U.S. patent application number 11/463944 was filed with the patent office on 2006-12-28 for exterior casing structure for an opening in a log wall.
This patent application is currently assigned to POINTBLANK DESIGN INC.. Invention is credited to Gregory A. Clarke.
Application Number | 20060288656 11/463944 |
Document ID | / |
Family ID | 32868605 |
Filed Date | 2006-12-28 |
United States Patent
Application |
20060288656 |
Kind Code |
A1 |
Clarke; Gregory A. |
December 28, 2006 |
EXTERIOR CASING STRUCTURE FOR AN OPENING IN A LOG WALL
Abstract
A casing structure for an opening in a log wall includes a
plurality of logs extending horizontally in an axial direction and
stacked vertically to form a wall having opposing interior and
exterior faces, at least selected vertically adjacent ones of the
logs each having an end face at one end thereof, the end faces
being generally vertically aligned with each other and defining a
side surface of an opening in the wall, the opening having a height
extending vertically along the adjacent end faces. A framing member
extends vertically along at least a portion of the height of the
opening, and a casing member generally abuts the exterior surface
of the wall and extends vertically alongside the side surface of
the opening, the casing member having a rear face generally
parallel to and directed towards the exterior face of the wall, the
rear face having a width extending in the axial direction of the
logs between a first casing side portion that overlaps a portion of
the logs adjacent the end faces and a second casing side portion
that overlaps at least a portion of the exterior edge surface of
the framing member.
Inventors: |
Clarke; Gregory A.; (London,
ON) |
Correspondence
Address: |
BERESKIN AND PARR
40 KING STREET WEST
BOX 401
TORONTO
ON
M5H 3Y2
CA
|
Assignee: |
POINTBLANK DESIGN INC.
1253 Wayne Court
London
CA
|
Family ID: |
32868605 |
Appl. No.: |
11/463944 |
Filed: |
August 11, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10372854 |
Feb 26, 2003 |
7117647 |
|
|
11463944 |
Aug 11, 2006 |
|
|
|
Current U.S.
Class: |
52/233 |
Current CPC
Class: |
F16B 2200/40 20180801;
F16B 7/0486 20130101; E04B 2/702 20130101; E04C 3/12 20130101; Y10T
403/4602 20150115; Y10T 403/73 20150115; F16B 2200/403 20180801;
F16B 2200/406 20180801; F16B 2200/30 20180801 |
Class at
Publication: |
052/233 |
International
Class: |
E04B 1/10 20060101
E04B001/10 |
Claims
1. A casing structure for an opening in a log wall, comprising: a)
a plurality of logs extending horizontally in an axial direction
and stacked vertically to form a wall having opposing interior and
exterior faces, at least selected vertically adjacent ones of the
logs each having an end face at one end thereof, the end faces
being generally vertically aligned with each other and defining a
side surface of an opening in the wall, the opening having a height
extending vertically along the adjacent end faces; b) a framing
member extending vertically along at least a portion of the height
of the opening, the framing member having a back surface directed
towards the end faces of the logs, a front surface opposite the
back surface, and an outside edge surface extending between the
front and back surfaces, the outside edge surface being generally
aligned with the exterior face of the wall; and c) a casing member
generally abutting the exterior face of the wall and extending
vertically alongside the side surface of the opening, the casing
member having a rear face generally parallel to and directed
towards the exterior face of the wall, the rear face having a width
extending in the axial direction of the logs between a first casing
side portion that overlaps a portion of the logs adjacent the end
faces and a second casing side portion that overlaps at least a
portion of the outside edge surface of the framing member, and the
casing member including a channel in the rear face, the channel
extending generally along the height of the casing member.
2. The casing structure of claim 1, wherein the rear face of the
casing member comprises a mounting surface secured to the outer
edge surface of the framing member.
3. The casing structure of claim 2, wherein the channel has a
channel width extending in the axial direction of the logs between
a first channel side portion and a second channel side portion.
4. The casing structure of claim 2, wherein at least the first
channel side portion overlaps a portion of the logs adjacent the
end faces.
5. The casing structure of claim 2, wherein at least the second
channel side portion overlaps at least a portion of the exterior
edge surface of the framing member.
6. The casing structure of claim 2, wherein at least the first
channel side portion overlaps a portion of the logs adjacent the
end faces, and at least the second channel side portion overlaps at
least a portion of the outer edge surface of the framing
member.
7. The casing structure of claim 2, wherein the mounting surface
and the outer edge surface are generally parallel.
8. The casing structure of claim 7, wherein the casing member is
secured to the framing member by finishing nails.
9. The casing structure of claim 2, comprising a vertically
extending seal recess provided in the rear face intermediate the
mounting surface and the channel.
10. The casing structure of claim 9, wherein the seal recess faces
a portion of the outer edge surface of the framing member.
11. The casing structure of claim 9, comprising a seal in the seal
recess.
12. The casing structure of claim 1, wherein the wall includes a
lower horizontal member extending from a lower end of the side
surface of the opening, the lower horizontal member defining sill
surface of the opening, the sill surface having at least one
drainage trough provided therein to facilitate draining liquid from
behind the casing outward to the exterior of the wall.
13. The casing structure of claim 11 wherein the at least one
drainage trough comprises a groove in the sill surface, the groove
having an inclined base extending from an upper end intersecting
the sill surface at a position vertically beneath the framing
member, and a lower end intersecting the exterior surface of the
wall at a position behind the channel of the casing member.
14. The casing structure of claim 1, wherein the framing member
comprises a sub-jamb member.
15. The casing structure of claim 14, wherein the sub-jamb member
generally abuts the end faces of the logs.
16. A casing structure for an opening provided in a wall
constructed of stacked horizontal walls, the opening having an
opening support structure comprising sub-jamb members along either
vertical side of the opening, the sub-jamb members accommodating
relative vertical movement between the logs and the sub-jamb
members, the casing structure comprising: a) a vertical casing
member extending along either vertical side of the opening, the
casing member having a rear face adjacent the logs and the sub-jamb
member along each side of the opening, and a width which spans the
interface between the logs and the sub-jamb member; b) a channel
provided in the rear face of the casing member, the channel
extending vertically along the length of the casing member, and the
channel having a width which spans the interface between the logs
and the sub-jamb member; and c) a mounting base provided along the
rear face of the casing member, the mounting base fixed to the
sub-jamb member.
17. A casing structure for an opening in a log wall, comprising: a)
a plurality of horizontally extending, vertically stacked logs
forming a wall with an opening therein, the wall having opposed
interior and exterior sides, the opening having spaced apart
vertical side surfaces defined by generally aligned end faces
provided in selected vertically adjacent logs of the plurality of
logs; b) a framing member adjacent each of the spaced apart
vertical side surfaces of the opening, each framing member coupled
to the wall and having an outer face generally in abutment with the
aligned end faces of the logs defining a joint interface between
the framing members and the vertical side surfaces, an inner face
opposite the outer face, and an exterior edge face extending
between the outer and inner faces and generally aligned with the
exterior side of the wall, each sub-jamb member having a height
that is less than the height of the vertical side surfaces of the
opening; c) a casing member extending along each vertical side of
the opening, each casing member having a rear face generally
abutting the exterior side of the wall adjacent a respective one of
the vertical side surfaces of the opening, each casing member
having a casing width measured horizontally and generally parallel
to the wall, the casing width spanning the interface between the
logs and the sub-jamb member; d) a channel provided in the rear
face of the casing member, the channel extending vertically along
the length of the casing member, and the channel having a width
that spans the joint interface between the logs and the framing
member; and e) a mounting base provided along the rear face of the
casing member, the mounting base fixed to the framing member.
Description
[0001] This application is a divisional of prior U.S. application
Ser. No. 10/372,854, filed Feb. 26, 2003, which is hereby
incorporated herein by reference.
FIELD
[0002] This invention relates to construction systems for
constructing log structures such as houses, cabins, and the like,
and more particularly to an exterior casing structure for an
opening in a log wall.
BACKGROUND
[0003] Homes or cabins built of logs are often considered desirable
for their aesthetics. However, constructing such log structures can
present a number of difficulties. For example, it can be difficult
to provide corner connection of logs at an intersecting corner that
is strong and weather tight, both at initial installation and after
the log walls have settled over time.
[0004] A known corner connection structure is disclosed in U.S.
Pat. No. 5,020,289 (Wrightman). The corner connection of Wrightman
provides a dovetail joint between the intersecting logs, and a pair
of splines having a `figure-8` cross-sectional profile. However,
the structural elements themselves leave seams through which the
weather could penetrate. Caulking could be provided for
weather-proofing, but caulking has a limited lifespan, and could
work loose during natural settling and shrinkage of the logs.
Alternatively, gaskets could be provided between the mating faces
of the dovetails, but gaskets can be relatively costly and
time-consuming to install.
[0005] Another corner connection structure is disclosed in U.S.
Pat. No. 4,353,191 (Schilbe). The corner connection structure of
Schilbe has an obliquely disposed mortise provided adjacent the
intersecting region of logs at a corner, and a wooden locking
section placed in the mortise. However, by providing the mortise
adjacent the intersecting region, rather than within the
intersecting region, the locking member is engaged only at its
outer ends by the mortise, which may limit the strength and support
provided by the locking member. Furthermore, Schilbe does not
address the natural settling of the logs that takes place over
time. The fit between the mortise and the locking member, as taught
by Schilbe, must be sufficient to prevent horizontal movement of
the logs relative to the locking member. However, such a tight fit
would also inhibit vertical movement of the logs relative to the
locking member, which could result in gaps forming between the logs
along the height of the walls at the intersecting corner. The
weather may then penetrate the corner structure, and moisture could
collect within the log structure, between the inside of the walls
and the locking member.
[0006] Providing through-bolts at corners or at intermediate
positions along the lengths of log walls can provide additional
strength and support for the walls. Known through-bolt devices are
described in U.S. Pat. No. 4,503,647 (Post) and U.S. Pat. No.
4,688,362 (Pedersen et al.). In both of these references, the
through-bolt devices include through-bolts extending along the
height of the walls, and regular hex nuts at the lower end of the
through-bolts for tightening the devices. These devices require
access to the hex nuts for wrenches or other tools when assembling
or adjusting the through-bolt devices. However, providing such
access may be difficult, and may require, for example, fairly large
openings cut into the lower sides of the walls. Specially cut
panels may then be required to conceal the openings.
[0007] It is often convenient in walls constructed of logs that two
shorter logs be joined end-to-end to span the length of the wall. A
butt joint for connecting logs end-to-end is disclosed in the
patent to Wrightman, already noted above. The butt joint according
to Wrightman has a two-piece spline with semi-circular lobes on one
face and opposing passages on the opposite face. Spikes are driven
into the passages to expand the two-piece spline, and provide an
interference fit between the lobes of the spline and matching
recesses provided in the logs. This butt joint is fairly complex
and may be time consuming to assemble. Furthermore, the
simultaneous alignment of the passageways and the lobes within the
recesses may be difficult to achieve.
[0008] Another butt joint is disclosed in U.S. Pat. No. 4,279,108
(Collister, Jr.). The butt joint of Collister Jr. has plastic
weather deflectors inserted into a slot, which spans the seam
between the adjacent end faces of the logs to be joined.
