AU2006202253A1 - Building element and construction method using the same - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: BUILDING ELEMENT AND CONSTRUCTION METHOD USING THE

SAME

Applicant: THE TRUSTEE FOR EHABITAT TRUST The following statement is a full description of this invention, including the best method of performing it known to me: 1 n WASASKIAPatents\773745 (254 50) lorms doc 2 BUILDING ELEMENT AND CONSTRUCTION METHOD USING THE SAME Field of the Invention The present invention relates generally to building structures and to methods of constructing them. It relates more particularly to an improved building element for constructing buildings.

Background to the Invention Conventional construction techniques typically involve erecting a timber frame using standard lumber. The use of timber in framework construction is desirable because of the ability to fasten other building materials, such as cladding, to any part of the structural frame. The use of timber also allows for easy modification in the length of the structural members. One disadvantage of the timber frame construction is that skilled labour is required and skilled labour is becoming increasingly expensive.

There is an ever increasing demand for more economical buildings and also for versatile buildings and many forms of kit type buildings and modular buildings have been made available in an attempt to meet this demand. Many of these include prefabricated timber components and prefinished panels. Such building systems typically offer savings in material costs and labour and can provide cost effective construction, particularly in remote areas.

However, kit or modular type homes tend to be limited in regard to floor plan flexibility and suitability to only certain types of sites. Erecting building structures in this manner does not make it easy to dismantle the building at some later stage to be reassembled at another site, or permit ready addition to additional modules or rooms to the building structure at a later stage.

The discussion of the background to the invention included herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to is published, known or part of the common general knowledge as at the priority date of the claims.

Summary of the Invention According to an aspect of the present invention, there is provided a building element including four elongate structural members each having a substantially oblong cross section and being arranged in an interlocking configuration to provide a plurality of exposed flanges for anchoring further building members and other building materials.

In a preferred embodiment of the present invention, the four structural members include two pairs of structural members, the members of a first pair being configured to be identical to one another but non identical and complementary to the members of a second pair, the identically configured members of each pair of structural members being arranged in opposed relationship such that each member interlocks with two non identical structural members at substantially 90 degrees.

Each structural member preferably includes interlocking means positioned in two adjacent corners of the structural member and along the length of the member, such that each structural member interlocks with two adjacently positioned members about their corners and substantially along their length.

In one form of the invention, interlocking of the four elongate structural members forms a cross-shaped building element having four perpendicularly arranged arms of substantially equal length thereby providing exposed flanges for anchoring other building members and building materials. This enables the building member to provide equal utility for erecting straight walls or corner walls since the building member provides exposed flanges in four directions at degree intervals.

In a preferred form of the invention, the interlocking of the four elongate structural members further forms a centrally located hollow in the building element.

The interlocking means may include a groove in at least two adjacent corners of the cross section of the structural element to form a depression and a projection.

The grooves in the corners of the first pair of elongate structural members may be angled to form a triangular projection and the second pair of elongate structural members includes complementarily configured depressions to receive the triangular projection.

In a particular embodiment of the invention, a first end of the building element is configured to receive another building element at substantially degrees. This feature is useful for mounting and tying down the building member on a bottom plate since the building member is configured to straddle the bottom plate. Similarly, a second end of the building element may be configured to receive a roofing member.

According to another aspect of the present invention, there is provided a method of forming a building element, the method including the following steps: providing two pairs of elongate structural members, the members of a first pair being configured to be identical to one another but non identical and complementary to the members of a second pair; arranging the two pairs of structural members in an opposed relationship such that such each member interlocks with two non identical structural members at substantially 90 degrees; securing the structural members in the arrangement.

In one embodiment of the invention, the two pairs of structural members are interlocked by means of a groove in each of at least two adjacent corners and along the length of the structural element, such that each structural member interlocks with two adjacently positioned members about their corners and substantially along their length.

According to yet another aspect of the present invention, there is provided a method of erecting a structural frame for a building, the method including the following steps: providing a bottom plate on a sub floor structure; vertically spacing first and second building elements, each including two pairs of elongate structural members, the members of a first pair being configured to be identical to one another but non identical and complementary to the members of a second pair, the identically configured members of each pair of structural members being arranged in opposed relationship such each member interlocks with two non identical structural members at substantially degrees, along the bottom plate; and horizontally positioning a third building element including two pairs of elongate structural members, the members of a first pair being configured to be identical to one another but non identical and complementary to the members of a second pair, the identically configured members of each pair of structural members being arranged in opposed relationship such each member interlocks with two non identical structural members at substantially 90 degrees, such that the building element extends at least between the two vertically spaced building elements.

In one embodiment, the method further includes the step of securing internal lining and/or external cladding to exposed flanges on the first, second and third building elements.

Brief Description of the Drawings The invention will hereinafter be described in greater detail by reference to the attached drawings. It is to be understood that the particularity of the drawings does not supersede the generality of the preceding description of the invention.

