U.S. patent application number 11/896566 was filed with the patent office on 2007-12-27 for system of interlocking wall and corner components for construction of buildings.
Invention is credited to Klaus Posselt.
Application Number | 20070294967 11/896566 |
Document ID | / |
Family ID | 32965610 |
Filed Date | 2007-12-27 |
United States Patent
Application |
20070294967 |
Kind Code |
A1 |
Posselt; Klaus |
December 27, 2007 |
System of interlocking wall and corner components for construction
of buildings
Abstract
A system of interlocking wall and corner components for
construction of a building include a plurality of elongate key
members and a plurality of elongate side members. The key members
are arranged as horizontal pairs of parallel upper and lower key
members sandwiching therebetween pairs of parallel side members.
The pair of parallel upper and lower key members form therebetween
a pair of dove-tail joint female receiver sockets. Opposed facing
sides of the pairs of the parallel side members have a
corresponding pair of laterally inwardly disposed dove-tail joint
male members for mating into dove-tail engagement in the female
receiver sockets to form a dove-tail joint. The pairs of key
members and the pairs of side members form elongate horizontal
beams mountable one on top of another to form a vertical array of
wall layers.
Inventors: |
Posselt; Klaus; (Burns Lake,
CA) |
Correspondence
Address: |
ANTONY C. EDWARDS
SUITE 200 - 270 HIGHWAY 33 WEST
KELOWNA
BC
V1X 1X7
CA
|
Family ID: |
32965610 |
Appl. No.: |
11/896566 |
Filed: |
September 4, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10793847 |
Mar 8, 2004 |
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11896566 |
Sep 4, 2007 |
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60453212 |
Mar 11, 2003 |
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Current U.S.
Class: |
52/233 |
Current CPC
Class: |
E04B 2/702 20130101;
E04B 2/705 20130101; E04C 3/127 20130101 |
Class at
Publication: |
052/233 |
International
Class: |
E04B 1/38 20060101
E04B001/38; E04B 2/70 20060101 E04B002/70 |
Claims
1. A system of interlocking wall and corner components for
construction of a building comprising: a plurality of elongate key
members and a plurality of elongate side members, wherein said key
members are arranged as horizontal pairs of parallel upper and
lower key members lying symmetrically in a corresponding pair of
vertically spaced parallel horizontal planes, said pairs of
parallel upper and lower key members sandwiching therebetween pairs
of parallel side members, and wherein said pairs of parallel side
members lie in a corresponding pair of parallel, laterally spaced
apart, vertical planes, and wherein each said key member having
symmetric faces, being each face of oppositely disposed upper and
lower faces of each said key member, when assembled in opposed
facing relation to an opposed facing said symmetric face of a
second key member in said pair of parallel upper and lower key
members, form therebetween a pair of joint female receiver sockets,
opposed facing sides of said pairs of said parallel side members
having a corresponding pair of laterally inwardly disposed joint
male members for mating into engagement in said female receiver
sockets to form a joint, wherein, when so mated, said pairs of key
members and said pairs of side members form elongate horizontal
beams mountable one on top of another to form a vertical array of
wall layers comprising a wall, and wherein each said side member in
said pairs of said parallel side members has a thickness when
viewed in lateral cross section therethrough and wherein each said
key member has a first width when viewed in said lateral cross
section, and wherein the sum of substantially one half of said
thickness of both of said side members in said pairs of said
parallel side members is substantially equal to at least one half
of said first width so that a cavity formed between said pairs of
laterally inwardly disposed joint male members and correspondingly
between said pairs of key members has a second width when viewed in
said lateral cross section which is substantially equal to or less
than said one half of said first width.
2. The system of claim 1 wherein the sum of said first width and
said sum of substantially one half of said thickness of both of
said side members provides a total width of each of said horizontal
beams and wherein said total width is substantially equal to a
total height of said each of said horizontal beams whereby said
lateral cross section is substantially dimensionally square.
3. The system of claim 2 wherein each said key member is, along a
length thereof, substantially symmetric about its corresponding
said horizontal plane.