Compressible gasket strips are also provided between the end faces
of the adjacent logs. Since no structural joint element engages the
logs in a transverse direction, it may be difficult to ensure that
the logs connected by this joint are in fact locked to inhibit
longitudinal movement. Furthermore, since the gasket strips are
installed prior to fixing the logs together, the strips may be
damaged during positioning and assembly of the logs.
[0009] Openings are often desirable in log walls to accommodate
windows, doors, and the like. It may be advantageous to provide
special support structures at such openings to facilitate building
the walls around the opening, and to provide a suitable mounting
means for the structural framing elements of the window or door to
be subsequently installed. A known opening support structure is
disclosed in U.S. Pat. No. 4,224,772 (Bene et al.). Bene et al.
discloses a connection member disposed between the log end faces at
the opening and the frame member of a window to be installed in the
opening. The connection member is attached to the logs by nails
driven through slots in the connection member and into the end
grain of the logs, so that relative vertical movement between the
connection member and the logs is possible. The frame member of the
window is in turn secured to the connection member. Using nails
driven into the end grain of the logs may not, however, provide a
secure joint because the nails may work loose as the fibers of the
wood separate. Furthermore, shrinkage of the logs over time may
compromise the strength of the support structure.
[0010] In building log walls, the logs themselves can be provided
with a particular profile to facilitate alignment of the logs
during construction and to increase the strength of the wall. In
the above-noted Wrightman patent, a log profile is disclosed in
which the tongues and grooves are provided in the upper and lower
surfaces of the logs, respectively. The upper and lower surfaces of
vertically adjacent logs fit together, providing a seam across the
width of the logs. However, at either side of the logs, the profile
provides a generally horizontal seam portion which could collect
moisture and cause associated wood preservation difficulties.
[0011] Another log profile is disclosed in U.S. Pat. No. 3,440,784
(Onjukka). The profile taught by Onjukka has matching tongues and
grooves in the upper and lower surfaces of vertically adjacent
logs. However, no provision is made for installing seals along the
seam between adjacent logs, at a point along the seam between the
outer horizontal edges. Accordingly, the weather-proofing of the
interface between adjacent logs may be compromised, particularly as
the logs shrink and settle over time.
[0012] In some log structures having walls constructed of stacked
horizontal logs, it can be advantageous to provide vertical posts
at the corners of intersecting walls, as well as at intermediate
points along the length of a wall. A post-to-log connection
structure can be provided for connecting the end faces of the logs
to a vertical surface along the post. A known post-to-log
connection structure is disclosed in U.S. Pat. No. 4,742,033
(Veech), wherein a vertical spline is inserted into corresponding
slots provided in the end faces of the logs and the surface of the
post. However, no adjustable fastening means is provided for
drawing the post and log ends snugly together.
SUMMARY
[0013] The following summary is intended to introduce the reader to
this specification but not to define any invention. In general,
this specification discusses one or more methods or apparatuses
related to constructing log structures. Aspects of the teaching
provided herein by the applicants include, but are not limited to,
corner connection structures, through-bolt clamping apparatuses,
logs with particular log profiles, log support structures, exterior
casing structures, butt-joint connection structures, log connection
structures, and joint sealing structures.
[0014] Various apparatuses or processes are described herein to
provide an example of an embodiment of each claimed invention. No
embodiment described below limits any claimed invention and any
claimed invention may cover processes or apparatuses that are not
described below. The claimed inventions are not limited to
apparatuses or processes having all of the features of any one
apparatus or process described below or to features common to
multiple or all of the apparatuses described below. It is possible
that an apparatus or process described below is not an embodiment
of any claimed invention. The applicants, inventors or owners
reserve all rights that they may have in any invention disclosed in
an apparatus or process described below that is not claimed in this
document, for example the right to claim such an invention in a
continuing application and do not intend to abandon, disclaim or
dedicate to the public any such invention by its disclosure in this
document.
[0015] According to one aspect, a casing structure for an opening
in a log wall is provided, the casing structure comprising: (a) a
plurality of logs extending horizontally in an axial direction and
stacked vertically to form a wall having opposing interior and
exterior faces, at least selected vertically adjacent ones of the
logs each having an end face at one end thereof, the end faces
being generally vertically aligned with each other and defining a
side surface of an opening in the wall, the opening having a height
extending vertically along the adjacent end faces; (b) a framing
member extending vertically along at least a portion of the height
of the opening, the framing member having a back surface directed
towards the end faces of the logs and extending laterally between
opposing generally vertical inner and outer framing member edges,
the inner and outer framing member edges being proximate the
interior and exterior faces of the wall, respectively, the framing
member including an exterior edge surface extending from the outer
framing member edge of the back surface and away from the end faces
of the logs; and (c) a casing member generally abutting the
exterior surface of the wall and extending vertically alongside the
side surface of the opening, the casing member having a rear face
generally parallel to and directed towards the exterior surface of
the wall, the rear face having a width extending in the axial
direction of the logs between a first casing side portion that
overlaps a portion of the logs adjacent the end faces and a second
casing side portion that overlaps at least a portion of the
exterior edge surface of the framing member, the rear face
including a mounting surface secured to the exterior edge surface
of the framing member, and the casing member including a
drainage/ventilation channel provided in the rear face and
extending generally along the height of the casing member.
[0016] In some embodiments, the channel has a channel width
extending in the axial direction of the logs between a first
channel side portion and a second channel side portion. At least
the first channel side portion can overlap a portion of the logs
adjacent the end faces. At least the second channel side portion
can overlap at least a portion of the exterior edge surface of the
framing member. In some embodiments, at least the first channel
side portion overlaps a portion of the logs adjacent the end faces,
and at least the second channel side portion overlaps at least a
portion of the exterior edge surface of the framing member.
[0017] In some embodiments, the mounting surface and exterior edge
surface are generally parallel with each other and with the
exterior face of the wall. The casing can be secured to framing
member by finishing nails. The casing structure can comprise a
vertically extending seal recess provided in the rear face
intermediate the mounting surface and the channel. The seal recess
can face a portion of the exterior edge surface of the framing
member. A seal can be provided in the seal recess.
[0018] In some embodiments, the wall includes a lower horizontal
member extending from a lower end of the side surface of the
opening, the lower horizontal member defining sill surface of the
opening, the sill surface having at least one drainage trough
provided therein to facilitate draining liquid from behind the
casing outward to the exterior of the wall. The at least one
drainage trough can comprise a groove in the sill surface, the
groove having an inclined base extending from an upper end
intersecting the sill surface at a position vertically beneath the
framing member, and a lower end intersecting the exterior surface
of the wall at a position behind the channel of the casing
member.
[0019] In some embodiments, the framing member comprises a sub-jamb
member. The sub-jamb member can generally abut the end faces of the
logs.
[0020] According to another aspect, an exterior side casing
structure for an opening provided in a wall constructed of stacked
horizontal walls is provided. The opening may have an opening
support structure including sub-jamb members along either vertical
side of the opening, the sub-jamb members accommodating relative
vertical movement between the logs and the sub-jamb members. The
side casing structure may have a vertical casing member extending
along either vertical side of the opening, the casing member having
a rear face adjacent the logs and the sub-jamb member along each
side of the opening, and a width which spans the interface between
the logs and the sub-jamb member.
[0021] A channel may be provided in the rear face of the casing
member, the channel extending vertically along the length of the
casing member, and the channel having a width which spans the
interface between the logs and the sub-jamb member. A mounting base
may be provided along the rear face of the casing member, the
mounting base being fixed to the sub-jamb member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] For a better understanding of the applicant's teaching and
to show how it may be carried into effect, reference will now be
made by way of example, to the accompanying drawings in which:
[0023] FIG. 1 is a perspective view of a portion of two
intersecting walls having, in accordance with examples of the
applicant's teaching, a corner connection structure, a through-bolt
clamping apparatus, logs with a particular log profile, an opening
support structure, an exterior casing structure, and a butt-joint
connection structure;
[0024] FIG. 2 is a perspective view showing the corner connection
structure of FIG. 1 in greater detail;
[0025] FIG. 3a is side view of a portion of a log used in the
connection structure of FIG. 2;
[0026] FIG. 3b is an end view of the portion of the log shown in
FIG. 3a;
[0027] FIG. 4 is an elevation view of the corner connection
structure of FIG. 1, in combination with a through-bolt clamping
apparatus;
[0028] FIG. 5 is a top view of two logs of the corner connection
structure of FIG. 1;
[0029] FIG. 6 is an exploded view of the logs shown in FIG. 5;
[0030] FIG. 7 is an enlarged view of one of the logs shown in FIG.
6;
[0031] FIG. 8 shows the logs of the corner connection structure of
FIG. 5 in combination with a corner spline according to the present
invention;
[0032] FIG. 8a is an enlarged view of a portion of FIG. 8;
[0033] FIG. 9a is a perspective view of a corner spline according
the present invention;
[0034] FIG. 9b is a side view of the spline of FIG. 9a;
[0035] FIG. 10 is an elevation view of an alternative embodiment of
a corner spline for use with a corner connection structure of the
present invention;
[0036] FIG. 11 is a perspective view of an alternative embodiment
of a corner spline for use with a corner connection structure of
the present invention;
[0037] FIG. 12 is an exploded view of the through-bolt clamping
apparatus of FIG. 4;
[0038] FIG. 13 is a top view of a corner spline shown in FIG.
12;
[0039] FIG. 14 is a bottom view of a lowermost log of the corner
connection structure of FIG. 1;
[0040] FIG. 15 is an exploded view of an alternative embodiment of
a portion of the apparatus of FIG. 12;
[0041] FIG. 16 is a portion of the elevation view of FIG. 4, in
combination with the apparatus of FIG. 15;
[0042] FIG. 17 is a front elevation view of another embodiment of a
through-bolt clamping apparatus according to the applicant's
teaching;
[0043] FIG. 18 is an exploded view of the apparatus of FIG. 17;
[0044] FIG. 19 is a side elevation view of the apparatus of FIG.
17;
[0045] FIG. 20 is an exploded view of an alternative embodiment of
a portion of the apparatus of FIG. 17;
[0046] FIG. 21 is a front elevation view of FIG. 20 in combination
with the apparatus of FIG. 17;
[0047] FIG. 22 is a cross-sectional view of the log profile of FIG.
1;
[0048] FIG. 23 is a cross-sectional view of one log of FIG. 22
stacked upon another;
[0049] FIG. 24 is a cross-sectional view of an alternative
embodiment of a log profile according to the applicant's
teaching;
[0050] FIG. 25 is a cross-sectional view of one log of FIG. 24
stacked upon another;
[0051] FIG. 26 is a front elevation view of the wall opening
support structure of FIG. 1;
[0052] FIG. 27 is a perspective view showing a portion of the
structure of FIG. 26 in further detail;
[0053] FIG. 28a is a side view of a support block of FIG. 27;
[0054] FIG. 28b is a side view of another support block of FIG.
27;
[0055] FIG. 29 is a perspective view of the structure of FIG. 26
showing further details;
[0056] FIG. 30 is a side elevation view in cross-section of a
portion of the structure of FIG. 26;
[0057] FIG. 31 is a top sectional view of a portion of the
structure of FIG. 26;
[0058] FIG. 32 is a top sectional view of a sub-jamb member of FIG.
