top board.
The side boards have right angle cutouts removed from the inside
corners thereof producing upper and lower horizontally extending
ledges. Polyurethane foam is provided in the cavity defined by the
side boards and top boards with said foam extending below the lower
horizontally extending ledges. Elongated wooden bolts extend
between the top boards of adjacent stacked modules drawing said
modules tightly together under compression so that the top board of
the next lower module compresses the foam extending below the lower
horizontally extending ledges of the module carried directly
therebelow producing a rigid sealed joint therebetween.
[0006] U.S. Pat. No. 5,163,259 to Hunsaker et al. discusses a
modular building component made of solid wood, capable of being
fitted onto other correspondingly shaped modules to provide a wall
of a building. The module includes a core made of horizontally
laminated wood with a lengthwise groove cut along the top and
vertically at one end for utility purposes, to which side boards
are attached in a manner which allows each module to lock into
adjoining modules both vertically and horizontally. The upper edges
of side boards are attached a short space from the top of the core,
the lower edges extending past the bottom of the core, creating
both a male and female fitting for adjoining modules. In the same
manner side boards are offset a short space from one end of the
core and extend past the core at the opposite end to allow the ends
of modules to lock as well. The side boards are attached at the
factory with adhesive bonding material and secured with fasteners.
To form walls, the modules are stacked a row at a time and locked
together using adhesive and metal fasteners for which holes have
been pre-drilled in the laminated cores.
[0007] In another example, U.S. Pat. No. 4,433,519 to Jenkins shows
a hollow cylindrical prefabricated modular construction element
formed by generally circular supports and a sheath. These hollow
cylinders are connected, using simple carpentry tools, at a
building site to create walls, having a simulated log
appearance.
[0008] U.S. Pat. No. 4,288,954 to O'Donnell is directed to
simulated log siding in which wire metal lath is shaped to the
generally semicircular configuration associated with a length of
log used in a log wall structure. Several layers of cement-plaster
are applied to the metal lath to waterproof it, and to lend texture
and color to it. The effect of the layered and colored
cement-plaster is to render the appearance of an actual log with
its bark in place. A simulated log wall siding is made up of
multiple lengths of such cement-plaster coated, simulated logs.
[0009] U.S. Pat. No. 3,552,079 to Mortensen discusses a building
element including a panel-shaped insulating material extending
between two timber half-beams, the whole element being formed as a
beam with one or more tongues and grooves and with the insulating
material extending in the full height of the beam from the bottom
of a groove or surface between two tongues to the opposite edge of
the beam, and an angle joint between two walls made of building
elements having notches round a neck section for mutual connection
of the elements.
[0010] While each of these patents show some advantages, it can be
seen from the foregoing that the need exists for a simple,
inexpensive construction system that provides the aesthetic
advantages of log structures without sacrificing the functional
advantages of modern building practices and materials.
SUMMARY OF THE INVENTION
[0011] A structural system includes a plurality of structural
elements. Each of the elements includes an interior layer and an
exterior layer cast of cementitious material, and an insulating
layer between the interior layer and the exterior layer. The
structural elements are stacked adjacent to one another to form a
wall. A respective cushion is placed between adjacent structural
elements. The cushions create airspaces such that there is no
direct surface contact between adjacent structural elements. The
exterior layers of the structural elements can be fabricated from
cast concrete material, and can be provided with simulative
exterior surfaces, for example, with exterior surfaces simulating
the appearance of structural logs.
DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic perspective view of a structure in
accordance with the principles of the present invention.
[0013] FIG. 2 is a detailed elevational view of the structure shown
in FIG. 1.
[0014] FIG. 3 is a sectional view taken generally along lines
III-III in FIG. 2.
[0015] FIG. 4 is a sectional view taken generally along lines IV-IV
in FIG. 2.
[0016] FIG. 5 is a detailed elevational view of a structural
element in accordance with the principles of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] A structure 10 in accordance with the principles of the
present invention is shown in FIG. 1. The structure 10 includes a
plurality of walls 12 having the external appearance of a
traditional wooden log home.
[0018] Each wall 12 of the structure 10 is made up of a plurality
of structural elements, joined together as are structural elements
14, 16, and 18 shown in FIG. 2. The structural elements 14, 16, and
18 are assembled in such a way as to simulate the appearance of
structural logs, with their visible faces and ends molded to
resemble log surfaces. The structural elements provide this
appearance while providing insulative and structural properties
unattainable with traditional log construction. This is
accomplished by the construction details of each structural
element.