4. The system of claim 2 further comprising laterally extending
channels formed adjacent ends of said key members, said notches for
forming overlapping corners between adjacent said beams in a single
said wall layer.
5. The system of claim 3 wherein in said vertical array of said
horizontal beams, vertically adjacent said beams in vertically
adjacent said wall layers share a common said key member
therebetween.
6. The system of claim 2 wherein said pairs of joint female
receiver sockets include sloping faces on each said key member
sloping inwardly from opposite sides of said key members and
downwardly towards said corresponding horizontal plane so that said
joints urge the corresponding mated said joint male members
laterally inwardly of said horizontal beams so as to snugly seat
said joint male members into said female receiver sockets.
7. The system of claim 4 further comprising separate end pieces,
said end pieces for sandwiching between said ends of said key
members when mounted in said vertical array.
8. The system of claim 7 wherein each end piece of said end pieces
has a tongue extending cantilevered from an end thereof, said
tongue for mating insertion into said cavity between said pair of
key members and said pair of side members.
9. The system of claim 2 wherein ends of said key members include
notches so that adjacent said key members in a single said wall
layer form a corner when overlapped at their ends so as to overlap
said notches.
10. The system of claim 9 further comprising vertical end boards
mountable to ends of said key members for tying said key members
together.
11. The system of claim 2 wherein ends of said side members include
vertically extending notches so that said pair of parallel side
members form vertical joint female receiving sockets at the ends of
said pair of parallel side members.
12. The system of claim 11 further comprising at least one post
having at least two vertically extending joint male members
mountable into said vertical joint female receiving sockets so as
to brace between adjacent said beams in a single said wall
layer.
13. The system of claim 12 wherein said post is a corner post and
said at least two vertically extending joint male members include
two orthogonally oriented male members.
14. The system of claim 2 wherein said key members are
substantially dumb-bell-shaped in lateral cross section.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation-in-Part of U.S. patent
application Ser. No. 10/793,847 filed Mar. 8, 2004 which claims
priority from U.S. Provisional Patent Application No. 60/453,212
filed Mar. 11, 2003 entitled System of Interlocking Wall and Corner
Components for Construction of Buildings.
FIELD OF THE INVENTION
[0002] This invention relates to dimensionally stable wall and
corner components for the construction of buildings which simulate
solid log construction buildings.
BACKGROUND OF THE INVENTION
[0003] Solid log construction buildings are desirable as residences
in many countries; however the expertise is not generally widely
available for either their manufacture or construction. Further,
relatively large diameter logs suitable for log home construction
generally are costly. In addition, conventional log building
construction contains intrinsic difficulties which are material
dependent and which require specific solutions. The well-known
problems associated with the log mass are handling and
transportation. Settling and drying of the logs after building
construction often results in warping and checking thereby creating
a reduced aesthetically pleasing and thermally efficient
structure.
[0004] In the prior art applicant is aware of U.S. Pat. No.
6,389,765 which issued May 21, 2002 to Hautala for a Corner Joint.
Inner and outer wall elements are kept in a parallel aspect by
internal spacers and corner elements are alternatively fitted
between intersecting wall elements in a ninety degree overlapping
orientation. The corner elements have a head, which is positioned
outside and parallel to one pair of wall elements and a tongue
which project between the wall elements. The tongue has notches
formed thereon to accept and securely retain wall elements from the
intersecting wall.
[0005] The applicant is further aware of U.S. Pat. No. 5,577,357
which issued Nov. 26, 1996 to Civelli for a Half Log Siding
Mounting System which illustrates facia siding pieces for
application to the exterior of a flat building wall. These siding
pieces have upper and lower notches which engage an elongated
retaining piece with complimentary shaped edges. The retaining
piece is firmly secured to the exterior side of the building
thereby providing the illusion of a log structure.
[0006] Applicant is also aware of U.S. Pat. No. 4,503,648 which
issued Mar. 12, 1985 to Mahaffey for a Lightweight Composite
Building Module which discloses modules for a wall of a building
including for each module a pair of spaced elongated wooden side
boards joined by a wooden top board. In one embodiment the wooden
top boards fit into notched corners formed in the side boards, and
in an alternative embodiment the side walls and top wall have a
dove-tail connection therebetween. The modules are secured together
with bolts and the cavity within the modules may be filled with
foam. Mahaffey teaches that when constructing the modules, jigs are
used for holding the side boards and top and bottom boards in place
while the foam is inserted into the cavity.