29;
[0059] FIG. 33 is a front elevation view of the sub-jamb member of
FIG. 32;
[0060] FIG. 34 is a perspective view showing further details of the
opening support structure and exterior side casing structure of
FIG. 1;
[0061] FIG. 35 is a cross-sectional view of a portion of the
exterior side casing structure of FIG. 34;
[0062] FIG. 36 is a top view of the exterior casing structure of
FIG. 34;
[0063] FIG. 37 is an exploded perspective view of the butt joint
connection structure of FIG. 1;
[0064] FIG. 38 is a top view of portions of the butt joint
connection structure of FIG. 1;
[0065] FIG. 39 is a top view of a spline of the butt joint
connection structure of FIG. 1;
[0066] FIG. 40 is a top cross-sectional view of the butt joint
connection structure of FIG. 1;
[0067] FIG. 41 is a section view of FIG. 40 taken along the line
41-41;
[0068] FIG. 42 is an exploded perspective view of a connection
structure according to the applicant's teaching;
[0069] FIG. 43 is an exploded view of a component of the of the
connection structure of FIG. 42;
[0070] FIG. 44 is a top view of the connection structure of FIG.
42;
[0071] FIG. 45 is a perspective view of alternative seal assembly
for use with the present invention; and
[0072] FIG. 46 is a top view of the assembly of FIG. 45 shown in
combination with a misaligned slot.
DETAILED DESCRIPTION
[0073] A corner connection structure according to the applicant's
teaching is shown generally at 10 in FIG. 1. The corner connection
structure 10 is provided at a corner 12 where walls 14a and 14b
intersect. The walls 14a and 14b form part of a building such as,
for example, but not limited to, a home or cabin.
[0074] Referring to FIG. 2, the walls 14a and 14b are constructed
of generally horizontally extending logs 16a and 16b, respectively.
The walls 14a and 14b are nonparallel, intersecting each other at
the corner 12. In the embodiment illustrated, the walls 14a and 14b
intersect at approximately 90.degree.. However, the angle of
intersection at corner 12 could be any angle, and it is to be
appreciated that the corner connection structure 10 could be used
on walls having any angle of intersection, and also on walls
meeting at a T-intersection.
[0075] The logs 16a and 16b of the walls 14a and 14b have ends 17a
and 17b which are proximate the corner 12. Adjacent the ends 17a
and 17b, the logs 16a and 16b are provided with overlap portions
18a and 18b, respectively, which overlap each other in an
alternating interlaced arrangement at the corner 12. The logs 16a,
16b have non-overlapping portions 22a, 22b adjacent the overlap
portions 18a, 18b, respectively.
[0076] Preferably, the overlap portions 18a, 18b of the logs 16a,
16b have a geometrical configuration 20a, 20b, which is shaped so
that the overlap portions 18a, 18b of adjacent logs 16a, 16b fit
together at the corner 12 in an interlocking arrangement. The
geometrical configuration 20a, 20b can include cut-outs as commonly
provided in saddle-notch corners, butt-and-pass corners, and in
dovetail corner construction.
[0077] In the embodiment illustrated (FIGS. 2 and 3), the
geometrical configurations 20a, 20b, comprise dovetails 21a, 21b
milled into the overlap portions 18a, 18b of the logs 16a, 16b.
Each dovetail 21 has a generally planer upper surface 23 and lower
surface 25, both of which are inclined to the horizontal. Generally
vertical shoulder surfaces 27 extend upward and downward from the
upper and lower surfaces 23 and 25 of the dovetail 21,
respectively, along the non-overlapping portions 22 of the logs 16.
Each dovetail 21 also has a generally vertical side face 29,
extending between the upper and lower surfaces 23 and 25.
[0078] Referring again to FIG. 2, the mating surfaces of adjacent
dovetails 21 at the corner 12 define corner joint interfaces 24.
More particularly, the upper and lower surfaces 23 and 25 of
adjacent dovetails 21 lie generally flush against each other
defining generally horizontal (although inclined) corner joint
interfaces. As well, the shoulder surfaces 27 lie generally flush
against the side faces 29 of the adjacent dovetails 21, defining
generally vertical corner joint interfaces.
[0079] Referring now to FIGS. 2 and 4, the wall 14a has a distinct
wall section 26a in which the non-overlapping portions 22a of the
logs 16a are vertically adjacent each other. Similarly, the wall
14b has a distinct wall section 26b in which the non-overlapping
portions 22b of the logs 16b are vertically adjacent each
other.
[0080] The area between the distinct wall sections 26a and 26b of
the intersecting walls 14a and 14b is defined as the corner joint
area 28. The corner joint area 28 is characterized as an area of
the intersecting walls 14a and 14b in which the overlapping
portions 18a and 18b of the logs 16a and 16b overlap each other in
an alternating, interlaced arrangement.
[0081] Referring to FIG. 5, the corner connection structure 10 is
further provided with a slot 30 that extends, in the horizontal,
obliquely across the corner joint area 28 of the intersecting walls
14a, 14b. The slot 30 extends, in the vertical, along substantially
the entire height of the walls 14a, 14b at the corner 12.
[0082] As best seen in FIG. 6, vertically aligned grooves 32a, 32b
are provided in the logs 16a, 16b. The grooves 32a, 32b cooperate
to form the slot 30 in the corner connection structure 10. More
specifically, each log 16a, 16b is provided with a groove 32a, 32b
that extends vertically through the height of the log 16, and
extends horizontally in a direction which is oblique to the
longitudinal axis of the log 16.
[0083] The particular angle between the grooves 32a, 32b and the
horizontal axis of the corresponding logs 16a, 16b can conveniently
be selected to be generally equal to each other. The slot 30 formed
by the cooperating grooves 32a, 32b is thereby generally
perpendicular to a line bisecting the included angle between the
intersecting walls 14a and 14b. In the embodiment illustrated, the
walls 14a, 14b intersect at 90.degree., and the grooves 32a, 32b
are oriented at about 45.degree. relative to the corresponding
longitudinal axes of the logs 16a, 16b.
[0084] Further details of the grooves 32 will now be described,
with reference to FIG. 7. Each groove 32 in the logs 16 has an open
vertical edge 34 positioned along the log 16 to abut the overlap
portion 18. In other words, the log material on either side of the
open vertical edge 34 of the groove 32 is part of the overlap
portion 18 of the log 16. The groove 32 extends horizontally to a
closed vertical edge 36, which is positioned within the adjacent
non-overlapping portion 22 of the log 16.
[0085] In logs 16 having overlap portions 18 with geometrical
configurations 20, the height of the log 16 will generally not be
constant along the length of the groove 32. For example, in the
embodiment illustrated having dovetails 21, the height of the log
16 has a step at the shoulder surface 27. The intersection of the
groove 32 and the shoulder surface 27 defines a threshold 33 within
the groove 32.
[0086] As best seen in FIG. 7, each groove 32 has an interstacking
portion 35 which extends within the overlap portion 18 of the log
16. In the embodiment illustrated, the interstacking portion 35 of
the groove 32 extends from the open vertical edge 34 to the
threshold 33. Each groove 32 also has a non-interstacking portion
37 extending within the non-overlap portion 22 of the log 16. In
the embodiment illustrated, the non-interstacking portion 37 of the
groove 32 extends from the threshold 33 to the closed vertical edge
36.
[0087] The side surfaces of the groove extending between the open
edge and the closed edge define an outer side surface 38 facing
towards the end 17 of the log 16 proximate the corner 12, and an
inner side surface 40 opposite the outer side surface 38.
[0088] As mentioned above, the grooves 32 of vertically adjacent
logs 16 at the corner 12 cooperate to form the slot 30. More
specifically, the overlap portions 18a of the logs 16a of the first
wall 14a and the overlap portions 18b of the logs 16b of the second
wall 14b overlap each other in an alternating, interlaced
arrangement at the corner 12 (FIG. 2). The interstacking portions
35a and 35b of the grooves 32a and 32b therefore also overlap in an
alternating fashion. The grooves 32a and 32b are positioned in the
logs 16a and 16b of the walls 14a, 14b, so that the outer side
surfaces 38a, 38b of the grooves 32a, 32b of vertically adjacent
logs 16a, 16b are substantially coplanar, providing a generally
continuous outer sidewall 42 of the slot 30 (FIGS. 5 and 6).
Similarly, the inner side surfaces 40a, 40b of the grooves 32a, 32b
of vertically adjacent logs 16a, 16b are in substantially coplanar
alignment, forming a generally continuous inner sidewall 44 of the
slot 30.
[0089] The non-interstacking portions 37a, 37b of the grooves 32a,
32b provided in logs 16a, 16b do not overlap each other in an
alternating, interlaced arrangement. The non-interstacking portions
37a are vertically adjacent other non-interstacking portions 37a,
and the non-interstacking portions 37b of the grooves 32b of logs
16b are vertically adjacent other non-interstacking portions
37b.
[0090] The open vertical edges 34a of the grooves 32a in the logs
16a generally adjoin the grooves 32b where the grooves 32b cut
through the shoulder surfaces 27b of adjacent logs 16b. In other
words, the open vertical edges 34a of the grooves 32a are
vertically aligned with the thresholds 33b of the grooves 32b in
the adjacent logs 16b. Similarly, the open vertical edges 34b of
the grooves 32b in the logs 16b generally adjoin the grooves 32a
where the grooves 32a cut through the shoulder surfaces 27a of the
adjacent logs 16a. This alignment of the grooves 32a and 32b forms
the slot 30, extending between generally continuous vertical edges
36a and 36b, and inner and outer sidewalls 44 and 42.
[0091] It is to be appreciated by one skilled in the art that logs
used to construct log homes typically do not have a vertically
symmetrical cross-sectional profile, but rather, the logs often
have distinct upper surface and lower surface profiles.
Accordingly, the logs of the first wall 14a and the logs of the
second wall 14b have grooves 32a, 32b which are mirror image to
each other, rather than identical to each other. Further details of
log profiles according to the present invention will be discussed
subsequently.
[0092] As seen in FIG. 2 the corner connection structure 10 is
further provided with a spline 50, which is adapted to fit snugly
in the slot 30. Referring to FIGS. 8, 9a and 9b, the spline 50 has
a horizontal width 52 which extends substantially all the way
across the width of the slot 30, between the opposed vertical edges
36a and 36b. The spline 50 has a thickness 54 which is small enough
to allow the spline 50 to be inserted in the slot 30, but is
preferably large enough to provide upper and lower horizontal edge
surfaces 56 which facilitate stacking of the splines 50 upon one
another in the slot 30. In the embodiment illustrated in FIG. 9a,
the spline 50 has a plate portion 58 that extends between opposed
vertical edges 57 and between upper and lower horizontal edges 56.
The plate portion 58 of the spline 50 has a thickness 54 which is
slightly less than the space between the sidewalls 44 and 42 of the
slot 30, and a width 52 which is slightly less than the space
between the edges 36a, 36b of the slot 30.
[0093] The height 55 of the spine 50 can be any height which is
convenient for the assembly of the corner connection structure 10.
As best seen in FIG. 4, the stacked spines 50 extend almost the
entire height of the walls 14a, 14b at the corner 12. The upper
edge 56 of the uppermost spline 50 is spaced below the tops of the
walls 14a, 14b to provide a settling gap 49.