[0019] As seen in FIG. 3, the structural element 18 includes an
interior layer 20, and exterior layer 22, and an insulating layer
24 between the interior layer 20 and the exterior layer 22. The
interior layer 20 and the exterior layer 22 can be fabricated by
being cast from a cementitious material, such as concrete, and can
be held together in a conventional manner, such as by connector
rods 26. One example of a suitable connection arrangement is shown
in U.S. Pat. No. 5,519,973 to Keith, the specification of which is
incorporated by reference herein. The insulating layer 24 can be
fabricated from any known, suitable insulation material used in
concrete paneling systems, such as Dow Chemical's Thermomass
System, Owens-Corning's Pink Core Panel System, FabCor's Panel tie
system, etc.
[0020] The structural elements 14 includes an interior layer 28,
and exterior layer 30, and an insulating layer 32 between the
interior layer 28 and the exterior layer 30. The interior layer 28
and the exterior layer 30 can be fabricated by being cast from a
cementitious material, such as concrete, and can be held together
in a conventional manner, such as by connector rods as described
previously. The insulating layer 32 can be fabricated from any
known, suitable insulation material as previously mentioned.
[0021] A cushion or shim 34 is located between the first structural
element 14 and the second structural element 18. The cushion 34
creates an airspace 36 such that there is no direct surface contact
between the adjacent structural elements 14, 18. The cushion 34
includes first and second elongated, resilient cushion elements,
38, 40 extending along a length of the structural elements 14, 18.
The first cushion element 38 is secured between the exterior layer
30 of the first structural element 14 and the exterior layer 22 of
the second structural element 18. The second cushion element 40 is
secured between the interior layer 28 of the first structural
element 14 and the interior layer 20 of the second structural
element 18.
[0022] Flexible synthetic chinking material 42 can be applied
between the exterior layer 30 of the first structural element 14
and the exterior layer 22 of the second structural element 18 at a
position outside of the first cushion element 38. Fill material 44,
which can be identical to the chinking material 42, can be applied
between the interior layer 28 of the first structural element 14
and the interior layer 20 of the second structural element 18.
[0023] As seen in FIG. 4, the insulating layers of the structural
elements can be provided with angled portions to provide a
substantially continuous layer of insulation between the interior
and the exterior of the structure. Here, the insulating layer 32 of
the structural element 14 is provided with an angled 46, which
aligns with an insulating layer 48 of the structural element
16.
[0024] The structural elements are secured together at bearing
points, here illustrated as grout sleeves 50, 52 extending through
the corner joints of the structural elements (FIG. 4 and 5). One
skilled in the art would be aware however of the necessary
placement of these bearing points along the wall of a composite
structure. The grout sleeves 50, 52 extend vertically through the
structural elements. Vertical reinforcing steel bars 66 are placed
into the aligned grout sleeves and extend to the foundation of the
structure, after which high-strength grout 68 is poured into the
sleeves to encase the rebar and permanently tie the structural
elements together into walls.
[0025] The interior and exterior layers of the structural elements
can be fabricated from cast concrete material, and can be provided
with simulative exposed surfaces. In the illustrated embodiment,
the exterior surfaces of the structural elements simulate the
appearance of hand-hewn structural logs, including end surfaces 54
(FIG. 1). It is also anticipated that the exterior surfaces could
be fabricated to simulate round logs, or any other desired
horizontal structural element, and that the simulated log surfaces
can be textured and stained to simulate stripped logs or logs with
the bark left on. Similarly, the interior surfaces of the
structural elements can be fabricated to simulate log surfaces,
wood paneling, stone, sheetrock, or any desired texture, and can te
stained or painted to any suitable interior finish. The structural
elements can be fabricated using rubber molds made from actual
timbers, logs, paneling, stones, etc. using rubber molds in a
generally known manner. Companies from which such molds are
available in other configurations include Symons, Burk, Scofield,
and Scott. Electrical and heating conduits 56, 58 can be cast in
the wall during fabrication to avoid surface mounting.
[0026] Walls assembled in accordance with the principles of the
present invention are nearly 100% insulated. It is contemplated
that their energy efficiency will far surpass that of "real" log
structures and other conventional building systems, due to their
provision of an interior heat sink. The structural elements can be
assembled on site using standard construction equipment in a manner
similar to that used in traditional log construction.
[0027] Although the present invention has been described with
reference to specific embodiments, those of skill in the art will
recognize that changes may be made thereto without departing from
the scope and spirit of the invention as defined by the appended
claims.
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