[0007] In view of the deficiencies in the prior art, it is an
object of the present invention to provide dimensioned wall and
corner components for a building, which upon assembly simulate a
log building without limitations such as imposed by the overall
length of the log.
[0008] It is also an object of the present invention to efficiently
utilize as much of a log as practical in the manufacture of
components and to create larger appearing timber components from
small logs.
[0009] A further object of the invention is to manufacture building
components that will suit the availability of raw logs.
SUMMARY OF THE INVENTION
[0010] The present invention is a self-supporting wall, which
comprises a plurality of elongate, horizontally disposed side wall
members which are interlocked with and supported by an elongate key
member. Additional corner members are designed to finish off
between the lapped horizontal side wall and key members to create
an aesthetically pleasing corner. It is understood herein that
reference to orthogonally oriented corner alignment is meant to
include orientations other than ninety degrees, as the construction
according to the present invention is not so limited. Both the side
wall members and the elongate key may be manufactured in standard
lengths and cut on site with simple hand tools to accommodate
doorways and window openings.
[0011] In one embodiment not intended to be limiting the elongate
key member forms a "dumb-bell"-like shape in lateral cross section
resulting in upper and lower paired sloping faces which slope
inwardly toward the center of the elongate key member, and opposed
upper and lower vertical faces.
[0012] Elongate side wall members are interleaved in layers between
the key members to form a wall of hollow beams, where the side
members are stood on edge and mounted to inner and outer edges of
each key member. The sloping notches of the key members mate with
complimentary and corresponding notches formed intermediate of the
inner and outer face of the side wall members. The weight of a
sidewall member when installed upon the edge of a key member
results in the side wall member sliding toward the wall centreline,
thus inhibiting separation of the wall members. The vertical faces
of the key member maintain a parallel separation of the side wall
members to create a void or cavity therebetween.
[0013] In summary, the present invention may be characterized as a
system of interlocking wall and corner components for construction
of a building. The system includes a plurality of elongate key
members and a plurality of elongate side members, wherein a
horizontal pair of parallel upper and lower key members lying in a
corresponding pair of vertically spaced parallel horizontal planes
sandwich therebetween a pair of parallel side members. The pair of
parallel side members lie in a corresponding pair of parallel,
laterally spaced apart, vertical planes.
[0014] Each key member is symmetric about its corresponding
horizontal plane, with the exception of laterally extending
channels or notches formed near the ends of key members used to
form overlapping corner embodiments, as better described below.
Each symmetric face of each key member, that is, each face of the
oppositely disposed upper and lower faces of each key member, when
assembled in opposed facing relation to an opposed facing symmetric
face of the other key member in the pair of parallel upper and
lower key members, form therebetween a pair of joint female
receiver sockets for mating thereinto of a corresponding pair of
laterally inwardly disposed joint male members on the opposed
facing sides of the pair of parallel side members. When so mated
the pair of key members and the pair of side members form an
elongate beam. The female receiver sockets and the male members may
form interlocking joints, for example tongue and groove joints,
herein collectively referred to as interlocking joints.
[0015] An array of horizontal beams form a wall, wherein each pair
of adjacent beams share a common key member therebetween. The
interlocking joints formed between pairs of adjacent key members
urge the corresponding mated pair of side members laterally
inwardly of the beam so as to snugly seat the male members into the
female receiver sockets of the interlocking joints. Advantageously,
the key members are substantially dumb-bell shaped in lateral cross
section.
[0016] Each side member in the pairs of parallel side members has a
thickness when viewed in lateral cross section therethrough. Each
key member has a first width when viewed in the lateral cross
section. The sum of substantially one half of the thickness of both
of the side members in the pairs of parallel side members is
substantially equal to at least one half of the first width. Thus a
cavity formed between the pairs of laterally inwardly disposed
joint male members and correspondingly between the pairs of key
members has a second width when viewed in the lateral cross section
which is no greater than substantially equal to or is less than the
one half of the first width.