[0094] In the embodiment illustrated, a typical spine 50 is shown
having a height approximately equal to the height of the logs 16a,
16b used to construct the walls 14a, 14b. The stacking of the
spines 50 produces seams 59 between the upper and lower horizontal
edge surfaces 56 of vertically adjacent spline 50.
[0095] The height 55 of the splines 50 in the corner connection
structure need not be uniform, and the height of some splines 50
can be increased to advantageously reduce the number of splines 50,
and hence the number of seams 59 between adjacent splines 50, at
the corner 12. Reducing the number seams 59 reduces the number of
potential gaps through which drafts and moisture can pass.
[0096] The splines 50 can be constructed of any suitable material,
such as, but not limited to, steel, aluminum, or polymer material.
The splines 50 may advantageously be cut to the desired height from
a length of extruded material.
[0097] As each log 16 is laid down at the corner 12, a spline 50 is
inserted into the slot 30, and pressed snugly against the
previously installed spline 50. This ensures that the grooves 32a,
32b are properly aligned to extend the slot 30 as successive logs
16 are installed, and also provides stability of the logs 16 as the
walls 14a, 14b are being built.
[0098] As best seen in FIG. 10, the spines 50 simultaneously block
off the joint interfaces 24 between the overlap portions 18a, 18b
of the adjacent logs 16a, 16b of the corner 12. In particular, the
generally horizontal joint interfaces between the upper and lower
surfaces 23 and 25 of adjacent dovetails 21, as well as the
generally vertical joint interfaces between the shoulder surfaces
27 and the adjacent side faces 29 of adjacent dovetails 21 are
sealed against weather intrusion by the spline 50. This
advantageously eliminates the need for gaskets or caulking between
the mating joint interface surfaces 24 at the corner 12.
[0099] To further enhance the weather-proofing characteristics of
the corner connection structure 10, the vertical position of the
seams 59 between vertically adjacent splines 50 can be adjusted so
that the seams 59 intersect with the joint interfaces 24 as few
times as possible. In the embodiment illustrated, having
geometrical configurations 20 comprising dovetails 21, the seams 59
are positioned at approximately the vertical midpoint of the
dovetail 21 of any single log 16a or 16b.
[0100] Furthermore, a sealant 60 can be provided between the upper
and lower edge surfaces 56 of adjacent splines 50 to enhance the
weatherproofing characteristics of the corner connection structure
10. The sealant 60 can be, for example, but not limited to, a strip
of asphalt-impregnated sealant tape.
[0101] Referring again to FIGS. 8, 9, and 10, the spline 50 can be
provided with a locking rib 62 having a thickness 64 which extends
transversely from the plate portion 58 of the spline 50. In the
embodiment illustrated in FIGS. 8 and 9, the rib thickness 64
extends from the outer surface of the spline, and the rib is
oriented generally vertically along the outer surface of the
spline, at about an equal distance from the opposed vertical side
edges 57 of the plate portion 58 of the spline 50.
[0102] The locking rib 62 enhances the corner connection structure
10 by preventing horizontal movement of the logs relative to one
another in a direction parallel to the plate portion 58 of the
spline 50. Furthermore, the rib 62 provides a fixed point towards
which the log 16 will draw as it dries and shrinks over time. By
providing a single point towards which the logs 16 in the walls 14
will shrink, a tighter, stronger joint is generated over time.
[0103] To accommodate the rib 62, the slot 30 is provided with a
generally continuous rib recess 66 (FIG. 5). In the embodiment
illustrated, the rib recess 66 comprises a generally cylindrical
bore 67 positioned adjacent the outer sidewall 42 of the slot 30.
The cylindrical bore 67 has a diameter tangentially intersected by
the slot 30.
[0104] To form the rib recess 66, pockets 68a, 68b are provided
along the grooves 32a, 32b in the logs 16a, 16b (FIG. 6). The
pockets 68a, 68b overlap in alternating arrangement at corner 12,
and are positioned to be in vertical alignment, thereby forming the
rib recess 66.
[0105] Referring to FIG. 8a, the cross-sectional profile of the
outer surface of the rib 62 can be shaped to cooperate with the
inner surface of the rib recess 66 so that areas of contact 70
between the rib 62 and the rib recess 66 are interspersed with
areas of non-contact 72. In the embodiment illustrated, the rib 62
has an outer surface which is polygonal having a plurality of
vertices 74, and the inner surface of the rib recess 66 is
generally cylindrical. The vertices 74 of the outer surface of the
rib 62 are sized to have a slight interference fit with the inner
surface of the rib recess 66. This provides good holding contact,
while also reducing the chances of binding in the vertical
direction. This is considered advantageous because relative
movement between the splines and the logs in the vertical direction
is desirable to accommodate natural settling of the logs over
time.
[0106] An alternative spline 80 is illustrated in FIG. 11. The
spline 80 is similar to the spline 50, having a plate portion 58
and a rib 62. However, in the spline 80, the plate portion 58 is
comprised of two distinct plate portion segments 82 and 84, each of
which extends contiguously in opposite directions from the rib 62.
In the embodiment illustrated, a gap 86 separates the plate portion
segments 82, 84, and the gap 86 is positioned adjacent the rib
62.
Through-Bolt System
[0107] The corner connection structure 10 can further be provided
with a through-bolt clamping apparatus shown generally at 110 in
FIGS. 1 and 4. The through-bolt clamping apparatus 110 has a
through-bolt 112 that extends generally vertically through the
plurality of courses of logs 16 forming the walls 14a, 14b.
[0108] In the embodiment illustrated in FIG. 4, the through-bolt
112 of the through-bolt clamping apparatus 110 extends through the
corner joint area 28 of the walls 14a, 14b at the corner 12. To
accommodate the through-bolt 112, the spline 50 can be provided
with a vertically oriented bolt cavity 114 (FIG. 12). In cross
section, the bolt cavity may be enclosed by the spline itself, or
by a combination of the spline and a sidewall of the slot.
[0109] As best seen in FIG. 13, in one embodiment the bolt cavity
114 is provided within the rib 62 of the spline 50. The cross
sectional area of the bolt cavity 114 is completely enclosed within
the spline 50. Furthermore, in the embodiment illustrated, the bolt
cavity 114 is polygonal in cross section. More specifically, the
bolt cavity 114 has an inner surface 116 which is hexagonal in
cross-section.
[0110] Referring again to FIG. 12, the through-bolt clamping
apparatus 110 is provided with transversely extending upper and
lower clamp arms 120, 121 (respectively), adjacent the upper and
lower ends 118, 119 of the through-bolt 112. The upper and lower
clamp arms 120, 121 are adapted to couple the through-bolt 112 to
the logs 16 at the upper and lower ends of the walls 14a, 14b,
respectively.
[0111] In the embodiment illustrated, the lower clamp arm 121 of
the through-bolt clamping apparatus 110 is part of an anchor spline
assembly 117 having an anchor plate 122 extending through a
horizontal groove 124 provided across the rib 62 of the lowermost
spline 50 of the corner connection structure 10. The anchor plate
122 has a centrally located aperture 126, which is aligned with the
bolt cavity 114 extending through the spline 50.
[0112] A fastener 128 extends upward through the aperture 126, and
engages an elongate hex-nut 130 which is provided within the bolt
cavity 114, adjacent the top surface 132 of the anchor plate 122.
The outer surface of the hex-nut 130 is slightly smaller than the
hexagonal inner surface 116 of the bolt cavity 114, thereby
permitting axial displacement of the hex-nut 130 within the bolt
cavity 114, but inhibiting rotation of the hex-nut 130 when the
threaded rod 112 is turned. Accordingly, an anti-rotate coupling
device is provided which enables assembly and adjustment of the
threaded rod 112 to the lower clamp arm 121 from the upper end of
the walls 14a, 14b, without need to access the through-bolt
apparatus 110 from the lower end of the walls 14a, 14b.
[0113] The fastener 128 passes through the aperture 126 in the
anchor plate 122 and is tightened securely, thereby producing the
anchor spline assembly 117. The length of the screw 128 and the
length of the hex-nut 130 are selected so that an upper portion of
the hex-nut 130 extends sufficiently beyond the upper end of the
screw 128, thereby providing adequate engagement with a threaded
portion 134 provided adjacent the lower end 119 of the through-bolt
112.
[0114] Referring to FIG. 14, a clamp arm recess 136 is provided in
the underside of the lowermost (starter) log 16 at the corner 12 of
the walls 14a, 14b, to accommodate the transversely extending
anchor plate 122. More specifically, the length and the width of
the clamp arm recess 136 are sized slightly larger than the length
and the width of the anchor plate 122. The depth of the recess 136
provides an indented horizontal contact surface 138 for bearing the
clamp load applied by the through-bolt clamping apparatus 110 on
the anchor plate 122.
[0115] Once the intersecting walls 14a, 14b have been completely
assembled, the threaded rod 112 of the through-bolt clamping
apparatus 110 can be inserted through the bolt cavity 114 and
rotated so that its lower threaded end 119 securely engages the
elongate hex-nut 130. Suitable washers 140 and a spline stacking
nut 142 can then be installed and tightened along a threaded
portion 143 provided adjacent the upper end 118 of the through-bolt
112. The spline-stacking nut serves to draw the splines 50
together, so that any seams 59 between vertically adjacent splines
50 are substantially weather-tight. The washers 140 and the spline
stacking nut 142 are sized so that collectively their outer
diameters are small enough to fit within the rib recess of the
corner connection structure, but are large enough to provide a
lower surface which positively engages an upper surface 56 of the
uppermost spline 50 provided in the corner connections structure
10.
[0116] It is considered advantageous to avoid direct application of
a clamp load generated by the clamping apparatus 110 onto the
corner joint area 28, because the portions of the logs 16 at the
corner joint area 28, namely the overlap portions 18, typically
shrink more quickly than the adjoining, non-overlap portions 22.
The increased rate of shrinkage can be the result of proximity to
the exposed ends 17 of the logs, and because the overlap portions
18, having geometrical configurations 20, have a reduced
cross-sectional area relative to the adjoining non-overlapping
portions 22.
[0117] Accordingly, the upper clamp arm 120 comprises a transfer
bar 144 coupled to the through-bolt 112 (FIG. 4). The transfer bar
144 is adapted to bridge the non-overlapping portions 26a, 26b of
the first and second walls 14a, 14b so that a clamping load
generated by the through-bolt clamping apparatus 110 can be
transferred directly to the non-overlapping portions 26a, 26b
rather than onto the corner joint area 28.
[0118] More specifically, the transfer bar 144 has a body 146 and a
pair of spaced-apart contact pads 148a and 148b. The first contact
pad 148a engages the first wall 14a at a position spaced away from
the corner joint area 28, along the non-overlapping distinct wall
section 26a of the wall 14a. The second contact pad 148b engages
the second wall 14b at a position spaced away from the corner joint
area 28, along the non-overlapping distinct wall section 26b of the
wall 14b.
[0119] Referring again to FIG. 12, the contact pads 148a, 148b of
the transfer bar 144 extend generally vertically from the transfer
bar body 146, which extends generally horizontally between the two
contact pads. In the embodiment illustrated, the transfer bar 144
comprises a plate having down-turned ends, resulting in an inverted
U-shaped member.