Figure 1A is an overhead diagram showing a cross section of the building element according to one embodiment of the present invention.

Figure 1B is a perspective view of the building element of Figure 1A.

Figure 2 is an overhead diagram showing a cross section of the building element according to another embodiment of the present invention.

Figure 3 is a perspective view of a building frame constructed using the building elements according to an embodiment of the present invention.

Figure 4 is a detailed view showing how the building elements intersect to construct a section of a building frame in accordance with an embodiment of the present invention.

Figure 5 is the section of the building frame shown in Figure 4 as viewed from another angle.

Detailed Description Referring firstly to Figure 1A, the invention provides a building element 100 including four elongate structural members 102 each having a substantially oblong cross section and being arranged in an interlocking configuration to provide a plurality of exposed flanges 104 for anchoring further building elements and other building materials 106, 108, 110.

The four structural members 102 include two pairs of structural members 102A, 102B, the members of a first pair 102A being configured to be identical to one another but non identical and complementary to the members of a second 6 Ipair 102B. In forming the building element 100, the identically configured 0 0members of each pair of structural members 102A, 102B are arranged in

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opposed relationship to one another, such that each structural member 102 interlocks with two non identical structural members at substantially 90 degrees.

This arrangement forms a building element 100, having a "cross" shape including four perpendicularly arranged arms of substantially equal length. The arms provide the exposed flanges 104 to which the further building elements Sand other building materials can be anchored.

OEach of the structural members 102 has interlocking means 112 IN 10 positioned in two adjacent corners 114 of the structural member 102 and along 0 the length of the member (see Figure such that each structural member 102A interlocks with two adjacently positioned members 102B about their corners 114 and substantially along their length. In the illustrated embodiment, the interlocking means 112 includes a groove in at least two adjacent corners 114 to form a depression 116 and a projection 118. The grooves in the corners 114 of the first pair of elongate structural members 102A are angled to form a triangular projection 118 and the second pair of elongate structural members 102B includes complementarily configured depressions to receive the triangular projection 118.

Referring now to Figure 1B, there is shown a perspective view of the building element 100 of Figure 1A showing more clearly how the building element 100 can be formed by simply interlocking the four structural members 102 by simply pushing the structural members 102 together. The structural members 102 are held in this arrangement using an adhesive. Figure 1B further illustrates that the interlocking means 112 extends along the length of the structural members 102.

Figure 2 shows a building element 200 in accordance with an alternate embodiment. The structural members 202 comprising building element 200, are configured differently to those shown in Figures 1A and 1B in terms of the shape of the interlocking means provided on two adjacent corners of each structural member. However, similarly to the previously described embodiment, the building element 200 includes two pairs of identical structural members 202A, 202B with a first pair of members 202A having interlocking means shaped to be complementary to the interlocking means provided on the second pair of structural members 202B. The arrangement of the two pairs relative to one another is also the same. The configuration of the interlocking means in Figures 1A and 1B is considered to be advantageous in that it enables the structural members to be simply pushed together into the interlocking arrangement. Various other configurations are envisaged as offering similar utility so long as they enable the structural members to be interlocked.

Figure 3 shows a timber frame 300 constructed using the building elements of the present invention. The building elements 100 described above are used to provide both vertical and horizontal support to a building structure erected using the construction system. That is, as well as forming the vertical "posts" 302, the building elements 100 are also used to form the horizontal "lintels" 304.

The ends of the horizontal building elements 304 are detailed to facilitate anchoring to vertical building elements 302. This is achieved by offsetting the first pair of structural members 102A from the second pair of structural members 102B (see for example Figure 1B) to permit one pair of structural members to straddle one of the structural members of the building elements that forms the anchor for the subsequent building element.

This end configuration has been developed further to provide a pair of structural members 306 at an upper end of a building member intended to provide a vertical support 302 which are truncated before the end of the building element typically on an angle so as to provide a cradle to support a roofing member such as a rafter 308. This "detailing" of the ends of the building elements simplifies the construction process by enabling building elements to be simply slotted together and secured using fastening means such as bolts, nails and the like.

Referring now to Figures 4A and 4B the relationship of the building elements with one another 402, 404 and with a bottom plate 406 and a rafter 408 can be seen more clearly. Bolt holes 412 may be predrilled in the building elements 402, 404 to enable them to be easily secured together by way of bolts or other fasteners. Figures 4A and 4B also show how the exterior cladding or interior lining 410 is attached to the exposed flanges of the building elements 402, 404. Where both exterior and interior panelling is used, the resulting wall cavity can be filled with insulation. Panes of glass can also be fixed to the exposed flanges of the building members 402,404 by for example using double sided adhesive and fixing tabs. This avoids the need for timber or other frames for fixed window areas. Window sashes can be inserted for areas which require windows to be able to be opened on demand.