[0017] The sum of the first width and the sum of substantially one
half of the thickness of both of the side members provides a total
width of each of the horizontal beams which is substantially equal
to a total height of the each of the horizontal beams. Thus the
lateral cross section may be substantially dimensionally
square.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is, in end view, side wall members according to an
embodiment having planar exterior faces.
[0019] FIG. 1a is, in end view side wall members having convex
exterior faces.
[0020] FIG. 1b is, in end view, one embodiment according to the
present invention of an elongate key.
[0021] FIG. 1c is, in end view, an alternative embodiment of
elongate key.
[0022] FIG. 1d is an alternative positioning within a log of the
formation of the side wall members of FIG. 1.
[0023] FIG. 1e and 1f are end views of embodiments of side wall
assemblies according to one aspect of the present invention.
[0024] FIG. 2 is an isometric end view of one form of side wall
assembly according to the present invention.
[0025] FIG. 2a is an isometric end view of an alternative form of
side wall assembly according to the present invention.
[0026] FIG. 2b is the side wall assembly of FIG. 2a using side wall
members having a convex exterior face.
[0027] FIG. 3 is an end view of the side wall assembly of FIG.
2.
[0028] FIG. 3a is an end view of the side wall assembly of FIG.
2a.
[0029] FIG. 3b is an end view of the side wall assembly of FIG.
2b.
[0030] FIG. 4 is a plan view of one form of corner assembly
according to the present invention.
[0031] FIG. 4a is an exploded isometric view of the corner assembly
illustrated in FIG. 4.
[0032] FIG. 4b is an isometric view, partially exploded of the
corner assembly of FIG. 4.
[0033] FIG. 5 is an isometric view of an alternative form of corner
assembly.
[0034] FIG. 5a is an exploded isometric view of the corner assembly
illustrated in FIG. 5, exploded along vertical alignment axis
C-C.
[0035] FIG. 5b is an isometric view of a pair of abutting side
members of FIG. 5.
[0036] FIG. 5c is a side view of the corner element of FIG. 5.
[0037] FIG. 5d is the exploded view of FIG. 5a showing alignment of
the side wall elements during assembly.
[0038] FIG. 6 is an isometric view of an alternative form of corner
assembly.
[0039] FIG. 6a is an exploded isometric view of several of the
components of FIG. 6.
[0040] FIG. 7 is a plan view of an alternative form of corner
assembly.
[0041] FIG. 7a is an exploded isometric view of the components of
FIG. 7.
[0042] FIG. 8a is an end view of further embodiments of the present
invention.
[0043] FIG. 8b is an end view of further embodiments of the present
invention.
[0044] FIG. 8c is an end view of further embodiments of the present
invention.
[0045] FIG. 8d is an end view of further embodiments of the present
invention.
[0046] FIG. 8e is an end view of further embodiments of the present
invention.
[0047] FIG. 8f is an end view of further embodiments of the present
invention.
[0048] FIG. 8g is an end view of further embodiments of the present
invention.
[0049] FIG. 8h is an end view of further embodiments of the present
invention.
[0050] FIG. 8i is an end view of further embodiments of the present
invention.
[0051] FIG. 9 is an enlarged portion of FIG. 8e with dimension
lines added.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0052] With reference to the drawing figures, wherein similar
characters of reference denote corresponding parts in each view,
the interlocking wall and corner construction 10, for example as
illustrated in FIG. 4b, includes side wall members 12, elongate key
members 14 and corner finishing members 18.
[0053] As may be readily understood by reference to FIGS. 1, 1a-1d,
a log 20, illustrated in broken outline, has a generally circular
cross section which reduces in cross sectional area from its butt
to its tip. Side wall members 12 are formed, for example cut or
milled, from the outer side portions of the log. This avoids
inclusion of heart wood from the log, thereby reducing checking or
splitting of side wall members 12 during drying. Members 12 may be
manufactured with the exterior face 12a being either planar as
illustrated in FIGS. 1 and 1d, or convex as illustrated in FIG. 1a.