[0120] The transfer bar 144 is provided with an aperture 150, which
is centrally located along the horizontally extending transfer bar
body 146. The threaded portion 143 of the upper end 118 of the
through-bolt 112 passes through the aperture 150, and a clamping
nut 152 can be installed adjacent an upper surface 151 of the
transfer bar, to apply the compressive load on the walls.
[0121] Preferably, as shown in the embodiment illustrated, a
compression spring 154 may be provided between the clamp nut 152
and the upper surface 151 of the transfer bar 144. Spring seats 156
can be provided at the upper and lower ends of the compression
spring 154, to ensure that the spring 154 remains generally
concentric about the through-bolt 112. The compression spring 154
can compensate for natural settling of the logs.
[0122] By spacing apart the contact pads 148a, 148b on the transfer
bar 144, the downward compressive force on the walls passes through
the non-overlapping portions 22a, 22b of the logs 16a, 16b rather
than along the overlap portions 18a, 18b, which have a reduced
cross-sectional area resulting from the geometrical configurations
20 provided therein. The present invention comprehends that the
overlap portions 18 of the logs 16 may dry out more quickly, and
may therefore shrink faster and to a greater extent than the
adjacent non-overlapping portions 22 of the logs.
[0123] Furthermore, the present invention comprehends that the logs
16 in the walls 14 will settle over time, causing a corresponding
decrease in the overall height of the walls 14. As the uppermost
surface of the walls 14 shifts downwards due to settling, the
spring 154 forces the transfer bar 144 downwards, thereby
maintaining a positive clamping force on the walls 14. The settling
gap 49, along with the additional clearance provided by downward
extension of the contact pads 148 from the transfer bar body 146,
ensures that the transfer bar can be pushed downward without
interfering with the uppermost spline 50.
[0124] To assist in transferring the clamp load generated by the
clamping apparatus 110 away from the corner joint area 28 and onto
the adjoining, distinct wall sections 26a, 26b of the walls 14a,
14b, an alternative anchor spline assembly 157 can be provided
(FIG. 15). The anchor spline assembly 157 has a lower clamp arm 121
comprising an inverted transfer bar 144.
[0125] More particularly, the anchor spline assembly 157 has a
spline 50, an elongate hex nut 130, and a transfer bar 144. The
transfer bar 144 is inverted, so that the contact pads 148a, 148b,
are directed upwardly. A fastener 160 extends upwardly through the
aperture 150 and engages the hex nut 130. The hex nut is then
inserted in the lower end of the bolt cavity 114 extending through
the rib 62 of the spline 50. In the embodiment illustrated, the
fastener 160 is a bolt welded to the body 146 of the transfer bar
144.
[0126] To accommodate the transfer bar 144 of the anchor spline
assembly 157, a clamp arm recess 162 is provided at the lower end
of the corner joint area 28 of the walls 14a, 14b at the corner 12.
The clamp arm recess 162 crosses the corner joint area 28, having
recess portions 162a and 162b in the logs 16a and 16b,
respectively. Inner sidewalls 164 extend generally vertically along
the perimeter of the recess 162. An assembly retaining screw 168,
passing through an aperture 166, can be used to hold the anchor
spline assembly 157 in position, prior to installation and
tightening of the clamping apparatus 110.
[0127] In use, the contact pads 148a, 148b of the transfer bar 144
of the anchor spline assembly 157 engage the walls 14a, 14b along
the distinct wall sections 26a, 26b respectively. Accordingly, the
clamping force applied by the clamping apparatus 110 is directed
through the non-overlapping portions 22a, 22b of the logs 16a, 16b
in the walls 14a, 14b rather than through the overlap portions 18a,
18b.
[0128] Furthermore, the mating hex profiles of the bolt cavity 114
and hex nut 130, along with the retaining screw 168 and inner
sidewalls 164 provide an anti-rotate coupling arrangement between
the transfer bar 144 and the trough-bolt 112.
[0129] Referring now to the FIG. 17, the through-bolt apparatus 110
can be provided not only adjacent the corner 12, but also along the
wall 14 between corners 12. A through-bolt cavity 170 extends
through the logs 16 of the wall 14 to accommodate the through-bolt
112.
[0130] The through-bolt clamping apparatus 110 can be provided with
an anti-rotate anchoring device 172 coupled to the lower end 119 of
the through-bolt 112. In one embodiment (FIG. 18), the anchoring
device 172 comprises an anchoring sleeve 174 and the lower clamp
arm 121. The lower clamp arm 121 can be a pin 176 adapted to fit in
a generally horizontal bore 178 passing through the anchoring
sleeve 174. The pin 176 is longer than the width of the sleeve 174,
so that ends 177 of the pin 176 extend beyond the outer surface of
the sleeve 174.
[0131] A generally horizontal locking bore 180 is provided in the
lowermost (starter) log 16 of the wall 14. The locking bore 180
intersects the through-bolt cavity 170 adjacent the bottom of the
wall 14, and is adapted to receive the pin 176.
[0132] In use, the sleeve 174 of the anchoring device 172 is
inserted into the through-bolt cavity 170 of the lowermost log 16
of the wall 14. The sleeve 174 is positioned so that the bore 178
of the sleeve 174 is aligned with the locking bore 180 of the log
16. The pin 176 is then inserted into the locking bore 180 and
pushed through the bore 178 of the sleeve 174. A plug 181 can be
inserted into the exposed end of the bore 180 for concealment.
[0133] The engagement of the ends 177 of the pin 176 with the inner
surface of the locking bore 180 of the log 16 provides a bearing
surface for the clamp load applied by the clamping apparatus 110,
and also provides an anti-rotate coupling arrangement of the pin
176 to the lower end 119 of the through-bolt 112.
[0134] More particularly, the sleeve 174 is provided with an
internally threaded vertical engagement bore 182, having a tapered
lead surface 184. The lower end 119 of the through-bolt 112 can be
lowered into the through-bolt cavity 170 from above, and guided
into the engagement bore 182 by the tapered lead surface 184. The
through-bolt 112 can then be rotated to securely engage the sleeve
174.
[0135] An alternative anchoring device 186 can be used in place of
anchoring device 172. Referring to the FIGS. 20 and 21, the
alternative anchoring device 186 comprises an inverted transfer bar
144 as its lower clamp arm 121. The fastener 160 extending from the
transfer bar 144 is coupled to a generally vertical internally
threaded bore 190 provided in an anchor sleeve 188. The upper end
of the bore 190 of the anchor sleeve 188 is provided with a tapered
lead surface 192, similar to the surface 184 of the sleeve 174.
[0136] To accommodate the transfer bar 144, a clamp arm recess 194
is provided in the underside of the lowermost log 16 of the wall
14. A retaining fastener 168 can be provided through an aperture
166 in the transfer bar 144 to retain the anchoring device 186
within the recess 194 in the log 16. The inner sidewalls of the
recess 194, along with the retaining fastener 168, prevent rotation
of the transfer bar 144, thereby permitting installation and
adjustment of the through-bolt 112 from the upper end of the wall
14, without the need for a second person to hold tight the
anchoring device 186.
Log Profile
[0137] A log profile according to the applicant's teaching is
referenced in the figures generally by character 210. The log
profile 210 may be provided in the log 16 used to construct walls
14 of, for example, but not limited to, a cabin or house.
[0138] Referring to FIG. 22, the profile 210 of the log 16 provides
a top surface 212, a bottom surface 214, an inner side surface 216,
and an outer side surface 218. The inner side surface 216 is a
generally planer vertical surface, extending between upper and
lower inner edges 220, 222, respectively. The outer side surface
218 is similarly a generally planer vertical surface, which extends
between upper and lower outer edges 224, 226, respectively.
[0139] The top surface 212 of the profile 210 extends between the
inner and outer upper edges 220 and 224. The top surface 212 has
two vertically upwardly projecting tongues 230, each having inner
and outer inclined sidewalls 232 and 234, respectively. In the
embodiment illustrated, the outer sidewall 234 is double-inclined,
having a steeper inclined upper portion 234a, and a less steeply
inclined lower portion 234b. The tongues 230 have generally
horizontal upper faces 236 extending between the inner and outer
sidewalls 232, 234 of the tongues 230.
[0140] The profile 210 further comprises a channel 238 extending
between the inner side surfaces 232, 232 of the tongues 230. A
v-groove 240 is provided in the channel 238, extending along the
longitudinal axis of the log 16.
[0141] The bottom surface 214 of the profile 210 extends between
the inner and outer lower edges 222 and 226. The bottom surface 214
has two upwardly directed engagement grooves 242 adapted to receive
the tongues 230 of the top surface 212 of an adjacent log 16. Each
groove 242 has inner and outer inclined sidewalls 244, 246,
respectively. In the embodiment illustrated, the outer sidewall 246
is double-inclined, having a more steeply inclined upper portion
246a, and a less steeply inclined lower portion 246b. Each groove
242 has a generally horizontal base 248 extending between the inner
and outer inclined sidewalls 244 and 246.
[0142] A seal recess 250 can be provided in the base 248 of the
grooves 242. In the embodiment illustrated, the seal recess 250 is
positioned in the base 248 of each groove 242, immediately adjacent
the outer inclined sidewall 246.
[0143] The profile 210 of the log 16 further provides a plateau
surface 252 extending between the inner sidewalls 244 of the
grooves 242. A v-groove 254 is provided in the plateau 252,
extending along the longitudinal axis of the log 16.
[0144] The bottom surface 214 of the log 16 is also provided with
reflexively inclined margin surfaces 256 adjacent the inner and
outer side surfaces 216 and 218. More specifically, one margin
surface 256 extends between the lower inner edge 222 of the log 16
and the outer sidewall 246 of the adjacent groove 242. Similarly, a
second margin surface 256 extends between the lower outer edge 226
of the log 16 and the outer sidewall 246 of the adjacent groove
242.
[0145] In use (FIG. 23), the top surface 212 and the bottom surface
214 of vertically adjacent logs 16 interlock with each other to
provide accurate stacked alignment of the logs in the wall 14. More
particularly, the tongues 230 of the top surface 212 of one log 16
engage the grooves 242 of the bottom surface 214 of another log 16
positioned immediately above the first log. The slopes of the
inclined tongue sidewalls 232, 234 match the slopes of the
corresponding groove sidewalls 244, 246 so that they are in flush
contact with each other. This contact assists in positively
locating the logs relative to each other, and provides lateral
stability of the wall 14 in a direction perpendicular to the axes
of the logs 16.
[0146] Furthermore, the upper faces 236 of the tongues 230 contact
the base surfaces 248 of the grooves 242, to provide positive
vertical positioning of one log 16 relative to another.
[0147] The staggered seam created by the adjacent top and bottom
surfaces 212, 214 provided by the log profile 210 also assists in
keeping out the weather. To further improve the weather proofing
characteristics of the interface between the upper surface 212 and
the lower surface 214 of adjacent logs 16, sealant 258 is provided
in the seal recess 250 of the bottom surface 214. The sealant 258
can be, for example, but not limited to, asphalt-impregnated
sealant tape. Preferably, the sealant 258 is compressed by the
assembly of one log 16 on top of another, to enhance the sealing
action of the sealant 258.