In Figures 1A, 1B and 2 it can be seen that the interlocking of the four elongate structural members forms a centrally located hollow 120 in the building element. This hollow 120 confers the advantage of reducing the weight of the finished building member 100 and in addition provides a multipurpose conduit within the resulting walls of the building structure which can be used to hold electrical or other service cables including window and door mechanisms and the like.

An advantage of the present invention is that the building element forms a vertical or horizontal support of substantially equal strength to a similarly dimensioned solid piece of timber whilst minimising weight and material usage.

The construction system using the building elements of the present invention reduces labour costs through speedy erection and the capacity for unskilled labourers to complete the frame. The building elements can be cut to and placed at intervals to provide spacing which permits off the shelf materials e.g. a standard 2100 x 1200 panel of fibrous cement sheeting to be screwed directly to the frame constructed of the building members without cutting.

It should be understood that using the building elements and the construction system of the present invention, it is possible to construct buildings and similar structures in a truly modular fashion. Since each building element can be used as a corner post, i.e. allows for walls to "turn off" at 90 degrees on the same post, it is possible to add or remove modules or rooms after the initial construction without impacting of the integrity or aesthetics of the structure.

This makes the construction system suitable for a large range of users and a large range of building sites.

A further advantage of the present invention is that a timber frame formed in accordance with the method and building elements of the present invention is completely demountable and can be reconstructed on another site.

This makes the system essentially recyclable.

It is to be understood that various additions, alterations and/or

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modifications may be made to the parts previously described without departing from the ambit of the invention.

IND

Claims (16)

1. A building element including four elongate structural members each having a substantially oblong cross section and being arranged in an I 5 interlocking configuration to provide a plurality of exposed flanges for anchoring further building members and other building materials.

2. A building element according to claim 1, wherein the four structural Smembers include two pairs of structural members, the members of a first pair IN 10 being configured to be identical to one another but non identical and 0 complementary to the members of a second pair, the identically configured members of each pair of structural members being arranged in opposed relationship such that each member interlocks with two non identical structural members at substantially 90 degrees.

3. A building element according to claim 1 or 2, wherein each structural member includes interlocking means positioned in two adjacent corners of the structural member and along the length of the member, such that each structural member interlocks with two adjacently positioned members about their corners and substantially along their length.

4. A building element according to any one of the preceding claims, wherein interlocking of the four elongate structural members forms a cross- shaped building element having four perpendicularly arranged arms of substantially equal length.

A building element according to any one of the preceding claims, wherein the interlocking of the four elongate structural members further forms a centrally located hollow in the building element.

6. A building element according to any one of the preceding claims, wherein the interlocking means includes a groove in at least two adjacent corners of the cross section of the structural element to form a depression and a projection.

7. A building element according to any one of the preceding claims, wherein the groovees in the corners of the first pair of elongate structural members are angled to form a triangular projection and the second pair of elongate structural members includes complementarily configured depressions to receive the triangular projection.

8. A building element according to any one of the preceding claims wherein a first end of the building element is configured to receive another building element at substantially 90 degrees.

9. A building element according to any one claims 1 to 7 wherein a second end of the building element is configured to receive a roofing member.

A method of forming a building element, the method including the following steps: providing two pairs of elongate structural members, the members of a first pair being configured to be identical to one another but non identical and complementary to the members of a second pair; arranging the two pairs of structural members in an opposed relationship such that such each member interlocks with two non identical structural members at substantially 90 degrees; securing the structural members in the arrangement.

11. A method of forming a building element according to claim 10, wherein the two pairs of structural members are interlocked by means of a groove in each of at least two adjacent corners and along the length of the structural element, such that each structural member interlocks with two adjacently positioned members about their corners and substantially along their length. 12

12. A method of erecting a structural frame for a building, the method including the following steps: providing a bottom plate on a sub floor structure; vertically spacing first and second building elements, each including two pairs of elongate structural members, the members of a first pair being configured to be identical to one another but non identical and complementary to the members of a second pair, the identically configured members of each pair of structural members being arranged in opposed relationship such each member interlocks with two non identical structural members at substantially degrees, along the bottom plate; and horizontally positioning a third building element including two pairs of elongate structural members, the members of a first pair being configured to be identical to one another but non identical and complementary to the members of a second pair, the identically configured members of each pair of structural members being arranged in opposed relationship such each member interlocks with two non identical structural members at substantially 90 degrees, such that the building element extends at least between the two vertically spaced building elements.

13. A method of erecting a structural frame for a building according to claim 12, further including the step of securing internal lining and/or external cladding to exposed flanges on the first, second and third building elements.

14. A building element substantially as hereinbefore described with reference to any one of the embodiments shown in the drawings.

A method of forming a building element substantially as hereinbefore described with reference to any one of the embodiments shown in the drawings.

16. A method of erecting a structural frame for a building substantially as hereinbefore described with reference to any one of the embodiments shown in the drawings. Dated: 26 May 2006 Phillips Ormonde Fitzpatrick Patent Attorneys for: The Trustee for Ehabitat Trust