Members 12 have opposite inside faces 12b and edges 12c. Planar
exterior face 12a has chamfers 12d on opposite vertically spaced
apart edges 12c. Side wall members 12 may be manufactured in
convenient lengths and may be trimmed and abutted end-to-end during
wall manufacture. The vertically spaced apart edges of inside edges
12b include notches 22. Notches 22 each include a first face 22a
and a second sloping face 22b. For assembly of a wall, first face
22a is generally vertically disposed.
[0054] Key members 14 may be manufactured from smaller diameter
logs, or from a portion near the reduced cross sectional area tip
of larger logs, so as to better utilize the available timber.
Members 14 have a `bow tie`-shape in lateral cross section. The
`bow tie`-shape includes parallel outer faces 14a and a medial body
having oppositely disposed ridges 14b extending between the outer
faces. Paired sloping faces 26 and 28, formed on either side of
medial body ridges 14b, slope generally from the extremities of
outer faces 14a toward the vertical centerplane A of key 14.
Sloping faces 26 and 28 terminate at vertical side faces 30 on
either side of ridges 14b. Vertical faces 30 define the width of
ridges 14b. Key members 14 are symmetric, with the exceptions noted
below, on either side of vertical plane A and horizontal plane
B.
[0055] As may be seen illustrated in FIGS. 3, 3a and 3b, side wall
members 12 are stacked vertically upon horizontal key members 14
with notches 22 snugly and matingly engaging sloping faces 26 and
28 of key members 14. The natural tendency of stacked side wall
members 12, due to their mass and the force of gravity, when
positioned with notches 22 mated on sloping faces 26 and 28, is to
slide inwardly of key members 14 until inside faces 12b or edges
12c abut vertical faces 30 or outer faces 14a respectively. Cavity
34 is thereby created between faces 12b, between which insulation
or services may be conveniently placed. The interior and exterior
faces of the wall constructed of members 12 may be flat or convex
when viewed in end-on cross section, or, as seen in FIG. 1e, a
combination of flat and convex, where the flat face may be to the
interior of the building.
[0056] In FIG. 4, 4a and 4b, a corner post 40 is mounted to side
members 12 by means of dovetail joints. Post 40 has projecting
tails 42 formed on adjacent sides. Side members 12 are vertically
chamfered so that the chamfers when in opposed facing relation
cooperatively form a socket 44. Tails 42 fit snugly into sockets
44. Key members 14 are trimmed so as to abut projecting tails 42
when the key members are mounted onto the side members. The mating
inside corners of the inside side members are further chamfered as
at 46 allowing a close tolerance inside cover fit.
[0057] As depicted in FIGS. 5, 5a, 5b, 5c and 5d, key members 50
have a notch 50a formed in one face, leaving a short end projection
50b extending therefrom. An orthogonally aligned pair of key
members 50 are interlocked by mating opposed facing notches 50a. A
key member layer is thereby formed for the corner. Side members 12
are mounted onto, so as to be sandwiched between layers of
orthogonally aligned pairs of key members 50, so that notches 50a
are aligned along axis C. Separate end pieces 52 each have an end
block 52a and an offset tongue 52b, offset from the vertical center
of the end block as better seen in FIG. 5c. Tongue 52b is
insertable respectively under and over cross-interlocked notches
50a of orthogonally mated upper and lower pairs of key members 50
so as to extend in direction D into voids 34 between the side
members until shoulder flanges 52c engage the ends of side members
12. Tongue 52a is offset into proximity to one face of end block
52a so that a pair of end pieces 52 may be mounted with the
shoulder flange 52c of one orthogonally overlapping the shoulder
flange 52c of the other, thus allowing the assembly of the snug
mounted corner 53 of FIGS. 5 and 5b. End piece 52 and key members
50 may be mounted together with nails, dowels, adhesives and/or any
other suitable fastening means to form corner 53.
[0058] FIG. 1f illustrates variations of the present invention in
which the locking joint between wall members 12' and horizontal key
14' may be minimally affected by lumber shrinkage as the members
dry after assembly.