[0148] The location of the sealant 258 along the interface between
the top surface 212 and bottom surface 214 of adjacent logs 16 is
also instrumental in blocking out moisture. Specifically, with
reference again to FIG. 23, the sealant 258 is located along the
base 248 of the groove 242 immediately adjacent the interface
between the inclined sidewalls 234 and 246 of the tongue 230 and
groove 242, respectively. Accordingly, the sidewall 234 presents an
upwards slope towards any moisture attempting to enter the
interface between the adjacent logs 16, from the exposed side
surface 218, 216. The force of gravity is thereby used to inhibit
the penetration of moisture through the interface.
[0149] Furthermore, the distal portion of the interface between the
logs 16 that extends from the outside face 218 to the seal 258 has
no horizontal surfaces. The sloping nature of the interface along
that portion of the cross-section of the logs inhibits the
collection of water between the logs.
[0150] Advantages of the double inclined outer sidewalls 234 of the
tongue 236 and the margin surface 256 are also best seen in FIG.
23. In particular, the double inclined sidewall 234 increases the
cross sectional area of material of the log 16 between the tongue
230 and the outside face 218 of the log 16. This strengthens the
lower outer portions of the logs 16, and resists any lateral
outward force exerted by the stacked weight of the logs. As well,
the double inclined sidewall 234 and the margin surface 256 provide
a blunter point 260 at the bottom of the log 16, which may be less
susceptible to damage during transport and handling of the logs
16.
[0151] The interaction of the v-grooves 240 and 254 provided in the
top surface 212 and bottom surface 214 of the logs 16 can also best
be seen in FIG. 23. Specifically, the opposed v-grooves 240 and 254
co-operate to form an aperture 262 between vertically adjacent logs
16 in the wall 14. The aperture 262 can serve a number of uses,
some of which will be discussed hereinafter.
[0152] Referring now to FIG. 24, an alternative profile 270 for the
logs 16 has a modified top surface 272 extending between the inner
and outer upper edges 220 and 224, and a modified bottom surface
extending between the inner and outer lower edges 232 and 226 of
the log 16.
[0153] The top surface 272 has a pair of upwardly extending tongues
276, each having inner and outer inclined sidewalls 278, 280,
respectively. Each tongue 276 has a top face 284 extending between
the inner and outer sidewalls 278, 280. A step-shaped seal recess
286 is provided in the top face 284 of each tongue 276, immediately
adjacent the outer sidewall 280.
[0154] The bottom surface 274 of the log profile 270 has a pair of
grooves 288, each having inner and outer inclined sidewalls 290 and
292, respectively. Each groove 288 has a base 293 extending between
the inner and outer sidewalls 290, 292.
[0155] In the alternative profile 270, the slopes of the inclined
tongue sidewalls 278, 280 do not match the corresponding groove
sidewalls 290, 292 (FIG. 25). More specifically, in the embodiment
illustrated, the outer sidewalls 292 of the grooves 288 are sloped
more steeply than the outer sidewalls 280 of the tongues 276. As
well, the inner sidewalls 278 of the tongues 276 are sloped more
steeply than the inner sidewalls 290 of the grooves 288.
[0156] Accordingly, when one log 16 is placed on top of another log
16 in the wall 14, the tongues 276 of the top surface 272 engage
the grooves 288 of the bottom surface 274 of the adjacent log 16.
However, the sidewalls 278, 280 of the tongues 276 are not in flush
contact with the sidewalls 290, 292 of the grooves. Rather,
cavities 294 are provided between the sidewalls 280 and 292.
Similarly, cavities 296 are provided between the sidewalls 278 and
290.
[0157] The cavities 294 cooperate with the seal recess 286 to
accommodate the sealant 258. The cavities 296 can accommodate
additional sealant 258 to further enhance the weather-proofing
characteristics of the log interface and to provide lateral
stability for alignment of the logs. When the top surface 272 and
the bottom surface 274 of two adjacent logs 16 engage each other,
the sealant 258 in the cavities 294 and 296 is compressed and
squeezed downward within the cavities 294, 296 into wedge-shaped
seal elements. This fills a portion of the space between the
opposed vertically inclined sidewalls, thereby locating the
corresponding logs in horizontal alignment with each other.
Moreover, the vertically adjacent logs can shrink and expand
independently without compromising the weather-proofing
characteristics of the sealed interface, since the resilient
sealant 258 can expand and contract to accommodate any difference
in the rates of expansion or contraction of the logs 16. In
addition, the sealant 258 is positioned away from the center of the
log where apertures for plumbing, electrical wiring, or
through-bolts are typically provided. Accordingly, the sealant 258
in the embodiment illustrated can extend without interruption along
the length of the walls 14, and problems related to squeeze-out of
sealant entering such apertures are eliminated.
Wall Support Structure
[0158] A support structure according to the applicant's teaching is
shown generally in the Figures at reference character 310.
Referring to FIG. 1, the support structure 310 is provided adjacent
an opening 312 in the wall 14. The opening 312 may be provided in
the wall 14 for a variety of reasons, such as, for example, but not
limited to, accommodating a window, door, or fireplace.
[0159] Referring now to FIG. 26, the opening 312 extends between
vertical side surfaces 314 and upper and lower horizontal surfaces
316a, 316b, respectively, extending along the logs 16 forming the
wall 14. The vertical side surfaces 314 are also referred to herein
as edge surfaces 314 of the wall 14. The upper and lower horizontal
surfaces 316a, 316b are also referred to herein as header and sill
surfaces 316a, 316b, respectively. In milled log packages, the
vertical side surfaces 314 of the opening 312 may be precut,
providing end faces 318 along either side surface 314 of the
opening 312. Typically, these precut end faces 318 are only
provided for logs whose full cross sectional height abuts the sides
314 of the opening 312. If the height of the opening 312 must be
extended partially across the height of adjacent logs, the builder
can make vertical extension cuts 320 in logs which run adjacent the
upper or lower sides 316 of the opening 312. In such cases the log
material extending between the extension cuts 320 of opposing side
surfaces 314 must also be removed, thereby producing the horizontal
surfaces 316 of the opening 312.
[0160] Referring now to FIG. 27, in openings 312 having a full
cross-sectional log 16 extending along the lower horizontal surface
316, support blocks 322, 324 can be provided along the top surface
212 of the log 16 having a profile 210, to square off the lower
surface 316 of the opening 312. In particular, and with reference
to FIG. 28a, the support blocks 322 each have an inclined base 326
in flush contact with the inclined sidewalls 234 of the tongues
230. A generally horizontal support surface 328 is provided
opposite the base 326. Referring to FIG. 28b, the support block 324
is generally rectangular in cross-section, having a base 330 in
flush contact with the channel 238 between the tongues 230 of the
log 16 having the profile 210. A generally horizontal support
surface 332 is provided opposite the base 330 of the support block
324.
[0161] Referring to FIGS. 26 and 29, the support structure 310
comprises connectors 336 positioned within the wall 14 adjacent the
opening 312. The connectors 336 have a connector body with lower
and upper log engagement portions 338, 340. In the embodiment
illustrated, the connectors 336 comprise dowel pins which are
vertically oriented in the wall 14. The lower engagement portion
338 engages a log in one course of the wall, and the upper
engagement portion 340 engages the log immediately above the log
engaged by the lower log engagement portion 338.
[0162] The number of connectors 336 provided along each vertical
side 314 of the opening 312 is such that each log 16 having a fully
exposed end face 318, has a connector 336 extending from both the
upper and lower surfaces of the log (FIG. 26). Accordingly, the
lowermost logs having end faces 318 adjacent the opening 312 are
connected to the log below, which spans the opening 312. Similarly,
the uppermost logs 16 having end faces 318 adjacent the opening 312
are connected to the log above, which spans the openings 312. The
connectors 336 thereby serve to strengthen the wall 14 at the
opening 312, and to align and support the logs as the wall is being
built.
[0163] As best seen in FIG. 30, the logs 16 are provided with upper
and lower connector apertures 342, 344, respectively, adapted to
receive the lower and upper log engagement portions 338, 340 of the
connectors 336. The upper and lower connector apertures 342, 344
extend into the top and bottom surfaces 212, 214 of adjacent logs
16, and can comprise upper and lower portions of apertures 346
extending through the height of the logs 16 adjacent the opening
312 in the wall 14.
[0164] The apertures 342, 344 are generally centrally located
across the cross-sectional width of the logs 16. More specifically,
the apertures 342, 344 intersect the v-grooves 240, 254 provided in
the top and bottom surfaces 212, 214 of the logs 16. Along the
length of the logs 16, the apertures 342, 344 are spaced away from
the end faces 318 of the logs 16, so that an axial load bearing
portion 348 of the log 16 is provided between the apertures 342,
344 and the end faces 318 (FIG. 31).
[0165] Referring now to FIG. 31, the cross-sectional profile of the
outer surface of the connector 336 can be shaped to cooperate with
the inner surface of the apertures 342, 344 so that areas of
contact 350 between the connector 336 and the apertures 342, 344
are interspersed with areas of non-contact 352. In the embodiment
illustrated, the connector body is hexagonal and the apertures 342,
344 are cylindrical. The vertices of the outer surface of the
connector 336 are sized to have a slight interference fit with the
apertures 342, 344. This provides good holding contact, while also
accommodating some degree of misalignment between the apertures
342, 344 provided in vertically adjacent logs 16.
[0166] Referring again to FIG. 26, the opening support structure
310 further comprises a sub-jamb member 360 having respective upper
and lower ends 360a and 360b, and positioned along each vertical
side surface 314 of the opening 312. The sub-jamb members 360 do
not extend the full height of the opening 312, but rather, a
settling gap 362 is provided between the upper horizontal surface
316 (i.e. the header surface 316a) of the opening 312 and the upper
end 360a of the sub-jamb members 360. Typically, this gap would be
about 1.5 inches, to accommodate natural settling of the logs over
time.
[0167] As best seen in FIG. 32, each sub-jamb 360 has inner and
outer vertical struts 364, 366 aligned with the inner and outer
faces 216, 218 (respectively) of the logs 16. Each strut 364, 366
is provided with a vertical groove 368, the openings of which face
each other in horizontal and vertical alignment. The grooves 368
cooperate to receive a central panel 370. The struts 364, 366 are
also provided with vertically extending seal recesses 372 along the
surface of the struts 364, 366 which lie adjacent the vertical side
surfaces 314 of the opening 312. Vertically elongate slots 374 are
provided in the central panel 370 of the sub-jamb 360.
[0168] To install the sub-jamb member 360 of the opening support
structure 310, fasteners 376 are provided. The fasteners 376 couple
the sub-jamb member 360 to the connectors 336.
[0169] More specifically, with reference again to a preferred
embodiment illustrated in FIG. 29, the fasteners 376 can comprise
bolts having an external threaded portion 378 at one end, and a
bolt head 379 at the opposite end. The bolts 376 extend through the
slots 374 of the sub-jamb member 360, with the threaded portion 378
directed into the vertical side surface 314 of the opening 312.
Washers 380 can be inserted between the sub-jamb 360 and the heads
379 of the bolts 376.
[0170] Fastener access passageways 382 are provided in the logs 16
to accommodate the bolts 376. The fastener access passageways 382
extend between the connectors 336 and the vertical side surfaces
314 of the opening 312. In the embodiment illustrated, the aperture
262 created by the opposed v-grooves 240, 254 in the logs 16
provides the fastener access passageways 382.
[0171] The connectors 336 are provided with fastener coupling means
384, for coupling the fasteners 376 to the connectors 336. In the
embodiment illustrated, the fastener coupling means 384 comprises
an internally threaded bore 385 extending horizontally through the
connector body, at a position between the first and second log
engagement portions 338, 340. The internally threaded bore 385 is
adapted to engage the threaded portion 378 of the bolt 376.
[0172] The connectors 336 can be further provided with an alignment
pin 386 extending generally horizontally beyond the body of the
connector 336. The alignment pin 386 can engage an alignment
surface 388 on an adjacent log, to assist in aligning the fastener
coupling means 384 with the fastener access passageway 382. In the
embodiment illustrated, the alignment pin 386 is positioned below
and in parallel alignment with the internally threaded bore 385.
The converging portion of the v-groove 240 provided in the upper
surface 212 of the logs 16 provides the alignment surface 388.
[0173] Having aligned the internally threaded bores 385 with the
fastener access passageways 382, the threaded portions 378 of the
bolts 376 can engage the internally threaded bores 385 upon
insertion through the passageways 382. The bolts 376 can then be
tightened to draw the sub-jamb 360 snugly against the vertical side
surfaces 314 of the opening 312.
[0174] Upon initial installation, prior to any settling, the
relative position of the bolts 376 along the length of the slots
374 is such that a space 390 is provided between the lower edge 392
of the slot 374 and the bolt 376 (FIG. 34). The space 390, along
with the settling gap 362 (FIG. 26), accommodate a reduction in the
height of the opening 312 which naturally occurs as the logs 16
settle over time. In particular, the bolts can shift downwards
within the slots 374, towards the lower edges 392 of the slots 374.
Similarly, the upper horizontal surface 316 of the opening 312 can
shift downwards towards the upper edges of the sub-jamb members
360.
[0175] This ability to accommodate settling of the logs 16 reduces
or eliminates the high stress loads which would otherwise be
transmitted onto the sub-jamb members 360 as the logs 16 settled
over time. Accordingly, the sub-jamb members 360 provide attachment
surfaces to which structural elements of a window or door can be
fastened, without risk of distortion or damage to the window or
door.
[0176] Furthermore, by coupling the sub-jamb members 360 to the
connectors 336, reliable mounting of the sub-jamb members 360 is
realized. In particular, the retaining force that holds the
sub-jamb members 360 in place is applied across the load-bearing
portion 348 of the logs 16 (FIG. 31). This is in contrast to simply
embedding a fastener in the end grain of the logs 16 through the
exposed end faces 318. Fasteners embedded in log end grain are
susceptible to loosening as the fibers of the wood can easily
spread apart.
Exterior Side Casing Structure
[0177] A casing structure according to an example of the
applicant's teaching is shown generally in FIG. 1 at reference
character 410. The casing structure 410 is provided on the outside
of the wall 14 around the perimeter of the opening 312.
[0178] Referring to FIG. 34, the casing structure 410 comprises
vertical casing members 412 extending along the outer side surfaces
218 of the logs 16, at a position adjacent a framing member such as
the sub-jamb members 360 of the opening support structure 310.
[0179] Referring to FIG. 35, the vertical casing members 412 can be
generally rectangular in cross-section, having a front face 414, a
rear face 416, and inner and outer side surfaces 418 and 420,
respectively. The rear face 416 has a mounting surface 422 adjacent
the inner side surface 418. A channel 424 is provided in the rear
face 416 adjacent the outer side surface 420.
[0180] Between the channel 424 and the mounting surface 422 of the
rear face 416, a seal recess 426 is provided. A sealant 428 (FIG.
36) can be provided in the seal recess 426. The sealant 428 can be,
for example, but not limited to, asphalt-impregnated sealant
tape.
[0181] Referring to FIG. 36, the vertical casing members 412 are
mounted adjacent the opening 312 by securing the mounting surface
422 of the rear face 416 to the sub-jamb member 360. In particular,
the mounting surface 422 of casing member 412 is seated against an
outside edge surface 367 of the sub-jamb member 360. Suitable
adhesive or fasteners can be used to attach the casing member 412
to the sub-jamb 360. In the embodiment illustrated, finishing nails
430 are used to attach the casing member 412 to the sub-jamb
360.
[0182] As best seen in FIG. 36, the channel 424 spans the seams 432
between the sub-jamb 360 and the end faces 318, 320 of the logs 16
adjacent the opening 312. This provides drainage and ventilation
for any moisture which may penetrate the area behind the casing
members 412 and the seams 432.
[0183] To enhance the drainage of any moisture behind the casing
members 412, drainage troughs 434 can be provided in the lower
horizontal surface 316 of the opening 312, directly below the seams
432 and adjacent the channel 424 of the casing member 412. In the
embodiment illustrated, the drainage troughs 434 comprise grooves
having an inclined base 436, an open upper edge 438 facing the
lower end of the sub-jamb 360, and an open front edge 440 facing
the channel 424 of the casing member 412.
Butt Joint Connection Structure
[0184] A butt joint connection structure according to an example of
the applicant's teaching is shown generally in FIG. 1 at reference
character 510. The butt joint connection structure 510 is provided
between adjacent end faces of any two logs 16 comprising the walls
14 so that the logs 16 may be joined together end-to-end.
[0185] Referring now to FIG. 37, the butt joint connection
structure 510 is illustrated in combination with two logs 512 and
514 of the logs 16 forming the wall 14. The logs 512, 514 have end
faces 516, 518, respectively, (not shown), which are in flush
contact with each other forming a seam 520 between the logs 512,
514.
[0186] The butt joint connection structure 510 comprises a butt
spline 522 and fasteners 524. The butt spline 522 is adapted to be
received in a generally vertical spline slot 526 which spans the
seam 520 between the adjacent end faces 516, 518 of the logs 512,
514. In the embodiment illustrated, the butt spline slot 526
extends horizontally in a direction which is substantially parallel
to the common longitudinal axes of the logs 512, 514.
[0187] To form the butt spline slot 526, spline grooves 528, 530
are provided in the end faces 516, 518 of the logs 512, 514,
respectively (FIG. 38). Each butt spline groove 528, 530 has an
open vertical edge 532 provided in the end face 516, 518 and an
opposed closed vertical edge 534 opposite the open vertical edge
532. Opposed butt spline groove inner and outer side faces 536, 538
extend between the open and closed vertical edges 532, 534.
[0188] The butt spline grooves 528 and 530 in the logs 512 and 514
are positioned so that the open vertical edges 532 align to face
each other. The inner side faces 536 of the grooves 528 and 530
cooperate to form a generally continuous inner sidewall 540 of the
butt spline slot 526. Similarly, the outer side faces of the
grooves 528 and 530 cooperate to form a generally continuous outer
sidewall 542 of the butt spline slot 526 (FIG. 37).
[0189] Referring now to FIG. 39, the butt spline 522 is generally
rectangular in cross-section, being adapted to fit snugly in the
butt spline slot 526. The butt spline 522 has a thickness 546 which
fits between the opposed inner and outer sidewalls 540, 542 of the
slot 526, and a width 548 which fits between the opposed closed
vertical edges 534 of the slot 526. The butt spline 522 has an
inner face 550 in flush contact with the inner sidewall 540 of the
slot 526, and an opposed outer face 552 in flush contact with the
outer sidewall 542 of the slot 526. The height of the butt spline
522 extends substantially along the cross-sectional height of the
logs 512, 514. The butt spline 522 can be constructed of wood,
polymer, or any other suitable material.
[0190] The butt spline 522 is provided with vertically extending
fastener recesses 554 that are adapted to cooperate with the
fasteners 524 for securing the butt joint connection structure 510.
In the embodiment illustrated, two recesses 554 are provided along
the inner face 550 of the spline 522. The recesses 554 are
generally semi-circular in cross-section, providing a recess
opening 556 in the plane of the inner face 550 of the spline 522.
Furthermore, lateral catch surfaces 558 are provided along the
inner surface of the recesses 554, extending inwardly from either
edge of the recess openings 556. The catch surfaces 558 of the
recesses 554 interact with the fasteners 524 to secure the butt
joint connection structure 510, as will be described
subsequently.
[0191] The two recesses 554 are spaced apart so that one recess is
on either side of the seam 520 between the logs 512, 514. In other
words, the recess opening 556 of one recess 554 abuts the inner
side face 536 of the groove 528 provided in the log 512. The recess
opening 556 of the second recess 554 abuts the inner side face 536
of the groove 530 provided in the log 514.
[0192] The interaction of the fasteners 524 and the recesses 554
will now be described. Referring to FIG. 40, the recesses 554 and
the inner faces 536 of the grooves 528, 530 cooperate to provide
apertures 560 for receiving the fasteners 524. The apertures 560
provide a cross-sectional area which is significantly less than the
cross-sectional area of the fasteners 524. More particularly, in
the embodiment illustrated, the fasteners 524 comprise spikes
having a shaft 562 of generally circular cross-section (FIG. 37).
The radius of the semi-circular recesses 554 is about equal to the
radius of the circular shaft 562 of the spikes 524. Accordingly,
the cross-sectional area of the apertures 560 is only about half
that of the cross-sectional area of the shaft 562 of the spikes
524.
[0193] As a result, the spikes 524 must be forced into the
semi-circular apertures 560 for assembly of the butt joint
connection structure 510. This generates a significant lateral
force, pressing the outer face 552 of the spline 522 against the
outer side faces 538 of the grooves 528, 530. This force impedes
any relative movement between the spline 522 and the logs 512, 514,
thereby securing the butt joint connection structure 510.
[0194] Furthermore, forcing the spikes 524 into the apertures 560
can create depressions 564 (shown in phantom in FIG. 40) in the
logs 512, 514, opposite the recesses 554 provided in the spline
522. The depressions 564 have log catch surfaces 566 which extend
into the inner side faces 536 of the grooves 528, 530. By forming
the depressions 564 upon insertion of the spikes 524 into the
apertures 560, the log catch surfaces 566 are necessarily aligned
with the opposing spline catch surfaces 558 of the recesses
554.
[0195] Accordingly, the shaft 562 of the spikes 524 engages the
catch surfaces 558 and 566 formed along the inner surfaces of the
apertures 560, and thereby prevent any horizontal movement of the
spline 522 relative to the logs 512, 514. In other words, by
extending transversely across the interface between the spline 522
and the grooves 528, 530, and by engaging the respective transverse
catch surfaces 558, 566, the shaft 562 of the spikes 524 locks the
logs 512 and 514 together.
[0196] Referring again to FIG. 37, the butt joint connection
structure 510 can further comprise seal assemblies 570. The seal
assemblies 570 are adapted to be received in seal slots 572, which
span the seam 520 between the adjacent end faces 516, 518, of the
logs 512, 514.
[0197] In the embodiment illustrated, two seal slots 572 are
provided in the butt joint connection structure 510. More
specifically, one seal slot 572 is provided between the spline slot
526 and the inner side surface 216 of the logs 512, 514, and
another seal slot 572 is provided between the spline slot 526 and
the outer side surface 218 of the logs 512, 514. The seal slots
extend vertically along the cross-sectional height of the logs 512,
514, and extend horizontally in a direction generally parallel to
the common axis of the logs 512, 514.