[0059] FIGS. 6 and 6a illustrate key members 60 each having a pair
of oppositely disposed laterally projecting ribs 60a located
medially of the sides. Ribs 60a are interrupted, as at 60b, near
the end 62 of each key member 60. As side wall members 12 are
mounted in overlapping succession on successive key members 60 so
as to build up corner 63, members 12 orthogonally abut key members
60 within area 60b. End portion 62 of key 60 extends outwardly of
the overlapping joint of corner 63. End blocks 64 are mated with
ends 62 of key members 60 and mounted thereto with nails, dowels,
adhesives or other suitable means.
[0060] In FIGS. 7 and 7a a variant corner assembly is illustrated
for corner 73. In the corner assembly of corner 73 the overlapping
key members 14 are tied together by vertical end boards 15, which
may be nailed, dowelled or otherwise secured or fastened in
place.
[0061] In a further embodiment, the timber elements, as shown in
FIGS. 8a-8i allow for distinctively different wall profiles
employing tongue-and-groove or other substantially dove-tail
joints. Chinking 75 may be incorporated on the inside and outside
or one side only by simply trimming one edge of a full key member
14. Wall element dimensions can be made any size but may be
approximately three inches by seven inches to four and a half
inches by nine inches. This combined with a full key member 14 and
two inch insulation/service space can create a wall width of up to
eleven inches and an effective stacking height of up to twelve
inches per course of timbers. By using different key width the
insulation/services space can be increased or eliminated
altogether. A timber/log siding or panelling can be installed on
framed walls without visible fasteners, creating a more realistic
look. Several wood species interior/exterior combinations are
possible. The average insulation R value for a wall with six inches
of wood and two inches of polystyrene insulation 77 is about the
same as that of a six inch framed wall with fibreglass insulation.
The advantage of three inches or more wood on the interior of the
insulation is that it provides a heat sink as experienced in log
homes during spring and fall weather conditions.
[0062] The present invention offers stability over the prior art
due in part to the relative dimension of the components so that the
components are interlocking and stable without the need for further
fastening by means of bolts, jigs or the like. Thus in one
embodiment which in applicant's experience provides improved
stability when building a structure from such sidewall members 12
and key members 14, and as seen in FIG. 9, the modular structures
according to the present invention have certain characteristic
dimensions which when combined as described and claimed herein
provide for improved stability over prior art structures. In
particular, in one embodiment, the height dimensions h and width
dimensions w in FIG. 9 may be as follows: TABLE-US-00001 height
(inches) width (inches) h.sub.1 = 7.56 w.sub.1 = 5.0 h.sub.2 = 7.31
w.sub.2 = 2.75 h.sub.3 = 0.87 w.sub.3 = 1.38 h.sub.4 = 1.5 w.sub.4
= 2.88 h.sub.5 = 0.625 w.sub.5 = 1.44 w.sub.6 = 2.01
[0063] Thus in one aspect the stability of the structure comes from
the relative width dimensions where for a certain width w.sub.1 of
key member 14, and where width w.sub.3 is substantially one half
the width of width w.sub.2, and where the width w.sub.5 is
substantially one half the width of width w.sub.4 the sum of widths
w.sub.3 and w.sub.5 are no less than one half of width w.sub.1.
Thus what this amounts to is that each of the side members 12
protrude into the space or cavity 34 between key members 14 by at
least one quarter of the width w.sub.1 of each of the key members
14 so that the remaining cavity 34 defined between side members 12
and key members 14 has a width w.sub.6 is no greater than one half
of width w.sub.1 of key members 14. In a further aspect, the total
height dimension for the beam cross section roughly equals the
total width of the beam, where the total height is substantially
the sum of one half the thickness of each of the pair of key
members 14 summed with the height h.sub.1 of the side members 12.
Thus the total height H may be expressed as
H=h.sub.1=2.times.h.sub.5. The beam in cross section is thus
approximately dimensionally square.
[0064] As will be apparent to those skilled in the art in the light
of the foregoing disclosure, many alterations and modifications are
possible in the practice of this invention without departing from
the spirit or scope thereof. Accordingly, the scope of the
invention is to be construed in accordance with the substance
defined by the following claims.
* * * * *