[0198] Referring again to FIG. 38, each seal slot 572 is formed of
opposed seal grooves 574 and 576 provided along the end faces 516
and 518 of the logs 512, 514 respectively. Each seal groove has an
end wall 578 and opposed side surfaces 580 and 582 extending
between the end wall 578 and the end face 516, 518. The side
surfaces 580, 582 of the grooves 574 are in alignment with the side
surfaces 580, 582 of the grooves 576, thereby forming the generally
continuous seal slots 572 extending between the end walls 578.
[0199] Referring again to FIG. 37, the seal assemblies 570 comprise
stiffening bars 584 which are affixed to a sealing element 586. The
sealing element is preferably compressible, and may be, for
example, but not limited to, asphalt-impregnated sealant tape. The
stiffening bars can be of generally rectangular cross-section, and
may be constructed of, for example, but not limited to, wood or
plastic.
[0200] In the embodiment illustrated, the seal assemblies 570
comprise two stiffening bars 584 provided on opposite sides of the
sealing element 586. Each stiffening bar 584 has an inner face 588
adjacent the sealing element 586, and an outer face 590 in contact
with an end wall 578 of the seal slot 572. The stiffening bars 584
and the sealing element 586 have a height which is generally equal
to the cross-sectional height of the logs 512, 514.
[0201] In the relaxed, unassembled state, the seal assemblies 570
have a thickness which fits snugly within the distance between the
opposed side surfaces 580 and 582 of the seal slots 572, and the
seal assemblies have a width which exceeds the distance between the
opposed end walls 578 of the seal slots 572. Accordingly, to insert
the seal assembly into the seal slot 572, the two stiffening bars
584 must be pressed together, thereby compressing the sealing
element 586. The seal assembly may then be pressed into the seal
slot 572, by applying force on the upper ends of the stiffening
bars 584. The stiffening bars facilitate proper placement of the
sealing element 586 along the height of the logs 512, 514, by
preventing the sealing element 586 from folding or crumpling upon
insertion into the seal slots 572.
[0202] As best seen in FIGS. 37 and 41, the butt joint connection
structure 510 can be provided with horizontal seals 592 and 594, to
further enhance the weather-proofing characteristics of the butt
joint 510. The seals 592, 594 can be, for example, but not limited
to, asphalt-impregnated tape.
[0203] The seals 592 are provided adjacent the upper and lower
edges of the butt spline 522. Accordingly, as best seen in FIG. 41,
the upper and lower seals 592 are compressed between the upper end
of the spline 522 and the plateau surface 252 of the log above the
spline 522, and the lower end of the spline 522 and the channel
surface 238 of the log below the spline 522.
[0204] The seals 594 are provided adjacent the upper ends of the
seal assemblies 570. The horizontal position of the seal assemblies
570 along the cross sectional width of the logs 16 can be
advantageously aligned with the sealant 258 provided in the
recesses 250 in the logs 16 (FIG. 41). Accordingly, the seals 594
are compressed between the upper ends of the seal assemblies 570
and the adjacent sealant 258. The lower end of each seal assembly
570 bears directly against the adjacent sealant 258. Additional
seals 594 could be provided between the lower ends of the seal
assemblies 570 and the adjacent sealant 258.
[0205] As seen in FIG. 41, the apertures 262 advantageously provide
clearance between vertically adjacent logs to accommodate the head
of the fastener 524.
Post-To-Log Connection Structure
[0206] A connection structure according to an example of the
applicant's teaching is shown generally at 610 in FIG. 42. The
connection structure 610 has a generally vertical post 612 to which
horizontal logs 16 of a wall 14 can be attached. The use of
vertical posts 612 can provide a method of connecting intersecting
walls 14, and can provide support points along a wall 14 and can
advantageously reduce the required length of the logs 16.
[0207] The post 612 has a generally vertical joint face 614 which
is shaped to engage end faces 616 of the logs 16 in substantially
flush contact. In the embodiment illustrated, the joint face 614
and end faces 616 are planar surfaces oriented generally vertically
(the end faces 616 defining an edge surface of wall 14), but other
configurations could also be provided. Furthermore, in the
embodiment illustrated, the vertical post 612 is generally square
in cross-section, and a single joint face 614 for connection to
logs 16 has been illustrated. The post 612 could have any one of a
variety of cross-sectional profiles, including, for example, but
not limited to, hexagonal or octagonal. The post 612 would
generally be provided with at least two joint faces 614.
[0208] The connection structure 610 further comprises a link
assembly 620 for coupling the logs 16 to the post 612. The link
assembly 620 comprises a post-engaging clamp bracket 622, a
log-engaging connector 624, and a fastener 626 extending between
the bracket 622 and connector 624.
[0209] As best seen in FIG. 43, in the embodiment illustrated, the
fastener 626 is a socket head cap screw. An elongate hex nut 628 is
threaded onto the end of the fastener 626. A lock pin 630 is
provided transversely through a distal end of the nut 628, for
purposes which will be described hereinafter. The lock pin 630 can
be press fit into a corresponding bore 629 provided through the nut
628.
[0210] The clamp bracket 622 has lateral clamp arm ends 631 which
extend beyond the profile of the hex nut 628. In the embodiment
illustrated, the clamp arm ends 631 comprise horizontally outer
portions of a pair of flanges 632a, 632b, which are connected along
a leading edge 634 to form a v-shaped profile. In the link assembly
620, the leading edge 634 of the bracket 622 is directed towards
the connector 624. The bracket 622 has an aperture 636 which is
generally centrally located, and intersects the leading edge 634.
The aperture 636 is sized to allow passage and rotation of the hex
nut 628 within the aperture 636.
[0211] The connector 624 has upper and lower log engagement
portions 638, 640, respectively, which are adapted to engage
vertically adjacent logs 16 in the wall 14. In the embodiment
illustrated, the connector 624 is a vertically oriented dowel pin
of hexagonal cross-sectional profile. The connector 624 also has a
horizontal bore 642 positioned between the upper and lower log
engagement portions 638, 640, which is adapted to receive the
fastener 626. More specifically, the bore 642 is sized to permit
sliding passage of the shaft of the fastener 626, and is
counter-bored opposite the bracket 622 to provide a recessed fit
for the head of the fastener 626 (FIG. 42).
[0212] The post 612 is provided with a channel 646 extending along
the joint face 614. The channel 646 has a bracket housing portion
648 shaped to receive the bracket 622, and a slot portion 650
extending between the bracket housing portion 648 and the joint
face 614. The bracket housing portion 648 is provided with oblique
retaining shoulders 652a, 652b which are shaped and positioned to
engage the flanges 632a, 632b of the bracket 622. More
specifically, the retaining shoulders 652a, 652b in the embodiment
illustrated extend outwardly from either side of the slot portion
650 of the channel 646, and away from the joint face 614 (FIG.
44).
[0213] The logs 16 are provided with upper and lower connector
apertures 662, 664, which are the same as the connector apertures
342, 344, provided in the opening support structure 310 of the
present invention. The upper and lower connector apertures 662, 664
in vertically adjacent logs 16 are shaped to receive the lower and
upper log engagement portions 640, 638, respectively, of the
connector 624.
[0214] In use, the post 612 is positioned adjacent a log 16, so
that the joint face 614 of the post 612 is in flush contact with
the end face 616 of the log 16.
[0215] The bracket 622 of the link assembly 620 can then be aligned
with, and slidingly inserted into, the bracket housing portion 648
of the channel 646 in the post 612. The link assembly 620 is
lowered to a point where the connector 624 contacts the log 16. The
connector 624 can then be aligned with the aperture 662 by
orienting the connector 624 to the vertical and adjusting the
fastener 626 as may be required to obtain the correct spacing
between the bracket 622 and the connector 624. During the alignment
process, the lock pin 630 passing through the nut 628 can be
advantageously seated within the converging flanges 632a, 632b to
provide an anti-rotate coupling arrangement of the nut 628 and the
fastener 626.
[0216] Once aligned, the connector 624 can be tapped or pressed
into place, so that the lower log engagement portion 640 of the
connector 624 engages the upper connector aperture 662 in the log
16. The lowermost installed position of the connector 624 is
achieved when the shank of the fastener 626 bottoms out in the
v-groove 240 provided along the top surface of the log 16.
[0217] Once the connector 624 has been installed, the fastener 626
can be tightened to draw the post 612 and the log 16 snugly
together. In particular, with reference to FIG. 44, tightening the
fastener 626 draws the clamp bracket 622 towards the connector 624.
Accordingly, the flanges 632a, 632b of the bracket 622 bear against
the retaining shoulders 652a, 652b, of the channel 646. This
provides a reliable connection and also serves to horizontally
align the log 16 and the post 612, due to the oblique angle at
which the retaining shoulders 652 and flanges 632 are provided.
[0218] After tightening the fastener 626, the next log 16 may be
laid down, ensuring that the lower connector aperture 664 in the
lower surface of the next log is aligned with and engages the upper
log engagement portion 638 of the connector 624.
[0219] Accordingly, the connection structure 610 provides a secure
joint which stabilizes the logs horizontally in a direction
perpendicular to the axis of the logs 16, but also draws the logs
16 snugly against the post 612. Moreover, the bracket 622 can shift
in a vertical direction relative to the post 612, allowing the
post-to-log connection structure 610 to accommodate natural
settling of the logs 16 relative to the post 612 over time.
[0220] The connection structure 610 can further be provided with a
seal assembly 570, as provided in the butt joint connection
structure 510. In the embodiment illustrated, two seal slots 672
are provided, each seal slot 672 being shaped to receive a seal
assembly 570.
[0221] Each seal slot 672 spans the seam between the joint face 614
of the post 612, and the end face 616 of the log 16. The seal slots
672 are similar to the seal slots 572, being formed of opposed seal
grooves 674 and 676 provided along the joint face 614 of the post
612 and the end face 616 of the log 16, respectively. As for the
butt joint connection structure 510, the seal assemblies 570 may be
inserted into seal slots 672 of the post-to-log connection
structure 610 by pressing the stiffening bars 584 together, so that
the sealing element 586 is compressed. The seal assembly 570 may
then be inserted into the slot 672 by applying a downward force to
the upper ends of the stiffener bars 584.
[0222] Referring to FIG. 45, an alternative seal assembly 670 is
illustrated. The seal assembly 670 may be used as an alternative to
the seal assembly 570 in either of the butt joint connection
structure 510 or post-to-log connection structure 610 of the
present invention.
[0223] The seal assembly 670 is provided with a pair of opposed
stiffener bars 684, but rather than having a single sealing element
586 extending between the bars 684, two separate sealing elements
686a and 686b are provided. Each of the sealing elements 686a, 686b
are affixed to only one stiffener bar 684. Accordingly, the seal
assembly 670 comprises two seal sub-assemblies 670a and 670b.
[0224] The seal assembly 670 can advantageously be used in cases
where the grooves 574 and 576, or 674 and 676, are not in precise
alignment with each other (FIG. 46). The slots 572, 672 so formed
can have an offset along the seams which they span. Accordingly,
one seal sub-assembly 670a, 670b can be squeezed into each groove
574, 674 or 576, 676 such that the sealing portions 686a, 686b abut
each other at the seam, and improved weather-proofing can thereby
be provided.
[0225] While preferred embodiments of the invention have been
described herein in detail, it is to be understood that this
description is by way of example only, and is not intended to be
limiting. The full scope of the invention is to be determined from
reference to the appended claims.
* * * * *